Rockwell Automation Allen-Bradley Kinetix 6000 User Manual
Kinetix 6000 Multi-axis
Servo Drive
Catalog Numbers
2094-AC05-MP5, 2094-AC05-M01,
2094-AC09-M02, 2094-AC16-M03,
2094-AC32-M05, 2094-BC01-MP5,
2094-BC01-M01, 2094-BC02-M02,
2094-BC04-M03, 2094-BC07-M05
2094-AC05-MP5-S, 2094-AC05-M01-S,
2094-AC09-M02-S, 2094-AC16-M03 -S,
2094-AC32-M05-S, 2094-BC01-MP5-S,
2094-BC01-M01-S, 2094-BC02-M02-S,
2094-BC04-M03-S, 2094-BC07-M05-S
2094-AMP5, 2094-AM01, 2094-AM02,
2094-AM03, 2094-AM05, 2094-BMP5,
2094-BM01, 2094-BM02, 2094-BM03,
2094-BM05
2094-AMP5-S, 2094-AM01-S,
2094-AM02-S, 2094-AM03-S,
2094-AM05-S, 2094-BMP5-S,
2094-BM01-S, 2094-BM02-S,
2094-BM03-S, 2094-BM05-S
2094-BSP2
User Manual
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (publication SGI-1.1
available from your local Rockwell Automation sales office or online at
http://literature.rockwellautomation.com
) describes some important
differences between solid state equipment and hard-wired electromechanical
devices. Because of this difference, and also because of the wide variety of
uses for solid state equipment, all persons responsible for applying this
equipment must satisfy themselves that each intended application of this
equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware
of safety considerations.
WARNING
Identifies information about practices or circumstances that can cause
an explosion in a hazardous environment, which may lead to personal
injury or death, property damage, or economic loss.
IMPORTANT
ATTENTION
Identifies information that is critical for successful application and
understanding of the product.
Identifies information about practices or circumstances that can lead
to personal injury or death, property damage, or economic loss.
Attentions help you identify a hazard, avoid a hazard, and recognize
the consequence
SHOCK HAZARD
Labels may be located on or inside the equipment, for example, a drive
or motor, to alert people that dangerous voltage may be present.
BURN HAZARD
Labels may be located on or inside the equipment, for example, a drive
or motor, to alert people that surfaces may be at dangerous
temperatures.
Allen-Bradley, CompactLogix, ControlLogix, DriveExplorer, Kinetix, RSLogix, RSLogix 5000, SoftLogix, SCANport, and Rockwell
Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Start
Planning the Kinetix 6000 Drive
System Installation
Table of Contents
Preface
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
About the Kinetix 6000 Drive System . . . . . . . . . . . . . . . . . . 12
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . 16
Agency Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CE Requirements (System without LIM) . . . . . . . . . . . . . . 17
CE Requirements (System with LIM) . . . . . . . . . . . . . . . . 17
Chapter 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Mounting Requirements. . . . . . . . . . . . . . . . . . . . 20
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Circuit Breaker/Fuse Selection. . . . . . . . . . . . . . . . . . . . . 22
Enclosure Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Minimum Clearance Requirements . . . . . . . . . . . . . . . . . 26
Minimizing Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . 29
Establishing Noise Zones . . . . . . . . . . . . . . . . . . . . . . . . 30
Cable Categories for Kinetix 6000 Systems . . . . . . . . . . . . 37
Noise Reduction Guidelines for Drive Accessories . . . . . . 39
Chapter 3
Mounting the Kinetix 6000 Drive
System
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Using 2094 Mounting Brackets . . . . . . . . . . . . . . . . . . . . 43
Installing the 2094 Power Rail . . . . . . . . . . . . . . . . . . . . . 44
Determining Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . 44
Mounting the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Mounting the External Shunt Module . . . . . . . . . . . . . . . . . . 48
Chapter 4
Kinetix 6000 Connector Data
3 Publication 2094-UM001A-EN-P — September 2006
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Locating IAM/AM Connectors and Indicators. . . . . . . . . . . . . 50
Safe-off Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . 52
I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Motor Feedback Connector Pinouts. . . . . . . . . . . . . . . . . 55
Auxiliary Feedback Connector Pinouts . . . . . . . . . . . . . . 57
IAM Input Connector Pinouts . . . . . . . . . . . . . . . . . . . . . 58
IAM and AM Motor Power and Brake Connector Pinouts . 59
4 Table of Contents
Connecting the Kinetix 6000 Drive
System
Understanding IAM/AM Signal Specifications. . . . . . . . . . . . 60
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SERCOS Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . 63
Motor/Resistive Brake Relay . . . . . . . . . . . . . . . . . . . . . 64
Control Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Understanding Feedback Specifications. . . . . . . . . . . . . . . . 66
Motor and Auxiliary Feedback Specifications . . . . . . . . . 66
Feedback Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 67
Locating Shunt Module Connectors and Indicators. . . . . . . . 68
Chapter 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Understanding Basic Wiring Requirements . . . . . . . . . . . . . 69
Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . 70
Routing Power and Signal Wiring . . . . . . . . . . . . . . . . . 70
Determining Your Type of Input Power . . . . . . . . . . . . . . . 71
Grounded Power Configurations . . . . . . . . . . . . . . . . . . 71
Ungrounded Power Configurations . . . . . . . . . . . . . . . . 73
DC Common Bus Configurations . . . . . . . . . . . . . . . . . . . . 74
Common Bus Fusing Requirements . . . . . . . . . . . . . . . . 75
Setting the Ground Jumper in Ungrounded
Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Setting the Ground Jumper . . . . . . . . . . . . . . . . . . . . . . 76
Grounding Your Kinetix 6000 System . . . . . . . . . . . . . . . . . 78
Grounding Your System to the Subpanel . . . . . . . . . . . . 78
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . 79
Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . 80
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Wiring the LIM Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 84
Wiring the Auxiliary Input Power (APL) Connector. . . . . 84
Wiring the VAC LINE (IPL) Connector . . . . . . . . . . . . . . 85
Wiring the VAC LOAD (OPL) Connector . . . . . . . . . . . . 86
Wiring the Control Power Output (CPL) Connector . . . . 87
Wiring the Auxiliary Power Output (P2L) Connector . . . 88
Wiring the Brake Power Output (24V dc) Connector . . . 89
Wiring the IAM/AM Connectors . . . . . . . . . . . . . . . . . . . . . 90
Wiring the Control Power (CPD) Connector. . . . . . . . . . 90
Wiring the Input Power (IPD) Connector . . . . . . . . . . . . 91
Wiring the Contactor Enable (CED) Connector . . . . . . . . 93
Wiring the Safe-off (SO) Connector . . . . . . . . . . . . . . . . 94
Wiring the Motor Power (MP) Connector . . . . . . . . . . . . 95
Wiring the Motor/Resistive Brake (BC) Connector . . . . . 101
Applying the Motor Cable Shield Clamp . . . . . . . . . . . . . . . 103
Understanding Feedback and I/O Cable Connections . . . . . 104
Flying-lead Feedback Cable Pin-outs . . . . . . . . . . . . . . . 105
Publication 2094-UM001A-EN-P — September 2006
Configure and Startup the
Kinetix 6000 Drive System
Table of Contents 5
Wiring Feedback and I/O Connectors. . . . . . . . . . . . . . . . . 108
Connecting Premolded Motor Feedback Cables . . . . . . . 108
Wiring Panel-mounted Breakout Board Kits. . . . . . . . . . 109
Wiring Low-profile Connector Kits . . . . . . . . . . . . . . . . 110
Understanding External Shunt Module Connections. . . . . . . 113
Understanding Resistive Brake Module Connections . . . . . . 114
Connecting Your SERCOS Fiber-optic Cables . . . . . . . . . . . 115
Chapter 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Configure the IAM/AM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Configure the Logix SERCOS interface Module . . . . . . . . . . 125
Configure the Logix Controller . . . . . . . . . . . . . . . . . . . 125
Configure the Logix Module . . . . . . . . . . . . . . . . . . . . . 126
Configure the Kinetix 6000 Modules . . . . . . . . . . . . . . . 128
Configure the Motion Group. . . . . . . . . . . . . . . . . . . . . 132
Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . 133
Download the Program. . . . . . . . . . . . . . . . . . . . . . . . . 134
Apply Power to the Kinetix 6000 Drive. . . . . . . . . . . . . . . . 135
Test and Tune the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Tune the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Troubleshooting the Kinetix 6000
Drive System
Removing and Replacing the
Kinetix 6000 Drive Modules
Chapter 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Interpreting Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 146
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
IAM/AM Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 152
SM Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Troubleshooting General System Problems . . . . . . . . . . . . . 155
Understanding Logix/Drive Fault Behavior . . . . . . . . . . 157
Supplemental Troubleshooting Information . . . . . . . . . . . . 160
Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . 160
Using Analog Test Points to Monitor System Variables . . 161
Chapter 8
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Removing Power Rail Modules . . . . . . . . . . . . . . . . . . . . . . 164
Replacing Power Rail Modules . . . . . . . . . . . . . . . . . . . . . . 165
Removing the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . 166
Replacing the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Publication 2094-UM001A-EN-P — September 2006
6 Table of Contents
Specifications and Dimensions
Appendix A
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Integrated Axis Module (converter) Power Specifications 170
Axis Module (inverter) Power Specifications. . . . . . . . . . 172
Shunt Module Power Specifications . . . . . . . . . . . . . . . . 173
Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . 177
Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Transformer Specifications for Control Power Input . . . . 179
Power Dissipation Specifications. . . . . . . . . . . . . . . . . . . . . 180
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . 181
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . 181
Weight Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . 183
External Shunt Module Specifications . . . . . . . . . . . . . . . . . 184
Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Interconnect Diagrams
Upgrading Firmware
Appendix B
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Power Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . 193
DC Common Bus Wiring Examples . . . . . . . . . . . . . . . . 197
Shunt Module Wiring Examples. . . . . . . . . . . . . . . . . . . 201
Axis Module/Motor Wiring Examples. . . . . . . . . . . . . . . 204
Controlling a Brake Example. . . . . . . . . . . . . . . . . . . . . 210
System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Appendix C
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Using ControlFLASH Software to Upgrade Drive Firmware. . 216
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Selecting the Drive to Upgrade . . . . . . . . . . . . . . . . . . . 217
Configuring Logix Communications . . . . . . . . . . . . . . . . 218
Flashing Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Troubleshooting ControlFLASH . . . . . . . . . . . . . . . . . . . 222
Verifying the Firmware Upgrade . . . . . . . . . . . . . . . . . . 223
Using DriveExplorer Software to Upgrade Drive Firmware. . 224
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Selecting Axis Modules to Upgrade . . . . . . . . . . . . . . . . 224
HyperTerminal Configuration . . . . . . . . . . . . . . . . . . . . 226
Flashing Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Publication 2094-UM001A-EN-P — September 2006
DC Common Bus Applications
Integrating Resistive Brake
Modules with Kinetix 6000 Drives
Table of Contents 7
Appendix D
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Calculating Total Bus Capacitance . . . . . . . . . . . . . . . . . . . 232
Calculating Additional Bus Capacitance . . . . . . . . . . . . . . . 232
Kinetix 6000 Capacitance Values . . . . . . . . . . . . . . . . . . . . 233
Common Bus Capacitance Example . . . . . . . . . . . . . . . . . . 234
Setting the Additional Bus Capacitance Parameter . . . . . . . . 235
Removing SERCOS Communication. . . . . . . . . . . . . . . . 235
Setting the Additional Bus Capacitance Parameter . . . . . 236
Saving the Add Bus Cap Parameter to
Non-Volatile Memory. . . . . . . . . . . . . . . . . . . . . . . . . 237
Reconnecting SERCOS Communication . . . . . . . . . . . . . 238
Appendix E
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Understanding Safety Precautions. . . . . . . . . . . . . . . . . . . . 240
Safety Standards for Reference . . . . . . . . . . . . . . . . . . . 240
Background on Safety Design . . . . . . . . . . . . . . . . . . . . 241
Stop Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Control Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Resistive Brake Module Wiring Examples . . . . . . . . . . . . . . 243
Setting the RBM Delay Time Using DriveExplorer . . . . . . . . 252
Removing SERCOS Communication. . . . . . . . . . . . . . . . 252
Setting the RBM Delay Time Parameter . . . . . . . . . . . . . 253
Saving the Delay Time Parameter to
Non-Volatile Memory. . . . . . . . . . . . . . . . . . . . . . . . . 254
Reconnecting SERCOS Communication . . . . . . . . . . . . . 255
Publication 2094-UM001A-EN-P — September 2006
8 Table of Contents
Publication 2094-UM001A-EN-P — September 2006
Preface
Read this preface to familiarize yourself with the rest of the manual.
About This Publication
Who Should Use this Manual
Conventions Used in This Manual
This manual provides detailed installation instructions for mounting,
wiring, and troubleshooting your Kinetix 6000 drive, and system
integration for your drive/motor combination with a Logix controller.
This manual is intended for engineers or technicians directly involved
in the installation and wiring of the Kinetix 6000 drive, and
programmers directly involved in the operation, field maintenance,
and integration of the Kinetix 6000 drive with a SERCOS interface
module.
If you do not have a basic understanding of the Kinetix 6000 drive,
contact your local Rockwell Automation sales representative before
using this product, for information on available training courses.
The conventions starting below are used throughout this manual.
• Bulleted lists such as this one provide information, not procedural
steps
• Numbered lists provide sequential steps or hierarchical
information
• Acronyms for the Kinetix 6000 drive components, shown in the
table below, are used throughout this manual.
Kinetix 6000 Component Catalog Numbers Acronym
Integrated Axis Module 2094-xCxx-Mxx IAM
Axis Module 2094-xMxx AM
Shunt Module 2094-BSP2 SM
Power Rail 2094-PRx PR
Power Rail (slim) 2094-PRSx PRS
Power Rail Slot Filler 2094-PRF PRF
Line Interface Module 2094-xLxx and -xLxxS-xx LIM
Resistive Brake Module 2090-XBxx-xx RBM
9 Publication 2094-UM001A-EN-P — September 2006
10
Additional Resources
The following documents contain additional information concerning
related Allen-Bradley products.
For Read This Document Publication Number
Information on the installation of your Bulletin 2094 Power Rail Kinetix 6000 Power Rail Installation Instructions 2094-IN003
Information on the installation and troubleshooting of your
Bulletin 2094 Line Interface Module (LIM)
Information on the installation of Bulletin 2094 Mounting
Brackets
Information on the installation and wiring of Bulletin 2090
Resistive Brake Modules
Information on proper handling, installing, testing, and
troubleshooting fiber-optic cables
Information on installing, configuring, and how to calculate the
data needed to correctly select a 1336 dynamic brake
Information, examples, and techniques designed to minimize
system failures caused by electrical noise
Information on wiring and troubleshooting your Kinetix 6000
safety drive
Specifications, motor/servo-drive system combinations, and
accessories for Kinetix motion control products
Drive and motor sizing with application analysis software Motion Analyzer CD, v4.2 or later PST-SG003
Information on configuring and troubleshooting your
ControlLogix and CompactLogix SERCOS interface modules
Information on configuring and troubleshooting your SoftLogix
PCI card
Line Interface Module Installation Instructions 2094-IN005
2094 Mounting Bracket Installation Instructions 2094-IN008
Resistive Brake Module Installation Instructions 2090-IN009
Fiber-optic Cable Installation and Handling Instructions 2090-IN010
1336 Dynamic Braking Installation Instructions 1336-5.64
System Design for Control of Electrical Noise Reference
Manual
EMC Noise Management DVD GMC-SP001
Kinetix Safe-off Feature Safety Reference Manual GMC-RM002
Kinetix Motion Control Selection Guide GMC-SG001
Motion Modules in Logix5000 Control Systems User
Manual
SoftLogix Motion Card Setup and Configuration Manual 1784-UM003
GMC-RM001
LOGIX-UM002
Information on installing, configuring, programming, and
operating a ControlLogix system
More detailed information on the use of ControlLogix motion
features and application examples
The instructions needed to program a motion application
For ControlFLASH information not specific to any drive family ControlFLASH Firmware Upgrade Kit User Manual 1756-6.5.6
Online product selection and system configuration tools,
including AutoCAD (DXF) drawings
For declarations of conformity (DoC) currently available from
Rockwell Automation
An article on wire sizes and types for grounding electrical
equipment
A glossary of industrial automation terms and abbreviations Rockwell Automation Industrial Automation Glossary AG-7.1
ControlLogix Controllers User Manual 1756-UM001
ControlLogix Motion Module Programming Manual 1756-RM086
Logix5000 Controllers Motion Instructions Reference
Manual
Rockwell Automation Configuration and Selection Tools
website
Rockwell Automation Product Certification website
National Electrical Code
1756-RM007
http://www.ab.com/
e-tools
http://
www.rockwellautomation.
com/products/certification
Published by the National
Fire Protection Association
of Boston, MA.
You can view or download publications at
http://literature.rockwellautomation.com
. To order paper copies of
technical documentation, contact your local Rockwell Automation
distributor or sales representative.
Publication 2094-UM001A-EN-P — September 2006
Start
Chapter
1
Introduction
Use this chapter to become familiar with the Kinetix 6000 drive
components. This chapter also reviews design and installation
requirements for Kinetix 6000 drive systems.
Top ic P ag e
Introduction 11
About the Kinetix 6000 Drive System 12
Catalog Number Explanation 16
Agency Compliance 16
11 Publication 2094-UM001A-EN-P — September 2006
12 Start
About the Kinetix 6000
The Kinetix 6000 multi-axis servo drive is designed to provide a
Kinetix Integrated Motion solution for applications with output power
Drive System
Kinetix 6000
Component
Integrated Axis
Module
Axis Module
Shunt Module 2094-BSP2
Power Rail
Power Rail Slot
Filler
Logix Controller
Platform
RSLogix 5000
Software
Servo Motors
Cables
AC Line Filters 2090-XXLF-xxxx
Line Interface
Module
External Shunt
Modules
Resistive Brake
Module
(1)
Refer to the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002, for more information.
Catalog Numbers Description
2094-xCxx-Mxx-S
2094-xCxx-Mxx
2094-BMxx-S
2094-xMxx Axis Module (AM), is a shared dc bus inverter (230V and 460V). The AM must be used with an IAM.
2094-PRSx
2094-PRx
2094-PRF
1756-MxxSE module
1768-M04SE module
1784-PM16SE PCI card
9324-RLD300ENE
MP-Series, 1326AB,
TL-Series,
F- and Y-Series
Motor Power, Feedback,
and Brake cables
Fiber-optic cables
2094-xLxx
2094-xLxxS
2094-XL75S-Cx
1394-SRxxxx
1336-MOD-Kxxxx
2090-XBxx-xx
(1)
(1)
requirements between 3 and 45 kW (4 and 49 A).
Kinetix 6000 Drive System Overview
Integrated Axis Module (IAM), with safe-off feature available with 230V and 460V ac input power and
contains an inverter and converter.
Integrated Axis Module (IAM), available with 230V and 460V ac input power and contains an inverter
and converter.
Axis Module (AM), with safe-off feature is a shared dc bus inverter (230V and 460V). The AM must be
used with an IAM.
Shunt Module (SM), This module mounts to the power rail and provides additional shunting capability in
regenerative applications.
Power Rail (PR) consists of copper bus bars and a circuit board with connectors for each module. The
power rail provides power and control signals from the converter section to adjacent inverters. The IAM,
AM, SM, and PRF modules mount to the power rail.
Power Rail Slot Filler (PRF) is used when one or more slots on the power rail are empty after all the
power rail components are installed. One PRF module is required for each empty slot.
SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix
platform and Kinetix 6000 drive system. The communication link uses the IEC 61491 SErial Real-time
COmmunication System (SERCOS) protocol over a fiber-optic cable.
RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of
controllers.
Compatible servo motors include the MP-Series (Low Inertia, Integrated Gear, Food Grade, and Stainless
Steel) 230 and 460V motors; TL-Series motors; 1326AB (M2L/S2L) and 1326AB (resolver) motors; F- and
Y-Series motors.
Motor power, feedback, and brake cables include integral molded, bayonet style, quick connect/
quick-release connectors at the motor. Power and brake cables have flying leads on the drive end and
straight connectors that connect to servo motors. Standard feedback cables have angled connectors
(45º) on the drive end and straight connectors that connect to servo motors. Optional feedback cables
have a straight connector on the motor end and flying leads that wire to a low-profile connector kit on
the drive end.
SERCOS fiber-optic cables are available in enclosure only, PVC, nylon, and glass with connectors at both
ends.
Bulletin 2090-XXLF-xxxx three-phase ac line filters are required to meet CE and available for use in 230V
and 460V systems.
Line Interface Module (LIM), contains the circuit breakers, ac line filter (2094-AL09 and -BL02 only),
power supplies, and safety contactor required for Kinetix 6000 operation. This module does not mount to
the power rail. Individual components can be purchased separately in place of the LIM.
Bulletin 1394 external passive shunt modules can be used when the IAM/AM internal shunt and power
rail mounted shunt module (2094-BSP2) capability is exceeded.
Bulletin 1336 external active shunt modules can be used when the internal shunt resistor (IAM/AM)
capability is exceeded.
Resistive Brake Module (RBM), includes a safety contactor for use in a control circuit. Contactors and
resistors reside in this module such that the motor leads can be disconnected from the drive with the
permanent magnet motor brought to an immediate stop. This module does not mount to the power rail.
Publication 2094-UM001A-EN-P — September 2006
Start 13
Typical Kinetix 6000 system installations include three-phase ac
configurations, with and without the line interface module (LIM), and
dc common bus configurations.
AC Line Filter
2090-XXLF-xxxx
SHOCK HAZARD
To avoid personal injury due to electrical shock, place a slot
filler module (catalog number 2094-PRF) in all empty slots on
the power rail.
Any power rail connector without a module installed will
disable the Kinetix 6000 three-phase power, however control
power is still present.
Typical Kinetix 6000 System Installation (with LIM)
Logix Controller Programming Network
Logix SERCOS interface Module
TM
SERCOS interface
Logix Platform
OK
CP
(ControlLogix is shown)
Tx (rear)
Rx (front)
Kinetix 6000 Multi-axis Servo Drive System
SERCOS Fiber-optic Ring
2090-SCxxx-x
RSLogix 5000
Software
Three-phase
Input Power
Line Interface Module
(optional component)
2094-xLxxS
and control string.
MP-Series, TL-Series, 1326AB (M2L/S2L),
F- and Y-Series Motors
(MPL-xxxx motors shown)
MAIN VAC
To input sensors
115/230V Control Power
Integrated
Axis Module
2094-xCxx-Mxx-S
Power Rail
2094-PRSx
I/O Connections
Motor Feedback Cable
2090-XXNFxx-Sxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Aux Feedback
2090-K6CK-Dxxx
Shunt Module
(optional component)
2094-BSP2
Slot Filler
Module
(required to
fill any unused
slots)
2094-PRF
Axis Modules (5)
2094-xMxx-S
Motor Power Cable
2090-XXNPxx-xxSxx
Publication 2094-UM001A-EN-P — September 2006
14 Start
Typical Kinetix 6000 System Installation (without LIM)
Line
Disconnect
Device
Input
Fusing
Magnetic
Contactor
Three-phase
Input Power
I/O Connections
To input sensors
and control string.
RSLogix 5000
Software
Single-phase
Control Power
AC Line Filter
2090-XXLF-xxxx
Integrated
Axis Module
2094-xCxx-Mxx-S
Power Rail
2094-PRSx
Logix Controller Programming Network
Kinetix 6000 Multi-axis Servo Drive System
SERCOS Fiber-optic Ring
2090-SCxxx-x
Logix SERCOS interface Module
Logix Platform
(ControlLogix is shown)
Shunt Module
(optional component)
2094-BSP2
Slot Filler
Module
(required to
fill any unused
slots)
2094-PRF
Axis Modules (5)
2094-xMxx-S
MP-Series, TL-Series, 1326AB (M2L/S2L),
F- and Y-Series Motors
(MPL-xxxx motors shown)
Motor Feedback Cable
2090-XXNFxx-Sxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Aux Feedback
2090-K6CK-Dxxx
Motor Power Cable
2090-XXNPxx-xxSxx
Publication 2094-UM001A-EN-P — September 2006
Typical DC Common Bus System Installation
Kinetix 6000 Multi-axis Servo Drive System
Start 15
Logix Controller Programming Network
Logix SERCOS interface Module
Three-phase
Input Power
Line Interface Module
(optional component)
2094-xLxxS
Integrated
Axis Module
2094-xCxx-Mxx-S
AC Line Filter
2090-XXLF-xxxx
115/230V Control Power
Integrated
Axis Module
2094-xCxx-Mxx-S
Power Rail
(2094-PRSx is shown)
DC Common Bus
Motors and other details common to both three-phase
ac and dc common bus configurations are removed.
SERCOS Fiber-optic Ring
2090-SCxxx-x
SERCOS interface
OK
CP
Logix Platform
(ControlLogix is shown)
Tx (rear)
Rx (front)
SERCOS Fiber-optic Ring
2090-SCxxx-x
RSLogix 5000
Software
Shunt Module
(optional component)
2094-BSP2
Slot Filler Module
(required to fill any
unused slots)
2094-PRF
Axis Modules (5)
2094-xMxx-S
Slot Filler Module
(required to fill any
unused slots)
2094-PRF
(2094-PRSx is shown)
Power Rail
Axis Modules (5)
2094-xMxx-S
In the example above, the leader IAM is connected to the follower
IAM via the dc common bus. When planning your panel layout, you
must calculate the total bus capacitance of your dc common bus
system to ensure that the leader IAM is sized sufficiently to pre-charge
the entire system.
Refer to Appendix D, beginning on page 231, for more information.
IMPORTANT
If total bus capacitance of your system exceeds the leader IAM
pre-charge rating and input power is applied, the IAM
seven-segment LED indicator will display error code E90
(pre-charge timeout fault). To correct this condition, you must
replace the leader IAM with a larger module or decrease the
total bus capacitance by removing axis modules.
Publication 2094-UM001A-EN-P — September 2006
16 Start
Catalog Number Explanation
Kinetix 6000 drive catalog numbers and descriptions are listed in the
table below.
Kinetix 6000 Drive Catalog Numbers
Integrated Axis Modules (230V
Kinetix 6000, IAM, 230V, 3 kW converter, 5 A inverter 2094-AC05-MP5-S 2094-AC05-MP5
Kinetix 6000, IAM, 230V, 3 kW converter, 9 A inverter 2094-AC05-M01-S 2094-AC05-M01
Kinetix 6000, IAM, 230V, 6 kW converter, 15 A inverter 2094-AC09-M02-S 2094-AC09-M02
Kinetix 6000, IAM, 230V, 11 kW converter, 24 A inverter 2094-AC16-M03-S 2094-AC16-M03
Kinetix 6000, IAM, 230V, 23 kW converter, 49 A inverter 2094-AC32-M05-S 2094-AC32-M05
Integrated Axis Modules (460V)
Kinetix 6000, IAM, 460V, 6 kW converter, 4 A inverter 2094-BC01-MP5-S 2094-BC01-MP5
Kinetix 6000, IAM, 460V, 6 kW converter, 9 A inverter 2094-BC01-M01-S 2094-BC01-M01
Kinetix 6000, IAM, 460V, 15 kW converter, 15 A inverter 2094-BC02-M02-S 2094-BC02-M02
Kinetix 6000, IAM, 460V, 28 kW converter, 30 A inverter 2094-BC04-M03-S 2094-BC04-M03
Kinetix 6000, IAM, 460V, 45 kW converter, 49 A inverter 2094-BC07-M05-S 2094-BC07-M05
Axis Modules (230V)
Kinetix 6000, AM, 230V, 5 A 2094-AMP5-S 2094-AMP5
Kinetix 6000, AM, 230V, 9 A 2094-AM01-S 2094-AM01
Kinetix 6000, AM, 230V, 15 A 2094-AM02-S 2094-AM02
Kinetix 6000, AM, 230V, 24 A 2094-AM03-S 2094-AM03
Kinetix 6000, AM, 230V, 49 A 2094-AM05-S 2094-AM05
Axis Modules (460V)
Kinetix 6000, AM, 460V, 4 A 2094-BMP5-S 2094-BMP5
Kinetix 6000, AM, 460V, 9 A 2094-BM01-S 2094-BM01
Kinetix 6000, AM, 460V, 15 A 2094-BM02-S 2094-BM02
Kinetix 6000, AM, 460V, 30 A 2094-BM03-S 2094-BM03
Kinetix 6000, AM, 460V, 49 A 2094-BM05-S 2094-BM05
Shunt Module
Kinetix 6000, SM, 230V/460V, 200W N/A 2094-BSP2
Catalog Number
(with safe-off feature)
Catalog Number
(without safe-off feature)
Agency Compliance
Publication 2094-UM001A-EN-P — September 2006
If this product is installed within the European Union or EEC regions
and has the CE mark, the following regulations apply.
ATTENTION
Meeting CE requires a grounded system, and the method of
grounding the ac line filter and drive must match. Failure to do
this renders the filter ineffective and may cause damage to the
filter.
For grounding examples, refer to Grounded Power
Configurations on page 71.
Start 17
For more information on electrical noise reduction, refer to the System
Design for Control of Electrical Noise Reference Manual, publication
GMC-RM001.
CE Requirements (System without LIM)
To meet CE requirements when your Kinetix 6000 system does not
include the line interface module (LIM), the following requirements
apply.
• Install an ac line filter (2090-XXLF-xxxx) as close to the integrated
axis module (IAM) as possible.
• Use 2090 series motor power cables or use connector kits and
terminate the cable shields to the chassis clamp provided.
• Combined motor power cable length for all axes on the same dc
bus must not exceed 240 m (787 ft) with 460V systems or 160 m
(525 ft) with 230V systems. Drive-to-motor power cables must not
exceed 90 m (295.5 ft).
• Use 2090 series motor feedback cables or use connector kits and
properly terminate the feedback cable shield. Drive-to-motor
feedback cables must not exceed 90 m (295.5 ft).
• Install the Kinetix 6000 system inside an enclosure. Run input
power wiring in conduit (grounded to the enclosure) outside of
the enclosure. Separate signal and power cables.
Refer to Chapter 5, beginning on page 69, for wiring instructions and
the Kinetix Motion Control Selection Guide, publication GMC-SG001,
for catalog numbers.
CE Requirements (System with LIM)
To meet CE requirements when your Kinetix 6000 system includes the
line interface module (LIM), follow all the requirements as stated in
CE Requirements (System without LIM) and these additional
requirements as they apply to the ac line filter.
• Install the LIM (2094-AL09 or -BL02) as close to the integrated axis
module (IAM) as possible.
• Install the LIM (2094-ALxxS, -BLxxS or -XL75S-Cx) with line filter
(2090-XXLF-xxxx) as close to the IAM as possible.
When the LIM (2094-ALxxS, -BLxxS or -XL75S-Cx) supports two
IAMs, each IAM requires an ac line filter installed as close to the
IAM as possible.
Publication 2094-UM001A-EN-P — September 2006
18 Start
Publication 2094-UM001A-EN-P — September 2006
Chapter
Planning the Kinetix 6000 Drive System
Installation
2
Introduction
This chapter describes system installation guidelines used in
preparation for mounting your Kinetix 6000 drive components.
Top ic P ag e
Introduction 19
System Design Guidelines 20
Minimizing Electrical Noise 27
ATTENTION
Plan the installation of your system so that you can perform all
cutting, drilling, tapping, and welding with the system removed
from the enclosure. Because the system is of the open type
construction, be careful to keep any metal debris from falling
into it. Metal debris or other foreign matter can become lodged
in the circuitry, which can result in damage to components.
19 Publication 2094-UM001A-EN-P — September 2006
20 Planning the Kinetix 6000 Drive System Installation
System Design Guidelines
Use the information in this section when designing your enclosure
and planning to mount your system components on the panel.
For on-line product selection and system configuration tools,
including AutoCAD (DXF) drawings of the product, refer to
http://www.ab.com/e-tools.
System Mounting Requirements
• In order to comply with UL and CE requirements, the Kinetix 6000
system must be enclosed in a grounded conductive enclosure
offering protection as defined in standard EN 60529 (IEC 529) to
IP55 such that they are not accessible to an operator or unskilled
person. A NEMA 4X enclosure exceeds these requirements
providing protection to IP66.
• The panel you install inside the enclosure for mounting your
system components must be on a flat, rigid, vertical surface that
won’t be subjected to shock, vibration, moisture, oil mist, dust, or
corrosive vapors.
• Size the drive enclosure so as not to exceed the maximum
ambient temperature rating. Consider heat dissipation
specifications for all drive components.
• Segregate input power wiring and motor power cables from
control wiring and motor feedback cables. Use shielded cable for
power wiring and provide a grounded 360° clamp termination.
• Use high-frequency (HF) bonding techniques to connect the
modules, enclosure, machine frame, and motor housing, and to
provide a low-impedance return path for high-frequency (HF)
energy and reduce electrical noise.
Refer to the System Design for Control of Electrical Noise
Reference Manual, publication GMC-RM001, to better understand
the concept of electrical noise reduction.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation 21
Transformer Selection
The integrated axis module (IAM) does not require an isolation
transformer for three-phase input power. However, a transformer may
be required to match the voltage requirements of the controller to the
available service.
To size a transformer for the main ac power inputs, refer to the Circuit
Breaker/Fuse Specifications on page 177 and Transformer
Specifications for Control Power Input on page 179.
IMPORTANT
If using an autotransformer, make sure that the phase to
neutral/ground voltages do not exceed the input voltage ratings
of the drive.
IMPORTANT
Use a form factor of 1.5 for three-phase power (where form
factor is used to compensate for transformer, drive module and
motor losses, and to account for utilization in the intermittent
operating area of the torque speed curve).
Example: Sizing a transformer to the voltage requirements of a
2094-AC05-M01 Integrated Axis Module:
2094-AC05-M01 = 3 kW continuous x 1.5 = 4.5 KVA transformer
Publication 2094-UM001A-EN-P — September 2006
22 Planning the Kinetix 6000 Drive System Installation
Circuit Breaker/Fuse Selection
The Kinetix 6000 system utilizes internal short circuit output
protection and is suitable for use on a circuit capable of delivering up
to 100,000 amperes, when protected by class CC, J, L, and R fuses.
Circuit breakers with adequate widthstand and interrupt ratings, as
defined in NEC 2002, article 110.9 and 110.10, are also permitted.
The Bulletin 140M product may be another acceptable means of
protection with the Kinetix 6000 system. As with fuses and circuit
breakers, you must make sure that the selected components are
properly coordinated and meet applicable codes. When applying the
140M product, evaluation of the short circuit available current is
critical and must be kept below the short circuit rating of the 140M
product. As long as you do this review, and the conditions for use are
met, the 140M product is appropriate for use with the Kinetix 6000
system.
The line interface modules (LIM), (models 2094-AL09 and -BL02)
contain supplementary protection devices. When these models are
used, protection on the line side of the LIM with a maximum let
through current of 5000 amperes is required. Fuses must be class J or
CC only.
Overcurrent protection must be adequately coordinated per NEC
2002, article 240.
In most cases, fuses selected to match the drive input current rating
will meet the NEC requirements and provide the full drive capabilities.
Dual element, time delay (slow acting) fuses should be used to avoid
nuisance trips during the inrush current of power initialization.
Refer to Circuit Breaker/Fuse Specifications on page 177 for
recommended circuit breakers and fuses.
Refer to Power Specifications on page 170 for input current and inrush
current specifications for your IAM.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation 23
Enclosure Selection
The following example is provided to assist you in sizing an enclosure
for your Kinetix 6000 system. The example system consists of the
following components:
• 6-axis Kinetix 6000 servo drive system
• Line Interface Module (LIM)
• ControlLogix chassis and modules (controller)
Size the Kinetix 6000 servo drive and LIM and use the results to
predict the amount of heat dissipated into the enclosure. You will also
need heat dissipation data from other equipment inside the enclosure
(such as ControlLogix controller). Once the total amount of heat
dissipation (in watts) is known, the minimum enclosure size can be
calculated.
Kinetix 6000 System Heat Dissipation Example
Enclosure Component Description
2094-AC09-M02
2094-AM02 Axis module (AM), 200/230V, 15 A 60% 82
2094-AM02 Axis module (AM), 200/230V, 15 A 60% 82
2094-AM01 Axis module (AM), 200/230V, 9 A 40% 69
2094-AM01 Axis module (AM), 200/230V, 9 A 40% 69
2094-AM01 Axis module (AM), 200/230V, 9 A 20% 62
2094-AL09 Line interface module (LIM), 200/230V, 6 kW, 6 A; 24V dc 3 A 100% 72
2094-PR6 Power rail, 230V, 6 axis N/A 0
2090-XB33-32 Resistive brake module (RBM), 33 A, 32 Ω N/A 30
Total Kinetix 6000 system wattage 572
(1)
To determine heat dissipation specifications for the Kinetix 6000 components, refer to Power Dissipation Specifications on page 180.
Integrated axis module (IAM),
200/230V
6 kW (converter section) 20% 33
15A (inverter section) 40% 73
Loading
(1)
Heat Dissipation
watts
(1)
Publication 2094-UM001A-EN-P — September 2006
24 Planning the Kinetix 6000 Drive System Installation
ControlLogix System Heat Dissipation Example
Enclosure
Component
Description
Backplane Power
(1)
Load
watts
Heat Dissipation
watts
1756-M08SE 8-axis SERCOS interface module 3.2 0
1756-L55M12 5555 ControlLogix processor 4.5 0
1756-IB16D 16 -point input module 0.84 5.8
1756-OB16D 16 -point output module 4.64 3.3
1756-ENBT Ethernet communications module 4.0 0
Backplane total
17.18
1756-PB72 24V dc ControlLogix power supply N/A
(2)
N/A
25
1756-A7 7-slot mounting chassis N/A N/A
Total ControlLogix system wattage 34.1
(1)
For ControlLogix module specifications, refer to the ControlLogix Selection Guide, publication 1756-SG001.
(2)
Real power heat dissipation is determined by applying the backplane power load (17.18W) to the graph below.
ControlLogix Real Power
(watts)
75
60
45
30
15
0
0 20 40 60 80 100
Real Power (watts)
1756-P B72
1756-P B75
dc
Backplane
Power Load
(1)
(2)
For backplane power loading requirements of other ControlLogix
power supplies, refer to the ControlLogix Selection Guide, publication
1756-SG001.
In this example, the amount of power dissipated inside the cabinet is
the sum of the Kinetix 6000 system value (572 W) and the
ControlLogix system value (34 W) for a total of 606 W.
With no active method of heat dissipation (such as fans or air
conditioning) either of the following approximate equations can be
used.
Metric Standard English
0.38Q
A
=
------------- -----------
1.8T 1.1–
Where T is temperature difference between
inside air and outside ambient (°C), Q is heat
generated in enclosure (Watts), and A is
enclosure surface area (m2). The exterior surface
of all six sides of an enclosure is calculated as
Where T is temperature difference between
inside air and outside ambient (°F), Q is heat
generated in enclosure (Watts), and A is
enclosure surface area (ft²). The exterior surface
of all six sides of an enclosure is calculated as
A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height) are in
meters.
Where d (depth), w (width), and h (height) are in
inches.
4.08Q
A
=
------------- --T 1.1–
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation 25
The maximum ambient rating of the Kinetix 6000 system is 50 °C
(122 °F) and if the maximum environmental temperature is 30 °C
(86 °F) then Q=606 and T=20 in the equation below.
0.38 606()
A
------------- ------------ -------6.59m
1.8 20()1.1–
≈=
2
In this example, the enclosure must have an exterior surface of 6.59
2
meters
. If any portion of the enclosure is not able to transfer heat, it
should not be included in the calculation.
Since the minimum cabinet depth to house the 230V drive (selected
for this example) is 200 mm (7.9 in.), then the cabinet needs to be
approximately 2100 mm (high) x 1250 mm (wide) x 200 mm (deep).
2 x (0.2 x 1.25) + 2 x (0.2 x 2.1) + 2 x (1.25 x 2.1) = 6.59m
2
Because this cabinet size is considerably larger than what is necessary
to house the system components, it may be more efficient to provide
a means of cooling in a smaller cabinet. Contact your cabinet
manufacturer for options available to cool your cabinet.
Publication 2094-UM001A-EN-P — September 2006
26 Planning the Kinetix 6000 Drive System Installation
Minimum Clearance Requirements
This section provides information to assist you in sizing your cabinet
and positioning your Kinetix 6000 system components.
IMPORTANT
Mount the module in an upright position. Do not mount the
module on its side.
Minimum Clearance Requirements
Clearance above
for airflow and installation.
Integrated Axis Module (IAM)
(2094-AC05-Mxx is shown
mounted on power rail)
Clearance left of the
module is not required.
(2094-PRSx is shown)
(1)
The power rail (slim), catalog number 2094-PRSx, does not extend left or right of the first or last module
(respectively). When using power rail (catalog number 2094-PRx) the power rail extends approximately
25.4 mm (1.0 in.) left of the IAM and right of the last module mounted on the rail.
(1)
Power Rail
Clearance right of the
module is not required.
Clearance below
for airflow and installation.
(1)
Minimum Clearance Dimensions
Cat. No. Clearance Above, Min Clearance Below, Min Cabinet Depth Clearance, Min
2094-AC05, -AC09, -AMP5, -AM01, -AM02
2094-BC01, -BC02, -BMP5, -BM01, -BM02
2094-BSP2
2094-AC16, -AC32, -AM03, -AM05
2094-BC04, -BC07, -BM03, -BM05 272 mm (10.7 in.)
IMPORTANT
50.8 mm (2.0 in.) 50.8 mm (2.0 in.)
305 mm (12.0 in.) 50.8 mm (2.0 in.)
Although clearance left and right of the power rail is not
necessary for ventilation, additional clearance is required when
200 mm (7.9 in.)
272 mm (10.7 in.)
200 mm (7.9 in.)
mounted adjacent to noise sensitive equipment or clean
wireways.
Refer to page 180 for power dissipation specifications.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation 27
Minimizing Electrical Noise
This section outlines best practices which minimize the possibility of
noise-related failures as they apply specifically to Kinetix 6000 system
installations. For more information on the concept of high-frequency
(HF) bonding, the ground plane principle, and electrical noise
reduction, refer to the System Design for Control of Electrical Noise
Reference Manual, publication GMC-RM001.
Bonding Modules
Bonding is the practice of connecting metal chassis, assemblies,
frames, shields, and enclosures to reduce the effects of
electromagnetic interference (EMI).
Unless specified, most paints are not conductive and act as insulators.
To achieve a good bond between power rail and the subpanel,
surfaces need to be paint-free or plated. Bonding metal surfaces
creates a low-impedance return path for high-frequency energy.
IMPORTANT
To improve the bond between the power rail and subpanel,
construct your subpanel out of zinc plated (paint-free) steel.
Improper bonding blocks the direct return path and allows
high-frequency energy to travel elsewhere in the cabinet. Excessive
high-frequency energy can effect the operation of other
microprocessor controlled equipment.
Publication 2094-UM001A-EN-P — September 2006
28 Planning the Kinetix 6000 Drive System Installation
The illustrations that follow show details of recommended bonding
practices for painted panels, enclosures, and mounting brackets.
Recommended Bonding Practices for Painted Panels
Stud-mounting the Subpanel
to the Enclosure Back Wall
Back Wall of
Enclosure
Subpanel Welded Stud
Star Washer
Nut
Use a wire brush to remove paint from
threads to maximize ground
connection.
Use plated panels or scrape paint on
front of panel.
Welded Stud
Mounting Bracket or
Flat Washer
Nut
Stud-mounting a Ground Bus
or Chassis to the Subpanel
Ground Bus
Flat Washer
If the mounting bracket is coated
with a non-conductive material
(anodized or painted), scrape the
Star Washer
material around the mounting hole.
Subpanel
Scrape Paint
Bolt-mounting a Ground Bus or Chassis to the Back-panel
Ground Bus or
Mounting Bracket
Flat Washer
Nut
Subpanel
Tapped Hole
Nut
Scrape paint on both sides of
panel and use star washers.
Star Washer
Flat Washer
Bolt
Star Washer
Star Washer
If the mounting bracket is coated
with a non-conductive material
(anodized or painted), scrape the
material around the mounting hole.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation 29
Bonding Multiple Subpanels
Bonding multiple subpanels creates a common low impedance exit
path for the high frequency energy inside the cabinet. Subpanels that
are not bonded together may not share a common low impedance
path. This difference in impedance may affect networks and other
devices that span multiple panels.
Multiple Subpanels and Cabinet Recommendations
Bond the top and bottom of each subpanel to the cabinet using
25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Cabinet ground bus
bonded to the subpanel.
Scrape the paint around each fastener to
maximize metal to metal contact.
Publication 2094-UM001A-EN-P — September 2006
30 Planning the Kinetix 6000 Drive System Installation
Establishing Noise Zones
Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or
-XL75S-Cx) is used in the Kinetix 6000 system and mounted left of the
IAM with the ac (EMC) line filter mounted above the LIM:
• The clean zone (C) is to the right and beneath the Kinetix 6000
system (grey wireway).
• The dirty zone (D) is to the left and above the Kinetix 6000
system, and above and below the LIM (black wireway).
• The very dirty zone (VD) is from the filter output to IAM. Shielded
cable is required on the EMC filter (load side) and the braided
shield attached to the clamp provided.
• The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM mounted left of IAM)
Dirty Wireway
D
D
VAC Load
D
VAC Line
D
AC Line Filter
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
MAIN VAC
Line Interface Module
VD
D
D
VD
Clean Wireway
Motor Power Cables
D
D
C
D
Fiber-optic Cable
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000 System
(1)
and Feedback Cables
I/O
(2)
Publication 2094-UM001A-EN-P — September 2006
Route 24V dc I/O
shielded cable.
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM I/O cable in dirty wireway.
(2)
When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For
examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication
GMC-RM001.
Route encoder/analog/registration
shielded cables.
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