Page 1
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
Page 2
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.
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
8 Table of Contents
Publication 2094-UM001A-EN-P — September 2006
Page 9
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
Page 10
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
Page 11
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
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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
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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
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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
Page 15
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.
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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.
Page 17
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.
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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
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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.
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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
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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.
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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)
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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–
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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.
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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.
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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
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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
Page 29
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
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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.
Page 31
Planning the Kinetix 6000 Drive System Installation 31
Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or
-XL75S-Cx) is used in the Kinetix 6000 system and mounted right of
the IAM with the ac (EMC) line filter mounted behind the IAM:
• The clean zone (C) is to the left and beneath the Kinetix 6000
system (grey wireway).
• The dirty zone (D) is to the right 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 with EMC filter behind IAM)
Clean Wireway
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
No sensitive
equipment within
150 mm (6.0 in.).
(1)
I/O
C
and Feedback Cables
Route encoder/analog/registration
shielded cables.
VD
(2)
VD
Dirty Wireway
Motor Power Cables
D
D
D
D
Fiber-optic
Cable
VAC Load
D
AC Line Filter
Kinetix 6000
System
C
VAC Line
AUX VAC Output,
and 24V dc Brake
MAIN VAC
Line Interface Module
Route 24V dc I/O
shielded cable.
D
Control VAC,
D
I/O
D
(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.
Publication 2094-UM001A-EN-P — September 2006
Page 32
32 Planning the Kinetix 6000 Drive System Installation
Observe the following guidelines when a LIM (2094-ALxxS or
-XLxxS-Cx) is used in the Kinetix 6000 system and mounted right of
the drive with the ac (EMC) line filter mounted behind the LIM:
• The clean zone (C) is to the left and beneath the Kinetix 6000
system (grey wireway).
• The dirty zone (D) is to the right 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 drive.
Shielded cable is required on the EMC filter (load side) and the
braided shield attached to the clamp (when provided).
Establishing Noise Zones (EMC filter behind LIM)
Clean Wireway
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
No sensitive
equipment within
150 mm (6.0 in.).
(2)
Kinetix 6000
System
(1)
I/O
C
and Feedback Cables
Route encoder/analog/registration
shielded cables.
VD
Motor Power Cables
D
D
Dirty Wireway
D
D
VAC Line
VAC Load
LIM
PR/PRS
MAIN VAC
Control VAC,
Auxiliary VAC,
and 24V dc Brake
PR
PRS
LIM
PR
LIM
D
I/O
VD
AC (EMC)
Line Filter
PR
PRS
LIM
LIM
PR/PRS
C
Line Interface Module
(2094-ALxxS shown)
PR
2094 Mounting
(3)
Brackets
x2
D
Route 24V dc I/O
shielded cable.
Publication 2094-UM001A-EN-P — September 2006
(1)
If drive system 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.
(3)
Only the 2094-ALxxS and -XL75S-Cx Line Interface Modules are compatible with the 2094 Mounting Brackets.
The 2094-BLxxS, -AL09, and -BL02 models are not compatible.
Page 33
Planning the Kinetix 6000 Drive System Installation 33
Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or
-XL75S-Cx) is used in a dc common bus configuration and the
follower IAM is mounted below the leader IAM:
Keep the dc common bus cable (very dirty) segregated from all other
cables (not in a wireway).
Establishing Noise Zones (dc common bus)
Dirty Wireway
D
VAC Line, AUX VAC Output, 24V
VAC Load
AC Line Filter
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
D
VAC Line
MAIN VAC
D
Very Dirty DC Bus Connections
Line Interface Module
Segregated (not in wireway)
Clean Wireway
VD
VD
Motor Power Cables
D
D
D
Fiber-optic Cable
D
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000 System
(leader IAM)
(1)
I/O
and Feedback Cables
C
D
D
D
D
(2)
VD
Fiber-optic Cable
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000 System
(follower IAM)
(1)
I/O
and Feedback Cables
C
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.
Publication 2094-UM001A-EN-P — September 2006
(2)
Page 34
34 Planning the Kinetix 6000 Drive System Installation
Observe the following guidelines when a LIM (2094-AL09 or -BL02) is
used in the Kinetix 6000 system and mounted left of the IAM:
This layout is preferred due to the reduced size of the very dirty zone.
• 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 limited to where the LIM VAC output
jumpers over to the IAM. Shielded cable is required only if the
very dirty cables enter a wireway.
• The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM mounted left of IAM)
Dirty Wireway
D
D
(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.
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
D
Line Interface Module
Route 24V dc I/O
shielded cable.
(1)
Motor Power Cables
D
VD
C
D
Route encoder/analog/registration
I/O
shielded cables.
Clean Wireway
Fiber-optic Cable
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
C
(1)
and Feedback Cables
(2)
Publication 2094-UM001A-EN-P — September 2006
Page 35
Planning the Kinetix 6000 Drive System Installation 35
Observe the following guidelines when a LIM (2094-AL09 or -BL02) is
used in the Kinetix 6000 system and mounted above the IAM:
• 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 LIM VAC output is very dirty (VD). Use shielded cable with a
braid clamp attached at both ends of the cable to reduce the rating
to dirty (D).
• The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM mounted above IAM)
Dirty Wireway Clean Wireway
D
D
D
Motor Power Cables
C
Route encoder/analog/registration
Route 24V dc I/O
shielded cable.
VD
D
Very dirty LIM/IAM
connections must be
shielded with braid
clamp at both ends.
Line Interface Module
Fiber-optic Cable
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
C
(2)
I/O
and Feedback Cables
shielded cables.
(1)
(2)
(1)
For examples of shield clamp attachment, refer to the System Design for Control of Electrical Noise Reference
Manual, publication GMC-RM001.
(2)
If IAM/AM I/O cable contains (dirty) relay wires, route cable in dirty wireway.
(3)
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.
Publication 2094-UM001A-EN-P — September 2006
Page 36
36 Planning the Kinetix 6000 Drive System Installation
Observe the following guidelines when individual input power
components are used in the Kinetix 6000 system and the LIM
(2094-xLxx or -xLxxS-xx) is not used:
• The clean zone (C) is beneath the Kinetix 6000 system and
includes the I/O wiring, feedback cable, and dc filter (grey
wireway).
• The dirty zone (D) is above the Kinetix 6000 system (black
wireway) and includes the circuit breakers, transformer, 24V dc
power supply, contactors, ac line filter, and motor power cables.
• The very dirty zone (VD) is limited to where the ac line (EMC)
filter VAC output jumpers over to the IAM. Shielded cable is
required only if the very dirty cables enter a wireway.
• The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (No LIM)
Dirty Wireway Clean Wireway
D
Circuit
Breaker
XFMR
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable in dirty wireway.
(2)
When space to the right of the IAM does not permit 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.
(3)
This is a clean 24V dc available for any device that may require it. The 24V enters the clean wireway and exits
to the right.
(4)
This is a dirty 24V dc available for motor brakes and contactors. The 24V enters the dirty wireway and exits to
the left.
24V Motor
Brake PS
(4)
D
Route 24V dc I/O
shielded cable.
DC
Filter
(3)
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
(1)
D
Contactors
Kinetix 6000 System
(1)
I/O
C
and Feedback Cables
VD
AC
Line Filter
Route encoder/analog/registration
shielded cables.
Motor Power Cables
D
(2)
(2)
C
Publication 2094-UM001A-EN-P — September 2006
Page 37
Planning the Kinetix 6000 Drive System Installation 37
Observe the following guidelines when installing your 1756-MxxSE
SERCOS interface module:
• The clean zone (C) is beneath the less noisy modules (I/O, analog,
encoder, registration, etc. (grey wireway).
• The dirty zone (D) is above and below the power supply and
noisy modules (black wireway).
• The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (ControlLogix)
Dirty Wireway
(1)
D
AC Line
Filter
Line Filter/Power Supply
Connections Segregated
(not in wireway)
Route dirty wireways directly above the ControlLogix rack
(shielded by the chassis).
D
Dirty I/O
(24V dc I/O, ac I/O)
Spare Slots
(Analog, Encoder
C
Clean I/O
Registration)
Clean Wireway
Cable Categories for Kinetix 6000 Systems
The table below indicates the zoning requirements of cables
connecting to the Kinetix 6000 drive components.
Integrated Axis Module (converter side)
Zone Method
Wire/Cable Connector
CTRL 1 and 2 CPD X
DC-/DC+ (unshielded cable)
L1, L2, L3 (shielded cable) X X
L1, L2, L3 (unshielded cable) X
CONT EN- and CONT EN+ (M1 contactor) CED X
DPI DPI X X
IPD
Ver y
Dirty
Dirty Clean
X
Publication 2094-UM001A-EN-P — September 2006
Ferrite
Sleeve
Shielded
Cable
Page 38
38 Planning the Kinetix 6000 Drive System Installation
Integrated Axis Module or Axis Module (inverter side)
Wire/Cable Connector
U, V, W (motor power) MP X X
MBRK-, MBRK+ (motor brake)
MBRK-, MBRK+ (motor brake)
1326AB motors with resolver feedback
DBRK-, DBRK+ (resistive brake) X
COM, PWR (24V dc), filtered
COM, PWR (24V dc), unfiltered
COM, PWR (24V dc), safety enable, and
feedback signals for safe-off feature
Motor feedback MF X X
Auxiliary feedback AF X X
Registration and analog outputs
Others X
Fiber-optic Rx and Tx No Restrictions
(1)
This is a clean 24V dc available for any device that may require it.
(2)
This is a dirty 24V dc available for motor brakes and contactors.
(1)
(2)
Zone Method
Ver y
Dirty
Dirty Clean
BC
SO X
IOD
Ferrite
Sleeve
Shielded
Cable
X
XX
X
X
XX
Line Interface Module
Zone Method
Wire/Cable Connector
Ver y
Dirty
Dirty Clean
Ferrite
Sleeve
Shielded
Cable
VAC line (main input) IPL X
230V ac input APL X
VAC load (shielded option)
VAC load (unshielded option) X
OPL
XX
Control power output CPL X
MBRK PWR, MBRK COM P1L/PSL X
Status I/O IOL X
Auxiliary 230V ac P2L X
External Shunt Resistor Kit
Zone Method
Wire/Cable Connector
COL, DC+ (shielded option)
COL, DC+ (unshielded option) X
RC
Thermal switch TS X X
Fan (if present) N/A X
Ver y
Dirty
Dirty Clean
Ferrite
Sleeve
Shielded
Cable
XX
Publication 2094-UM001A-EN-P — September 2006
Page 39
Planning the Kinetix 6000 Drive System Installation 39
Resistive Brake Module
Zone Method
Wire/Cable Connections
Resistive brake module coil power TB3-6 and TB3-7 X
Resistive brake module I/O
Resistive brake module
drive and motor power
230V power TB4 X
TB1-1...-5
and TB3-8
TB1 and TB2 X X
Ver y
Dirty
Dirty Clean
Noise Reduction Guidelines for Drive Accessories
When mounting an ac (EMC) line filter or external shunt resistor refer
to the sections below for guidelines designed to reduce system
failures caused by excessive electrical noise.
Ferrite
Sleeve
X
Shielded
Cable
AC Line Filters
Observe the following guidelines when mounting your ac (EMC) line
filter (refer to the figure on page 36 for an example):
• Mount the ac line filter on the same panel as the Kinetix 6000
drive and as close to the power rail as possible.
• Good HF bonding to the panel is critical. For painted panels, refer
to the examples on page 28.
• Segregate input and output wiring as far as possible.
IMPORTANT
CE test certification applies only to ac line filter and single
power rail. Sharing a line filter with multiple power rails may
perform satisfactorily, but the user takes legal responsibility.
Publication 2094-UM001A-EN-P — September 2006
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40 Planning the Kinetix 6000 Drive System Installation
External Shunt Resistor
Observe the following guidelines when mounting your external shunt
resistor outside the enclosure:
• Mount circuit components and wiring in the very dirty zone or in
an external shielded enclosure. Run shunt power and fan wiring
inside metal conduit to minimize the effects of EMI and RFI.
• Mount resistors (other than metal-clad) in a shielded and
ventilated enclosure outside the cabinet
• Keep unshielded wiring as short as possible. Keep shunt wiring as
flat to the cabinet as possible.
• Route thermal switch and fan wires separate from shunt power.
External Shunt Resistor Outside the Enclosure
Customer-supplied
Metal Enclosure
clearance (min) on all four
sides of the shunt module.
Shunt thermal Switch and Fan Wires (when present)
Dirty Wireway
Shunt Power Wiring Methods:
Twisted pair, two twists per foot (min) (3rd choice).
Very Dirty Connections Segregated
(not in wireway)
D
D
Line Interface Module
D
D
150 mm (6.0 in.)
Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
(1)
Motor Power Cables
D
VD
C
1394 Digital Servo Controller
300W Shunt Module
ALLEN-BRADLEY
R
BULLETIN 1394 300W SHUNT MODULE
CAT. PART SER.
INPUT DC INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.
FOR USE WITH 1394-SJT22-X SYSTEM MODULE
D
VD
I/O and Feedback Cables
Metal Conduit
(where required
by local code)
Clean Wireway
2094-BSP2
Shunt Module
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
C
Route 24V dc I/O
shielded cable.
Publication 2094-UM001A-EN-P — September 2006
Enclosure
Route encoder/analog/registration
shielded cables.
Page 41
Planning the Kinetix 6000 Drive System Installation 41
When mounting your shunt module inside the enclosure, follow these
additional guidelines:
• Metal-clad modules can be mounted anywhere in the dirty zone,
but as close to the Kinetix 6000 system as possible.
• Shunt power wires can be run with motor power cables.
• Keep unshielded wiring as short as possible. Keep shunt wiring as
flat to the cabinet as possible.
• Separate shunt power cables from other sensitive, low voltage
signal cables.
External Shunt Resistor Inside the Enclosure
Dirty Wireway
Shunt thermal Switch and Fan Wires (when present)
Very Dirty Connections Segregated
(not in wireway)
D
D
Line Interface Module
D
D
Enclosure
clearance (min) on all four
sides of the shunt module.
VD
C
150 mm (6.0 in.)
Motor Power Cables
D
1394 Digital Servo Controller
ALLEN-BRADLEY
R
BULLETIN 1394 300W SHUNT MODULE
CAT. PART SER.
INPUT DC INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.
FOR USE WITH 1394-SJT22-X SYSTEM MODULE
300W Shunt Module
VD
Shunt Power Wiring Methods:
Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
Twisted pair, two twists per foot (min) (3rd choice).
D
2094-BSP2
Shunt Module
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
I/O and Feedback Cables
Clean Wireway
C
Route 24V dc I/O
shielded cable.
Route encoder/analog/registration
shielded cables.
Publication 2094-UM001A-EN-P — September 2006
Page 42
42 Planning the Kinetix 6000 Drive System Installation
Resistive Brake Modules
Observe the following guidelines when mounting your resistive brake
module (RBM):
• Mount circuit components and wiring in the dirty zone or in an
external shielded enclosure. If mounting the RBM in a separate
ventilated shielded enclosure, run wiring inside metal conduit to
minimize the effects of EMI and RFI.
• Keep unshielded wiring as short as possible. Keep wiring as flat to
the cabinet as possible.
• Route RBM power and I/O cables separate from other sensitive
low voltage signal cables.
Establishing Noise Zones (RBM mounted above AM)
Dirty Wireway
D
Very Dirty LIM/IAM Connections
Segregated (not in wireway)
LIM VAC Input Power
D
Line Interface Module
D
LIM and IAM/AM (dirty) I/O
Fiber-optic
Cable
VD
D
RBM I/O
D
IAM/AM Feedback and
Clean Wireway
D
Motor Power
Cables
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
C
(clean) I/O
Publication 2094-UM001A-EN-P — September 2006
Motor Brake and Thermal Switch
The thermal switch and brake are mounted inside the motor, but how
you connect to the axis module depends on the motor series.
Refer to Wiring the Motor/Resistive Brake (BC) Connector on page
101 for wiring guidelines. Refer to Axis Module/Motor Wiring
Examples beginning on page 204 for the interconnect diagram of your
drive/motor combination.
Page 43
Chapter
Mounting the Kinetix 6000 Drive System
3
Introduction
This chapter provides the system installation procedures for mounting
your Kinetix 6000 drive components to the panel.
Top ic P ag e
Introduction 43
Determining Mounting Order 44
Mounting the Modules 45
Mounting the External Shunt Module 48
The procedures in this chapter assume you have prepared your panel
and understand how to bond your system. For installation instructions
regarding equipment and accessories not included here, refer to the
instructions that came with those products.
SHOCK HAZARD
ATTENTION
To avoid hazard of electrical shock, perform all mounting and
wiring of IAM, AM, SM, LIM, RBM, or power rail prior to
applying power. Once power is applied, connector terminals
may have voltage present even when not in use.
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.
Using 2094 Mounting Brackets
Bulletin 2094 mounting brackets can be used to mount the power rail
or line interface module over the ac line filter. Refer to the 2094
Mounting Brackets Installation Instructions, publication 2094-IN008,
when using mounting brackets with your Kinetix 6000 drive system.
43 Publication 2094-UM001A-EN-P — September 2006
Page 44
44 Mounting the Kinetix 6000 Drive System
Installing the 2094 Power Rail
The Kinetix 6000 power rail comes in lengths to support one
integrated axis module (IAM), and up to seven additional axis
modules (AM) or shunt module (SM). The connector pins for each slot
are covered by a protective boot. The boot is designed to protect the
pins from damage and make sure that no foreign objects lodge
between the pins during installation. Refer to the Kinetix 6000 Power
Rail Installation Instructions, publication 2094-IN003, when installing
your power rail.
Determining Mounting Order
Highest Power Utilization or Amp Rating
Integrated Axis Module
2094-AC09-M02
Axis Module
2094-AM02
ATTENTION
To avoid damage to the power rail during installation, do not
remove the protective boots until the module for each slot is
ready for mounting.
Mount IAM, AM, SM, and slot filler (PRF) modules in the order (left to
right) as shown in the figure below. Mount axis modules according to
power utilization (highest to lowest) from left to right starting with the
highest power utilization. If power utilization is unknown, position
axis modules (highest to lowest) from left to right based on amp
rating.
Module Mounting Order
Lowest Power Utilization or Amp Rating
Axis Module
2094-AM02
Axis Module
2094-AM02
Axis Module
2094-AM01
Axis Module
2094-AM01
Shunt Module
2094-BSP2
Slot Filler Module
2094-PRF
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Mounting the Kinetix 6000 Drive System 45
Mounting the Modules
IMPORTANT
The integrated axis module (IAM) must be positioned in the
leftmost slot of the power rail. Position your axis modules (AM),
shunt module (SM), and slot fillers (PRF) to the right of the IAM.
The SM must be installed to the right of the last AM. Only slot
filler modules may be installed to the right of the SM.
Do not mount the SM on power rails with a follower IAM.
Common-bus follower IAMs will disable the internal, rail
mounted, and external shunt modules.
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 system, however control power will
still be present.
Follow these steps to mount the IAM, AM, SM, and PRF modules. All
modules mount to the power rail using the same technique
(integrated axis module is shown).
1. Remove the protective boots from the power rail connectors.
IMPORTANT
The IAM must be positioned in the leftmost slot of the
power rail. Position your axis modules, shunt module, and
slot fillers to the right of the IAM.
2. Determine the next available slot and module for mounting.
3. Remove the label (applied to back and side of module) covering
the pins that mate with the power rail.
ATTENTION
To avoid damage to the pins located on the back of each
module (IAM, AM, SM, and PRF) and to make sure that
module pins mate properly with the power rail, hang
modules as shown in Steps 4...7.
The power rail must be mounted vertically on the panel
before hanging modules on the power rail. Do not mount
modules if the power rail is horizontal.
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46 Mounting the Kinetix 6000 Drive System
4. Hang the mounting bracket from the slot on the power rail.
Slots for additional axis modules,
shunt module, or slot filler.
Power Rail
Mounting Bracket
Power Rail Slot
Integrated Axis Module
5. Pivot module downward and align the guide pins on the power
rail with the guide pin holes in the back of the module.
Pivot module downward
and align with guide pins.
Guide Pin
Integrated Axis Module
(rear view)
TIP
Holes
Power rail
(side view)
in upright
vertical position.
The IAM can have two or three power rail connectors and guide
pins, the AM can have one or two, all other modules have one.
Guide Pins
Integrated Axis Module
(side view)
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Page 47
Power Rail
Mounting the Kinetix 6000 Drive System 47
6. Gently push the module against the power rail connectors and
into the final mounting position.
Bracket secured in slot.
Bottom front view of
double-wide IAM or AM
(AM is shown).
Integrated Axis Module
7. Use 2.26 Nm (20 lb-in.) torque to tighten the mounting screws.
Bottom front view of
single-wide AM, SM, or PRF
(AM is shown).
Mounting Screws
IMPORTANT
There are two mounting screws when mounting
2094-AC32-M05, -BC04-M03, and -BC07-M05 (double-wide)
IAMs and 2094-AM05, -BM03, and -BM05 (double-wide) AMs.
8. Determine if you have additional modules to mount
If You Then
Have additional modules to mount
Do not have additional modules to mount Go to Mounting the External Shunt Module.
Return to Step 1 and complete installation of
your next AM, SM, or PRF module.
Publication 2094-UM001A-EN-P — September 2006
.
Page 48
48 Mounting the Kinetix 6000 Drive System
Mounting the External Shunt Module
If your Kinetix 6000 drive requires a means of dissipating regenerative
energy that exceeds the capacity of the 2094 shunt module, install a
Bulletin 1394 external shunt module.
BURN HAZARD
Follow these steps to install your external shunt module.
1. Layout the position for your shunt module in the enclosure.
Follow the panel layout recommendations as shown in External
Shunt Resistor on page 40.
2. Attach the shunt resistor to the cabinet. The recommended
mounting hardware is M6 metric (1/4 in.) bolts.
Follow the recommended high-frequency (HF) bonding
techniques as shown in the Bonding Modules on page 27.
To avoid the hazard of shock or burn and ignition of flammable
material, appropriate guarding must be provided. These
resistors can reach temperatures in excess of 350 °C (662 °F).
Install per local codes.
3. Tighten all mounting fasteners.
For external shunt module mounting dimensions, refer to the Kinetix
Motion Control Selection Guide, publication GMC-SG001.
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Page 49
Kinetix 6000 Connector Data
Chapter
4
Introduction
This chapter provides power, feedback, and I/O connector locations
and signal descriptions for your Kinetix 6000 drive.
Top ic P ag e
Introduction 49
Locating IAM/AM Connectors and Indicators 50
Understanding IAM/AM Signal Specifications 60
Understanding Feedback Specifications 66
Locating Shunt Module Connectors and Indicators 68
49 Publication 2094-UM001A-EN-P — September 2006
Page 50
50 Kinetix 6000 Connector Data
Locating IAM/AM Connectors and Indicators
Integrated Axis Module, Top View
(2094-AM05-MP5-S is shown)
Control Power
(CPD) Connector
DC Bus / AC Input Power
(IPD) Connector
Contactor Enable
(CED) Connector
Safe-off
(SO) Connector
(present only on the 2094-xCxx-Mxx-S)
Although the physical size of the 460V modules is larger than the 230V
modules, the location of the connectors and indicators is identical.
Integrated Axis Module Connectors and Indicators
Motor Cable
Shield Clamp
1 2
CTRL 2
CTRL 1
1 2 3 4 5 6
DCDC+
L3
L2
L1
1 2
CONT ENCONT EN+
1 2 3 4 5 6 7 8 9
MBRK -
MBRK +
COM
PWR
DBRK DBRK +
RX
DPI
W
V
U
1 2 3 4
1 2 3 4 5 6
TX
BAUD
RATE
DPI Connector
SERCOS Receive (Rx) Connector
Motor Power
(MP) Connector
Motor/Resistive Brake
(BC) Connector
SERCOS Baud Rate
and Optical Power Switches
SERCOS Transmit (Tx) Connector
Integrated Axis Module, Front View
(2094-AC05-MP5-x is shown)
I/O (IOD) Connector
Mounting Screw
SERCOS
Node Address Switch
Seven-segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
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Page 51
Axis Module Connectors and Indicators
Axis Module, Top View
(2094-AMP5-S is shown)
Kinetix 6000 Connector Data 51
Motor Cable
Shield Clamp
Safe-off
(SO) Connector
(present only on the 2094-xMxx-S)
Axis Module, Front View
(2094-AMP5 is shown)
W
V
U
1 2 3 4 5 6 7 8 9
MBRK MBRK +
COM
PWR
DBRK -
DBRK +
RX
Motor Power
(MP) Connector
1 2 3 4
Motor/Resistive Brake
(BC) Connector
1 2 3 4 5 6
TX
BAUD
RATE
SERCOS Baud Rate
and Optical Power Switches
SERCOS Transmit (Tx) Connector
SERCOS Receive (Rx) Connector
Seven-segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Mounting Screw
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
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52 Kinetix 6000 Connector Data
Integrated Axis Module/Axis Module Connectors
Designator Description Connector
Present on
IAM or AM
IOD User I/O (drive) 26-pin high-density D-shell IAM/AM
MF Motor feedback 15-pin high-density D-shell (female) IAM/AM
AF Auxiliary feedback 15-pin high-density D-shell (male) IAM/AM
CPD Control input power (drive) 2-position plug/header IAM
VAC Input Power (drive) 230V and
dc bus
6-position plug/header IAM
IPD
VAC Input Power (drive) 460V and
dc bus
6-position plug/header IAM
CED Contactor enable 2-position plug/header IAM
MP Motor power 4-position plug/header IAM/AM
BC Dynamic/motor brake 6-position plug/header IAM/AM
SO Safe-off 9-position plug/header IAM/AM
Tx and Rx SERCOS transmit and receive SERCOS fiber-optic (2) IAM/AM
DPI DPI DPI IAM
Safe-off Connector Pinout
Kinetix 6000 IAM/AM
(Kinetix 6000 AM is shown)
Each IAM (2094-xCxx-Mxx-S) and AM (2094-xMxx-S) ships with the
(9-pin) wiring plug header and motion allowed jumper installed in the
safe-off (SO) connector. With the motion allowed jumper installed, the
safe-off feature is not used.
Motion Allowed Jumper
1
1
2
3
Safe-off
(SO) Connector
4
5
67
8
9
Motion Allowed Jumper
Wiring Plug Header
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Page 53
Kinetix 6000 Connector Data 53
Headers in this table extend the safe-off (SO) connector signals for use
in wiring single and multiple safe-off drive configurations, or to
jumper around (not use) the safe-off feature.
IAM/AM Safe-off 9-pin (SO) Connector
Safe-off (SO)
Connector Pin
1
2 Other side of the normally-closed monitoring contact of relay 2 FDBK23 One side of the normally-closed monitoring contact of relay 1 FDBK1+
4 Other side of the normally-closed monitoring contact of relay 1 FDBK15 Coil of safety-relay 2 SAFETY ENABLE2+
6 Return for safety-relay coil power (both relays) SAFETY ENABLE7 Coil of safety relay 1 SAFETY ENABLE1+
8
9 Power return used for continuous enable of safety function 24V_COM
Also Applies to These
SO Connector Headers
• Wiring plug header
• First-drive wiring header
(2090-XNSM-W)
• Wiring plug header
• Motion allowed jumper
Description Signal
One side of the normally-closed monitoring contact of relay 2 FDBK2+
Power for continuous enable of the safety function, 500 mA max 24V+
IMPORTANT
Pins SO-8 and -9 (24V+) are only used by the motion allowed
jumper. When wiring to the wiring plug header, the 24V supply
must come from an external source.
Refer to the Kinetix Safe-off Feature Safety Reference Manual,
publication GMC-RM002, for more information on safe-off headers.
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54 Kinetix 6000 Connector Data
I/O Connector Pinout
IAM/AM I/O 26-pin (IOD) Connector
IOD Pin Description Signal IOD Pin Description Signal
1 Hardware enable 24V dc power supply +24V_PWR 14 High speed registration 1 input REG1
2 Hardware enable input ENABLE 15 Common for registration REG_COM
3 Common +24V_COM 16 24V registration power REG_24V
4 Home switch 24V dc power supply +24V_PWR 17 High speed registration 2 input REG2
5 Home switch input HOME 18 Common for registration REG_COM
6 Common +24V_COM 19 Reserved —
7 Positive overtravel 24V dc power supply +24V_PWR 20 Reserved —
8 Positive overtravel limit switch input OT+ 21 Reserved —
9 Common +24V_COM 22 Reserved —
10 Negative overtravel 24V dc power supply +24V_PWR 23 Analog output 0 DAC0
11 Negative overtravel limit switch input OT- 24 Analog output common DAC_COM
12 Common +24V_COM 25 Analog output 1 DAC1
13 24V registration power REG_24V 26 Analog output common DAC_COM
IMPORTANT
Signals +24V_PWR and +24V_COM are a 24V dc source you
can use only for the inputs listed above.
Pin Orientation for 26-pin I/O (IOD) Connector
26-pin IAM/AM
I/O Connector
Pin 18
Pin 26
Pin 19
Pin 10
Pin 9
Pin 1
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Kinetix 6000 Connector Data 55
Motor Feedback Connector Pinouts
Stegmann Hiperface (SRS/SRM)
MF Pin Description Signal MF Pin Description Signal
1 Sine differential input+ SINE+ 9 Reserved —
2 Sine differential input- SINE- 10 Hiperface data channel DATA-
(1)
3 Cosine differential input+ COS+ 11
Motor thermal switch (normally closed)
4 Cosine differential input- COS- 12 Reserved —
5 Hiperface data channel DATA+ 13 Reserved —
6 Common ECOMM 14 Encoder power (+5V) EPWR_5VM
7 Encoder power (+9V) EPWR_9VM 15 Reserved —
8Reserved —
(1)
Not applicable unless motor has integrated thermal protection.
TTL or Sine/Cosine with Index Pulse and Hall Commutation
TS
MF Pin Description Signal MF Pin Description Signal
1 AM+ / Sine differential input+ AM+ / SINE+ 9 Reserved —
2 AM- / Sine differential input- AM- / SINE- 10 Index pulse- IM-
(1)
3 BM+ / Cosine differential input+ BM+ / COS+ 11
Motor thermal switch (normally closed)
TS
4 BM- / Cosine differential input- BM- / COS- 12 Single-ended 5V hall effect commutation S1
5 Index pulse+ IM+ 13 Single-ended 5V hall effect commutation S2
6 Common ECOMM 14 Encoder power (+5V) EPWR_5VM
7 Encoder power (+9V) EPWR_9VM 15 Reserved —
8 Single-ended 5V hall effect commutation S3
(1)
Not applicable unless motor has integrated thermal protection.
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56 Kinetix 6000 Connector Data
Resolver Transmitter (transformation ratio = 0.25)
MF Pin Description Signal MF Pin Description Signal
1 Sine differential input+ S2 9 Reserved —
2 Sine differential input- S4 10 Resolver excitation R2
3 Cosine differential input+ S1 11
4 Cosine differential input- S3 12 Reserved —
5 Resolver excitation R1 13 Reserved —
6 Common ECOMM 14 Encoder power (+5V) EPWR_5VM
7 Encoder power (+9V) EPWR_9VM 15 Reserved —
8Reserved —
(1)
Not applicable unless motor has integrated thermal protection.
(2)
When using 1326AB (resolver-based) motors, use Low-profile Connector Kit (2090-K6CK-D15MF) that connects the filtered thermal switch (pins 16 and 17) to MF-11 and
MF-6.
Motor thermal switch
(normally closed)
(1) (2)
TS
IMPORTANT
To meet CE requirements, 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).
Pin Orientation for 15-pin Motor Feedback (MF) Connector
15-pin IAM/AM
Motor Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
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Kinetix 6000 Connector Data 57
Auxiliary Feedback Connector Pinouts
For TTL devices, the position count will increase when A leads B. For
sinusoidal devices, the position count will increase when cosine leads
sine.
Stegmann Hiperface (SRS and SRM only)
AF Pin Description Signal AF Pin Description Signal
1 Sine differential input+ SINE+ 9 Reserved —
2 Sine differential input- SINE- 10 Hiperface data channel DATA3 Cosine differential input+ COS+ 11 Reserved —
4 Cosine differential input- COS- 12 Reserved —
5 Hiperface data channel DATA+ 13 Reserved —
6 Common ECOM 14 Encoder power (+5V) EPWR_5V
7 Encoder power (+9V) EPWR_9V 15 Reserved —
8Reserved —
TTL or Sine/Cosine with Index Pulse
AF Pin Description Signal AF Pin Description Signal
1 A+ / Sine differential input+ A+ / SINE+ 9 Reserved —
2 A- / Sine differential input- A- / SINE- 10 Index pulse- I3 B+ / Cosine differential input+ B+ / COS+ 11 Reserved —
4 B- / Cosine differential input- B- / COS- 12 Reserved —
5 Index pulse+ I+ 13 Reserved —
6 Common ECOM 14 Encoder power (+5V) EPWR_5V
7 Encoder power (+9V) EPWR_9V 15 Reserved —
8Reserved —
Pin Orientation for 15-pin Auxiliary Feedback (AF) Connector
15-pin IAM/AM
Auxiliary Feedback Connector
Pin 6
Pin 11
Pin 15
Pin 1
Pin 5
Pin 10
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58 Kinetix 6000 Connector Data
IAM Input Connector Pinouts
Control Power Connector
CPD Pin Description Signal
1
2CTRL 1
Control power VAC input
DC Bus and Input Power Connector
IPD Pin Description Signal
1 An integral, unregulated power supply,
2DC+
3 Chassis ground.
consisting of ac line input, three-phase
bridge rectifier, and filter capacitors.
CTRL 2
DC-
4
5L2
6L1
Three-phase input power.
L3
Contactor Enable Connector
CED Pin Description Signal
1 Relay-driven dry contact used in the
2 CONT EN+
safety string for a three-phase power
contactor.
CONT EN-
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Page 59
Kinetix 6000 Connector Data 59
IAM and AM Motor Power and Brake Connector Pinouts
Motor Power Connector
MP Pin Description Signal
4 Chassis ground
3
2V
1U
IMPORTANT
Three-phase motor power
To meet CE requirements, combined motor power cable length
for all axes on the same dc bus must not exceed 240 m (787 ft)
W
with 460V systems or 160 m (525 ft) with 230V systems.
Drive-to-motor power cables must not exceed 90 m (295.5 ft).
Motor Brake/Resistive Brake Connector
BC Pin Description Signal
6
5 MBRK+
4 Motor brake common COM
3
2 Resistive brake module (RBM)
1 DBRK+
Motor brake connections
+24V brake input power (from LIM or
customer supplied)
connections (from RBM and safety
string)
MBRK-
PWR
DBRK-
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60 Kinetix 6000 Connector Data
Understanding IAM/AM Signal Specifications
A description of the Kinetix 6000 IAM/AM input/output (IOD),
SERCOS, contactor enable (CED), brake (BC), and control power
(CPD) connectors is provided on the following pages.
Digital Inputs
Two fast registration inputs and four other inputs are available for the
machine interface on the integrated sxis module (IAM) and axis
module (AM). Each IAM and AM supplies 24V dc @ 500 mA for the
purpose of registration, home, enable, over-travel positive, and
over-travel negative inputs. These are sinking inputs that require a
sourcing device. A 24V power and common connection is provided
for each input.
IMPORTANT
IMPORTANT
To improve registration input EMC performance, refer to the
System Design for Control of Electrical Noise Reference
Manual, publication GMC-RM001.
Overtravel limit input devices must be normally closed.
Understanding Digital Inputs
IOD Pin Signal Description
IOD-2 ENABLE
IOD-5 HOME
IOD-14
IOD-17
IOD-8
IOD-11
REG1
REG2
OT+
OT-
Optically isolated, single-ended active high signal. Current loading is
nominally 10 mA. A 24V dc input is applied to this terminal to enable each
axis.
Optically isolated, single-ended active high signal. Current loading is
nominally 10 mA. Home switch (normally open contact) inputs for each axis
require 24V dc (nominal).
Fast registration inputs are required to inform the motor interface to
capture the positional information with less than 3 μs uncertainty. Optically
isolated, single-ended active high signal. Current loading is nominally
10 mA. A 24V dc input is applied to this terminal to enable each axis.
Overtravel detection is available as an optically isolated, single-ended
active high signal. Current loading is nominally 10 mA per input. The pos/
neg limit switch (normally closed contact) inputs for each axis require 24V
dc (nominal).
Digital Input Specifications
Parameter Description Min Max
On-state voltage
On-state current Current flow to guarantee an on-state. 3.0 mA 10.0 mA
Off-state voltage
Voltage applied to the input, with respect
to IOCOM, to guarantee an on-state.
Voltage applied to the input, with respect to IOCOM, to guarantee an
off-state.
Capture
Time
20 ms Level
20 ms Level
500 ns Edge
20 ms Level
ENABLE, HOME, and OT+/OT- 10.8V 26.4V
REG1 and REG2 21.6V 26.4V
-1.0V 3.0V
Edge/Level
Sensitive
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Page 61
I/O SUPPLY
INPUT
IOD-1, -4, -7, -10
IOD-2, -5, -8, -11
Kinetix 6000 Connector Data 61
Enable, Home, and Overtravel Digital Input Circuits
(1)
24V dc
3k Ω
0.1 μF
511 Ω
VCC
CTRL_INPUT
IO_COM
Customer-supplied Input Device
I/O SUPPLY
INPUT
IO_COM
Customer-supplied Registration
Input Device
IOD-3, -6, -9, -12
IOD-13, -16
IOD-14, -17
IOD-15, -18
Kinetix 6000 IAM/AM
(1)
24V dc source (range) = 21.6V - 26.4V (supplied by drive, not to exceed 500 mA total).
Maximum current input = 10 mA
Registration Digital Input Circuits
+24V dc
3k Ω
0.001 μF
Kinetix 6000 IAM/AM
511 Ω
HCPL-0631
SERCOS Connections
1k Ω
VCC
1k Ω
REG_INPUT
Two fiber-optic connectors (transmit and receive) are provided on the
integrated axis module (IAM) and axis module (AM).
SERCOS Communications Specifications
Specification Description
Data Rates 2, 4, and 8 Mbps
Node Addresses
(1)
Node address assignments begin with the integrated axis module (IAM). Node addresses for additional axes on
the same power rail are assigned by incrementing from left to right (starting with the IAM address).
01...99
(1)
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62 Kinetix 6000 Connector Data
Analog Outputs
The integrated axis module (IAM) and axis module (AM) include two
analog outputs (IOD-23 and -25) that can be configured through
software to represent drive variables.
Analog Output Circuit
Oscilloscope
2.5V = 0 ref
2.5V
DAC
IMPORTANT
Kinetix 6000 IAM/AM
(second channel not shown)
Output values can vary during power-up until the specified
power supply voltage is reached.
CH1
CH2
Analog Output Specifications
Parameter Description Min Max
Resolution
Output
current
Output signal
range
Offset error Deviation when the output should be at 0V. — 1 mV
Bandwidth Frequency response of the analog output dc 7.2k Hz (3 db)
Number of states that the output signal is divided
into, which is 2
Current capability of the output. 0 +2 mA
Range of the output voltage. 0 +5V
(to the number of bits)
.
— ±11 bits
Publication 2094-UM001A-EN-P — September 2006
For configuration/setup of the analog outputs, refer to Supplemental
Troubleshooting Information beginning on page 160.
Page 63
Kinetix 6000 Connector Data 63
Contactor Enable Relay
Contactor enable is a relay-driven contact used in the safety control
string to protect the drive electronics during certain fault conditions. It
is capable of handling 120V ac or 24V dc at 1 A or less. Contactor
enable is a function of the converter and is not available in the axis
modules. An active state indicates the drive is operational and does
not have a fault.
ATTENTION
Wiring the contactor enable relay is required. To avoid personal
injury or damage to the drive, wire the contactor enable relay
into your safety control string so that:
• three-phase power is removed from the drive in the event of
shutdown fault conditions.
• drive operation is prevented when the Power Rail is not fully
populated.
• control power is applied to the drive prior to three-phase
power.
Refer to IAM Wiring Example (without LIM) on page 196 for a
wiring example.
IMPORTANT
Contactor Enable Relay Circuit
All power rail slots must have a module installed or the
contactor enable relay will not close.
Normally
Open
Relay
Kinetix 6000 IAM
CONT EN+
CONT EN-
Contactor Enable Relay Output Specifications
Parameter Description Min Max
On-state
current
On-state
resistance
Off-state
voltage
Current flow when the relay is closed — 1 A
Contact resistance when the relay is closed — 1 Ω
Voltage across the contacts when the relay is open —
Publication 2094-UM001A-EN-P — September 2006
120V ac or
24V dc
Page 64
64 Kinetix 6000 Connector Data
Motor/Resistive Brake Relay
Two connections are required for the (customer-supplied) motor/
resistive brake input power (BC-3 and -4) and two connections each
for the motor and resistive brake output, as shown in the figure
below. Connections are rated for +24V and current as shown in the
table below.
An active signal releases the motor brake (BC-5 and -6). The brake
signal is the same as the contactor enable signal, with the addition of
the turn-on and turn-off delays specified by the brake active delay and
brake inactive delay (configurable in RSLogix 5000 software). Refer to
Axis Module/Motor Wiring Examples beginning on page 204 and
Controlling a Brake Example on page 210 for wiring examples.
The resistive brake relay (BC-1 and -2) controls the resistive brake
module (RBM) contactor. The RBM is wired between the drive and
motor, using an internal contactor to switch the motor between the
drive and a resistive load. The RBM contact delay is the time it takes
to fully close the contactor across the motor power input lines, and
must be configured in RSLogix 5000 software. Refer to Integrating
Resistive Brake Modules with Kinetix 6000 Drives beginning on page
239 for wiring examples.
Brake Relay Circuit
Kinetix 6000 IAM/AM
(1)
Noise suppression device.
COM
(BC-4)
DBRK(BC-2)
1
DBRK+
(BC-1)
MBRK-
(BC-6)
1
MBRK+
(BC-5)
PWR
(BC-3)
Brake Relay Output Specifications
Parameter Description IAM/AM Max
2094-AC05-Mxx, -AC09-Mxx,
2094-AMP5, -AM01, -AM02
2094-BC01-Mxx, -BC02-Mxx,
On-state current
Current flow when the
(1)
relay is closed
2094-BMP5, -BM01, -BM02
2094-AC16-Mxx, -AC32-Mxx,
2094-AM03, -AM05
2094-BC04-Mxx, -BC07-Mxx,
2094-BM03, -BM05
On-state resistance Contact resistance when the relay is closed 1 Ω
Off-state voltage Voltage across the contacts when the relay is open 30V
(1)
For motors requiring more than the maximum current specified, a relay must be added.
1.0 A
1.3 A
3.0 A
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Page 65
Kinetix 6000 Connector Data 65
Control Power Input
The integrated axis module (IAM) requires ac input power for logic
circuitry.
IMPORTANT
The control power input requires an ac (EMC) line filter for CE
certification. For wiring examples, refer to Power Wiring
Examples beginning on page 193.
IMPORTANT
Source 2094-ACxx-Mxx (230V) IAM control power from the
three-phase input power (line-to-line). Supplying 230V control
power from any other source requires an isolation transformer.
If used, do not ground either leg of the isolation transformer
output. Control power isolation, via a step-down transformer, is
required for all 460V applications.
Refer to Transformer Specifications for Control Power Input on
page 179.
Control Power Current Specifications
Specification Description
Input voltage 95...264V ac rms, single-phase
Input power frequency 47...63 Hz
Control Power Current Requirements
Number of Axis
Modules
0 750 mA 350 mA 150 VA
1 1.5 A 700 mA 200 VA
2 2.25 A 1 A 275 VA
3 3 A 1.35 A 350 VA
4 3.75 A 1.7 A 450 VA
5 4.5 A 2 A 550 VA
6 5.25 A 2.4 A 650 VA
7 6 A 3 A 750 VA
(1)
(1)
This number does not include the axis module (inverter section) that resides inside the integrated axis module.
Current Requirements
(110/115V ac input)
Current Requirements
(220/230V ac input)
Input VA
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66 Kinetix 6000 Connector Data
Understanding Feedback Specifications
The integrated axis module (IAM) and axis module (AM) can accept
motor and auxiliary feedback signals from the following types of
encoders:
• Stegmann Hiperface
• TTL or Sine/Cosine with index pulse and Hall commutation
• Resolver Transmitter TR = 0.25 (motor feedback only)
TIP
Auto-configuration in RSLogix 5000 software of intelligent
absolute, high-resolution, and incremental encoders is possible
only with Allen-Bradley motors.
Motor and Auxiliary Feedback Specifications
AM, BM, and IM input encoder signals are filtered using analog and
digital filtering. The inputs also include illegal state change detection.
AM, BM, and IM Motor Encoder Input Circuits
+5 V
+
1k Ω
-
Drive
1k Ω
56 pF
1k Ω
56 pF
1k Ω
1k Ω
56 pF
56 pF
AM and BM Channel Inputs
1k Ω
1k Ω
100 pF
100 pF
10k Ω
10k Ω
+
-
10k Ω
1k Ω
56 pF
1k Ω
56 pF
10k Ω
Drive
IM Channel Input
Motor Encoder Feedback Specifications
Specification Description
Encoder types
Maximum input frequency
Commutation feedback Hall sensor
Incremental, A quad B, sine/cosine, intelligent, resolver, and
absolute
5.0 MHz (TTL input) per channel
250 kHz (sine/cosine input)
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Kinetix 6000 Connector Data 67
AM, BM, and IM Input Specifications for TTL Encoders
Parameter Description Min Max
AM, BM, and IM
On-state input voltage
AM, BM, and IM
Off-state input voltage
Common mode
input voltage
DC current draw Current draw into the + or - input. -30 mA 30 mA
AM, BM input
signal frequency
IM pulse width
AM, BM phase error
2.5 MHz line frequency
AM, BM phase error
1 MHz line frequency
Input voltage difference between the plus (+) input and
the minus (-) input that is detected as an on-state.
Input voltage difference between the plus (+) input and
the minus (-) input that is detected as an off-state.
Potential difference between any encoder signal and
logic ground.
Frequency of the AM or BM signal inputs. The count
frequency is 4 times this frequency, since the circuitry
counts all four transitions.
Pulse width of the index input signal. Since the index is
active for a percentage of a revolution, the speed will
determine the pulse width.
Amount that the phase relationship between the AM
and BM inputs can deviate from the nominal 90°.
Amount that the phase relationship between the AM
and BM inputs can deviate from the nominal 90°.
+1.0V +7.0V
-1.0V -7.0V
-7.0V +12.0V
— 5.0 MHz
125 nS —
-22.5° +22.5°
-45° +45°
AM, BM, and IM Input Specifications for Sine/Cosine Encoders
Parameter Description Min Max
Sine/cosine
input signal
Frequency of the Sine or Cosine signal inputs. — 250 kHz
frequency
Sine/cosine
input voltage
Peak-to-peak input voltages of the Sine or Cosine
inputs.
0.5V (p-p) 2.0V (p-p)
Feedback Power Supply
The IAM and AM power circuit board generates +5V and +9V dc for
motor and auxiliary feedback power. Short circuit protection and
separate common mode filtering for each channel is included.
Motor and Auxiliary Feedback Power Specifications
Supply Reference
+5V dc EPWR_5V 5.13 5.4 5.67 10
+9V dc EPWR_9V 8.3 9.1 9.9 10
(1)
400 mA on the 5V supply split in any manner between the channels with no load on the 5V supply.
(2)
275 mA on the 9V supply split in any manner between the channels with no load on the 9V supply.
(3)
300 mA on the 5V supply on one channel with 150 mA on the 9V supply on the second channel.
Voltage Current mA
Min Nominal Max Min Max
400
275
(1) (3)
(2) (3)
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68 Kinetix 6000 Connector Data
Locating Shunt Module Connectors and Indicators
Motor Cable
Shield Clamp
The Kinetix 6000 shunt module (2094-BSP2) is suitable for both 230V
and 460V applications.
Locating Shunt Module Connectors and Indicators
Shunt Module, Front View
(2094-BSP2)
COL
INT
DC+
1 2 3
TS2
TS1
1 2
External Shunt Resistor
(RC) Connector
External Thermal Switch
(TS) Connector
Shunt Module, Front View
(2094-BSP2)
Shunt Fault LED
Over-Temp Fault LED
Bus Status LED
Mounting Screw
Shunt Module Connectors
Designator Description Connector
RC External shunt resistor connector Three-position connector housing
TS Thermal switch connector Two-position connector housing
External Shunt Resistor Three-pin (RC) Connector Pinout
RC Pin Description Signal
1 External shunt resistor connection DC+
2 Internal shunt connection INT
3 Shunt collector connection COL
External Thermal Switch Two-pin (TS) Connector Pinout
TS Pin Description Signal
1
2TS2
External passive shunt module thermal
switch connections
TS1
Refer to Understanding External Shunt Module Connections on page
113 when wiring the RC and TS connectors.
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Page 69
Chapter
Connecting the Kinetix 6000 Drive System
5
Introduction
This chapter provides procedures for wiring your Kinetix 6000 system
components and making cable connections.
Top ic P ag e
Introduction 69
Understanding Basic Wiring Requirements 69
Determining Your Type of Input Power 71
Setting the Ground Jumper in Ungrounded Power Configurations 75
Grounding Your Kinetix 6000 System 78
Power Wiring Requirements 80
Wiring Guidelines 83
Wiring the LIM Connectors 84
Wiring the IAM/AM Connectors 90
Applying the Motor Cable Shield Clamp 103
Understanding Feedback and I/O Cable Connections 104
Understanding External Shunt Module Connections 113
Understanding Resistive Brake Module Connections 114
Connecting Your SERCOS Fiber-optic Cables 115
Understanding Basic
This section contains basic wiring information for the Kinetix 6000
drive.
Wiring Requirements
ATTENTION
SHOCK HAZARD
69 Publication 2094-UM001A-EN-P — September 2006
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.
To avoid hazard of electrical shock, perform all mounting and
wiring of IAM, AM, SM, LIM, RBM, or power rail prior to
applying power. Once power is applied, connector terminals
may have voltage present even when not in use.
Page 70
70 Connecting the Kinetix 6000 Drive System
IMPORTANT
This section contains common PWM servo system wiring
configurations, size, and practices that can be used in a
majority of applications. National Electrical Code, local
electrical codes, special operating temperatures, duty cycles, or
system configurations take precedence over the values and
methods provided.
Building Your Own Cables
IMPORTANT
• Connect the cable shield to the connector shells on both ends of
the cable with a complete 360° connection.
• Use a twisted pair cable whenever possible. Twist differential
signals with each other and twist single-ended signals with the
appropriate ground return.
Factory-made cables are designed to minimize EMI and are
recommended over hand-built cables to optimize system
performance.
Refer to the Kinetix Motion Control Selection Guide, publication
GMC-SG001 for low profile connector kit, drive-end (mating)
connector kit, and motor-end connector kit catalog numbers.
Routing Power and Signal Wiring
Be aware that when you route power and signal wiring on a machine
or system, radiated noise from nearby relays, transformers, and other
electronic drives can be induced into motor or encoder feedback
signals, input/output communications, or other sensitive low voltage
signals. This can cause system faults and communication problems.
Refer to Minimizing Electrical Noise on page 27 for examples of
routing high and low voltage cables in wireways. Refer to the System
Design for Control of Electrical Noise Reference Manual, publication
GMC-RM001, for more information.
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Connecting the Kinetix 6000 Drive System 71
Determining Your Type of Input Power
Before wiring input power to your Kinetix 6000 system, you must
determine the type of input power you are connecting to. The IAM is
designed to operate in both grounded and ungrounded environments.
ATTENTION
When using a LIM with your Kinetix 6000 drive, the VAC LINE
input power must come from a grounded configuration (refer to
the figure below).
When not using a LIM with your Kinetix 6000 drive, ungrounded
configurations are permitted, but you must set the jumper to
prevent high electrostatic build-up.
Refer to Setting the Ground Jumper in Ungrounded Power
Configurations on page 75 for more information.
Grounded Power Configurations
The grounded (WYE) power configuration lets you ground your
three-phase power at a neutral point. This type of grounded power
configuration is preferred.
Three-phase
Input VAC
Phase Ground
Grounded Power Configuration (WYE Secondary)
Integrated Axis Module, Top View
(2094-ACxx-Mxx-S is shown)
1 2
CTRL 2
Transformer (WYE) Secondary
L3
Tr an sf or m er
L2
L1
Bonded Cabinet
Ground
Ground Grid or
Power Distribution Ground
CTRL 1
1 2 3 4 5 6
DCDC+
L3
L2
L1
1 2
CONT ENCONT EN+
Connect to power rail ground stud.
1 2 3 4 5 6 7 8 9
MBRK MBRK +
COM
PWR
DBRK -
DBRK +
RX
DPI
W
V
U
1 2 3 4
1 2 3 4 5 6
TX
BAUD
RATE
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72 Connecting the Kinetix 6000 Drive System
Grounded (B-Phase) Power Configuration (Delta Secondary)
Transformer (Delta) Secondary
Tra ns fo rme r
Integrated Axis Module, Top View
(2094-BCxx-Mxx-S is shown)
L3
L2
L1
1 2
CTRL 2
CTRL 1
1 2 3 4 5 6
DCDC+
L3
L2
L1
1 2
CONT ENCONT EN+
1 2 3 4 5 6 7 8 9
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
RX
DPI
W
V
U
1 2 3 4
1 2 3 4 5 6
TX
BAUD
RATE
Bonded Cabinet
Connect to power rail ground stud.
Ground
Ground Grid or
Power Distribution Ground
The integrated axis module (IAM) has a factory-installed ground
jumper configured for grounded power distribution.
IMPORTANT
If you determine that you have grounded power distribution in
your plant, you do not need to modify your IAM.
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Connecting the Kinetix 6000 Drive System 73
Ungrounded Power Configurations
Ungrounded power configurations are allowed, but you must jumper
across a 120 kΩ resistor (internal to the IAM) to prevent high
electrostatic build-up. The ungrounded power configuration (shown
below) does not provide a neutral ground point. The IAM has a
ground jumper set for grounded power distribution (default
configuration).
Three-phase
Input VAC
Chassis Ground
IMPORTANT
If you determine that you have ungrounded power distribution
in your facility, you need to move the default jumper (configured
for grounded power) to the ungrounded power position to
prevent electrostatic buildup inside the IAM.
Refer to Setting the Ground Jumper in Ungrounded Power
Configurations on page 75 for more information.
Ungrounded Power Configuration
Integrated Axis Module, Top View
(2094-BCxx-Mxx-S is shown)
Transformer
L3
L2
L1
Bonded Cabinet
Ground
1 2
CTRL 2
CTRL 1
1 2 3 4 5 6
DCDC+
L3
L2
L1
1 2
CONT ENCONT EN+
1 2 3 4 5 6 7 8 9
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
RX
DPI
W
V
U
1 2 3 4
1 2 3 4 5 6
TX
BAUD
RATE
Power Distribution Ground
Ground Grid or
ATTENTION
Connect to power rail ground stud.
Ungrounded systems do not reference each phase potential to a
power distribution ground. This can result in an unknown
potential to earth ground.
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74 Connecting the Kinetix 6000 Drive System
DC Common Bus Configurations
When an integrated axis module (IAM) is used in a dc common bus
configuration, the IAM is known as a leader IAM or follower IAM. The
IAM (non-common bus) and leader IAM have identical three-phase
input power connections. The leader IAM is responsible for
discharging the dc bus, and for providing common bus follower drives
with dc bus pre-charge, bus regulation, phase-loss detection, and
ground fault detection. Follower IAMs do not have three-phase input
power connections, but have dc bus connections from a leader IAM.
IAM Terminology and Use
This IAM Is Wired And is
IAM With three-phase input power. Not wired in common bus mode.
Leader IAM
Follower IAM
With three-phase input power, but has dc common
bus connections to a follower IAM.
Without three-phase input power, but has dc
common bus connections from a leader IAM.
IMPORTANT
Use Kinetix 6000 drive firmware v1.85 and RSLogix 5000
software v15 or later, for dc common bus power configurations.
Wired in common bus mode.
Wired in common bus mode and
configured using RSLogix 5000 software.
The Kinetix 6000 leader IAM can operate with non-Kinetix 6000
follower drives, as can the Kinetix 6000 follower IAM operate with
non-Kinetix 6000 common bus leader drives. However, non-Kinetix
6000 leader and follower drives must meet the same functional
requirements as the Kinetix 6000 leader and follower IAMs.
Bonded Cabinet
Ground
Three-phase
Input Power
DC Common Bus
Connections
Integrated Axis Module
(2094-xCxx-Mxx-S)
Common Bus Leader IAM
1 2
CTRL 2
CTRL 1
1 2 3 4 5 6
DCDC+
L3
L2
L1
1 2
CONT ENCONT EN+
1 2 3 4 5 6 7 8 9
RX
DPI
W
V
1 2 3 4
U
MBRK MBRK +
COM
PWR
DBRK -
1 2 3 4 5 6
DBRK +
TX
IMPORTANT
Any non-Kinetix 6000 common bus leader that does not provide
pre-charge is required to add an additional external pre-charge
circuit before connecting to any Kinetix 6000 common bus
follower IAM.
Typical DC Common Bus Configuration
Axis Module
(2094-xMxx-S)
W
V
1 2 3 4
U
MBRK -
1 2 3 4 5 6 7 8 9
MBRK +
COM
PWR
DBRK -
1 2 3 4 5 6
DBRK +
RX
TX
BAUD
RATE
BAUD
RATE
MBRK -
1 2 3 4 5 6 7 8 9
MBRK +
RX
W
V
1 2 3 4
U
COM
PWR
DBRK -
1 2 3 4 5 6
DBRK +
TX
BAUD
RATE
N.C.
N.C.
N.C.
Integrated Axis Module
(2094-xCxx-Mxx-S)
Common Bus Follower IAM
1 2
CTRL 2
CTRL 1
1 2 3 4 5 6
DCDC+
L3
L2
L1
1 2
CONT ENCONT EN+
1 2 3 4 5 6 7 8 9
RX
DPI
W
V
1 2 3 4
U
MBRK MBRK +
COM
PWR
DBRK -
1 2 3 4 5 6
DBRK +
TX
BAUD
RATE
Axis Module
(2094-xMxx-S)
W
V
1 2 3 4
U
MBRK -
1 2 3 4 5 6 7 8 9
MBRK +
COM
PWR
DBRK -
1 2 3 4 5 6
DBRK +
RX
TX
W
V
1 2 3 4
U
MBRK -
1 2 3 4 5 6 7 8 9
MBRK +
COM
PWR
DBRK -
1 2 3 4 5 6
DBRK +
RX
BAUD
RATE
TX
BAUD
RATE
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Connecting the Kinetix 6000 Drive System 75
Common Bus Fusing Requirements
When using a Kinetix 6000 leader IAM, dc bus fuses are only required
when wiring to more than one Kinetix 6000 follower IAM. When
wiring multiple follower IAMs, terminal blocks are required to extend
the dc common bus power to additional drives. Fuses should be
installed in both lines of the dc bus between the dc bus terminal block
and each follower IAM. These fuses should be rated based on the dc
input current of each follower IAM.
When using a non-Kinetix 6000 common bus leader, dc bus fuses are
required in both lines of the dc bus, between the common bus leader
and follower IAM. These fuses should be rated based on the leader’s
dc output current. When using more than one follower IAM, fuses
should be installed in both lines of the dc bus between the
non-Kinetix 6000 common bus leader and the terminal block as well
as between the dc bus terminal block and each follower IAM.
Refer to Circuit Breaker/Fuse Specifications on page 177 for
recommended fuse sizes. Refer to DC Common Bus Wiring Examples
on page 197 for interconnect diagrams.
Setting the Ground Jumper in Ungrounded Power Configurations
Setting the ground jumper is only necessary when using an
ungrounded power configuration. Setting the jumper involves
removing the IAM from the power rail, opening the IAM, and moving
the jumper.
Setting the ground jumper is best done when the integrated axis
module (IAM) is removed from the power rail and placed face-up on
a solid surface equipped as a grounded static safe workstation.
ATTENTION
To remove the IAM from the power rail, refer to Removing Power Rail
Modules on page 164.
IMPORTANT
To avoid personal injury and/or equipment damage, remove the
IAM from the power rail before setting the ground jumper.
If you have grounded power distribution, you do not need to set
the ground jumper. Go to Grounding Your Kinetix 6000 System
on page 78.
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76 Connecting the Kinetix 6000 Drive System
When using ungrounded input power in common bus configurations,
use the table below to determine where to set the ground jumper.
Ground Jumper to Set
When Leader Drive is And Follower Drive is
Kinetix 6000 IAM Kinetix 6000 IAM Leader Drive.
Kinetix 6000 IAM non-Kinetix 6000 IAM Leader Drive.
non-Kinetix 6000 IAM Kinetix 6000 IAM
Then Set the Jumper in This
Drive
Follower Drive (if no setting
exists in the leader drive).
Setting the Ground Jumper
Follow these steps to set the ground jumper.
1. Remove the top and bottom front panel screws.
Refer to the appropriate figure for your 230V or 460V IAM.
Setting the Ground Jumper (230V IAM)
Top Screw
P17
P16
P15
Ground jumper set
for ungrounded configuration.
Ground jumper set
for grounded configuration
(default setting).
Front Panel (opened)
Integrated Axis Module (230V)
2094-ACxx-Mxx-S
Bottom Screw
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Page 77
Setting the Ground Jumper (460V IAM)
P13
P14
P12
Ground jumper set
for ungrounded configuration.
Ground jumper set
for grounded configuration
Connecting the Kinetix 6000 Drive System 77
Top Screw
Integrated Axis Module (460V)
2094-BCxx-Mxx-S
(default setting)
Front Panel (opened)
Bottom Screw
2. Swing the front panel open to the right, as shown, and locate the
ground jumper.
IMPORTANT
Do not attempt to remove the front panel from the IAM.
The front panel LEDs and switches are also connected to
the IAM with a ribbon cable. The ribbon cable will act like
a hinge and allow you to swing the front panel open and
access the ground jumper.
3. Determine if you have a 230V system or 460V system.
For This IAM Move the Ground Jumper From
2094-ACxx-Mxx-S (230V) P16 to P17
2094-BCxx-Mxx-S (460V) P14 to P12
4. Replace the IAM front panel and two screws.
Apply 1.6 Nm (14 lb-in) torque.
5. Mount the IAM back on the power rail.
Refer to Mounting the Modules on page 45 for instructions.
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78 Connecting the Kinetix 6000 Drive System
LIM
PRS
PR
LIM
PRS
PR
Grounding Your Kinetix 6000 System
All equipment and components of a machine or process system
should have a common earth ground point connected to chassis. A
grounded system provides a ground path for short circuit protection.
Grounding your modules and panels minimize shock hazard to
personnel and damage to equipment caused by short circuits,
transient overvoltages, and accidental connection of energized
conductors to the equipment chassis.
ATTENTION
The National Electrical Code contains grounding requirements,
conventions, and definitions. Follow all applicable local codes
and regulations to safely ground your system.
For CE grounding requirements, refer to Agency Compliance on
page 16.
Grounding Your System to the Subpanel
The 2094 power rail (2094-PRx or 2094-PRSx) ships with a braided
ground strap, 100 mm (3.9 in.), that connects to the bonded cabinet
ground bus. Connect the other end to either the power rail ground
stud or mounting bracket ground stud, if mounting brackets are used.
2094 Power Rail
(2094-PRSx shown)
Ground Stud
2094 Power Rail
on 2094 Mounting Brackets
(2094-PRSx shown)
Ground Stud
Braided
Ground Strap
Connecting the Braided Ground Strap Examples
Braided
Ground Strap
Bonded Cabinet
Ground Bus
Ground Grid or Power
Distribution Ground
2094 Mounting Bracket
LIM
PR/PRS
PR
PRS
LIM
(2094-XNBRKT-1)
Bonded Cabinet
Ground Bus
Ground Grid or Power
Distribution Ground
Ground Strap
PR
PR
Braided
Line Interface Module
on 2094 Mounting Brackets
(2094-ALxxS shown)
2094 Mounting Bracket
(2094-XNBRKT-1)
Ground Stud
Bonded Cabinet
Ground Bus
Ground Grid or Power
Distribution Ground
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Connecting the Kinetix 6000 Drive System 79
For power rail dimensions, refer to the Kinetix 6000 Power Rail
Installation Instructions, publication 2094-IN003.
For mounting bracket dimensions, refer to the 2094 Mounting
Brackets Installation Instructions, publication 2094-IN008.
IMPORTANT
When 2094 mounting brackets are used to mount the power rail
or LIM over the ac line filter, the braided ground strap must be
removed from the power rail and attached to a mounting
bracket ground stud.
Grounding Multiple Subpanels
Extending the chassis ground to multiple subpanels is illustrated in the
figure below. High-frequency (HF) bonding is not illustrated.
Subpanels Connected to a Single Ground Point
Follow NEC and
applicable local codes.
Bonded Ground Bus
Ground Grid or Power
Distribution Ground
For HF bonding information, refer to Bonding Multiple Subpanels on
page 29.
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80 Connecting the Kinetix 6000 Drive System
Power Wiring
Wire should be copper with 75 °C (167 °F) minimum rating. Phasing
of main ac power is arbitrary and earth ground connection is required
Requirements
Module Catalog Number Description
2094-AC05-Mxx-S
IAM
(230V)
IAM
(460V)
IAM
(230V or 460V)
(1)
DC common bus connections (leader IAM to follower IAM) should be kept as short as possible.
(2)
The actual gauge of the contactor enable wiring depends on the system configuration. Consult your machine builder, the NEC, and applicable local codes.
2094-AC09-Mxx-S
2094-AC16-Mxx-S 10 (8)
2094-AC32-Mxx-S 25 (4)
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-BC04-Mxx-S 10 (8)
2094-BC07-Mxx-S 25 (4)
2094-xCxx-Mxx-S
for safe and proper operation.
IMPORTANT
IAM Power Wiring Requirements
(1)
DC bus
and
VAC input power
Control input power
Contactor Enable
The National Electrical Code and local electrical codes take
precedence over the values and methods provided.
Connects to Terminals Recommended
Pin Signal
IPD-1
IPD-2
IPD-3
IPD-4
IPD-5
IPD-6
CPD-1 CTRL 2
CPD-2 CTRL 1
CED-1 CONT ENCED-2 CONT EN+
DCDC+
L3
L2
L1
Wire Size
mm2 (AWG)
2.5 (14) 10 (0.38)
4.0 (12) 10 (0.38)
2.5 (14)
(2)
2.5 (14)
Strip Length
mm (in.)
16 (0.63)
16 (0.63)
10 (0.38)
Tor que Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
2.4 - 3.0
(21.6 - 26.5)
1.2 - 1.5
(10.6 - 13.2)
2.4 - 3.0
(21.6 - 26.5)
0.5 - 0.6
(4.4 - 5.3)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
ATTENTION
To avoid personal injury and/or equipment damage, make sure
installation complies with specifications regarding wire types,
conductor sizes, branch circuit protection, and disconnect
devices. The National Electrical Code (NEC) and local codes
outline provisions for safely installing electrical equipment.
To avoid personal injury and/or equipment damage, make sure
motor power connectors are used for connection purposes only.
Do not use them to turn the unit on and off.
To avoid personal injury and/or equipment damage, make sure
shielded power cables are grounded to prevent potentially high
voltages on the shield.
Page 81
Connecting the Kinetix 6000 Drive System 81
IAM/AM Power Wiring Requirements
Module Catalog Number Description
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-AMP5-S, -AM01-S,
-AM02-S, -BMP5-S,
-BM01-S, and -BM02-S
Motor power
2094-AC16-Mxx-S
2094-AC32-Mxx-S
2094-AM03-S, -AM05-S
2094-BC04-Mxx-S
2094-BC07-Mxx-S
2094-BM03-S, -BM05-S
IAM or AM
IAM or AM
(230 or 460V)
2094-xCxx-Mxx-S and
Brake power
2094-xMxx-S
IAM or AM
(230 or 460V)
2094-xCxx-Mxx-S and
Safe-off
2094-xMxx-S
Connects to Terminals Recommended
Wire Size
Pin Signal
mm2 (AWG)
Motor power
cable depends
on motor/drive
MP-4
MP-3
MP-2
MP-1
W
V
U
combination.
6 (10) max
25 (4) max 16 (0.63)
BC-6
BC-5
BC-4
BC-3
BC-2
BC-1
MBRKMBRK+
COM
PWR
DBRKDBRK+
0.75 (18) 10 (0.38)
FDBK2+
SO-1
SO-2
SO-3
SO-4
SO-5
SO-6
SO-7
SO-8
SO-9
FDBK2FDBK1+
FDBK1SAFETY
ENABLE2+
SAFETY
ENABLESAFETY
ENABLE1+
24V +
0.75 (18)
(stranded wire
with ferrule)
1.5 (16)
(solid wire)
24V_COM
Strip Length
mm (in.)
10 (0.38)
10 (0.38)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
1.2 - 1.5
(10.6 - 13.2)
2.4 - 3.0
(21.6 - 26.5)
0.22 - 0.25
(1.9 - 2.2)
7.0 (0.275) 0.235 (2.0)
Shunt Module Power Wiring Requirements
Module Description
1394-SR-xxxx
External passive
SM (230/460V)
2094-BSP2
(1)
105 °C (221 °F), 600V.
shunt module
Thermal switch
Connects to Terminals Recommended
Wire Size
Pin Signal
mm
2
(AWG)
RC-1 DC+
(1)
RC-2 INT
10 (8)
RC-3 COL
TS-1 TS1
0.75 (18)
TS-2 TS2
Torque Value
Nm (lb-in)
1.2 - 1.5
(10.6 - 13.2)
0.22 - 0.25
(1.9 - 2.2)
Publication 2094-UM001A-EN-P — September 2006
Page 82
82 Connecting the Kinetix 6000 Drive System
Refer to Power Specifications on page 170 for additional information.
Refer to Power Wiring Examples on page 193 for interconnect
diagrams.
ATTENTION
ATTENTION
This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. You are required to follow static control
precautions when you install, test, service, or repair this
assembly. If you do not follow ESD control procedures,
components can be damaged. If you are not familiar with static
control procedures, refer to Allen-Bradley publication
8000-4.5.2, Guarding Against Electrostatic Damage or any other
applicable ESD Protection Handbook.
To avoid personal injury and/or equipment damage, ensure
installation complies with specifications regarding wire types,
conductor sizes, branch circuit protection, and disconnect
devices. The National Electrical Code (NEC) and local codes
outline provisions for safely installing electrical equipment.
To avoid personal injury and/or equipment damage, ensure
motor power connectors are used for connection purposes only.
Do not use them to turn the unit on and off.
To avoid personal injury and/or equipment damage, ensure
shielded power cables are grounded to prevent potentially high
voltages on the shield.
Publication 2094-UM001A-EN-P — September 2006
Page 83
Connecting the Kinetix 6000 Drive System 83
Wiring Guidelines
Use these guidelines as a reference when wiring the connectors on
your Kinetix 6000 drive modules or line interface module (LIM).
IMPORTANT
IMPORTANT
Refer to the Line Interface Module Installation Instructions, publication
2094-IN005, for LIM power wiring requirements and connector
locations. Refer to Wiring Examples beginning on page 192 for
interconnect diagrams including the LIM.
Follow these steps when wiring the connectors on your Kinetix 6000
drive modules or line interface module (LIM).
Refer to page 50 for the connector locations of the Kinetix 6000
drive modules.
When tightening screws to secure the wires, refer to the tables
beginning on page 80 for torque values.
When removing insulation from wires, refer to the tables
beginning on page 80 for strip lengths.
To ensure system performance, run wires and cables in the
wireways as established in Establishing Noise Zones on page
30.
1. Prepare the wires for attachment to each connector plug by
removing insulation equal to the recommended strip length.
IMPORTANT
2. Route the cable/wires to your Kinetix 6000 drive module or LIM.
3. Insert wires into connector plugs.
Refer to connector pinout tables in Chapter 4 or the interconnect
diagrams in Appendix B.
4. Tighten the connector screws.
5. Gently pull on each wire to make sure it does not come out of its
terminal. Re-insert and tighten any loose wires.
6. Insert the connector plug into the module connector.
Use caution not to nick, cut, or otherwise damage strands
as you remove the insulation.
Publication 2094-UM001A-EN-P — September 2006
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84 Connecting the Kinetix 6000 Drive System
Wiring the LIM Connectors
This section provides examples and wiring tables to assist you in
making connections to the line interface module (LIM) connectors.
Wiring the Auxiliary Input Power (APL) Connector
The Auxiliary Input Power (APL) connector is present only on the
2094-XL75S-Cx models.
Line Interface Module (APL connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
L2/N
1 2
L1
Auxiliary Input Power (APL) Connector
Single-phase Supply APL Pin Signal
L1 1 L1
L2 2 L2/N
Recommended
Wire Size
2
(AWG)
mm
0.2-4.0
(24-10)
Strip Length
mm (in.)
7.0
(0.28)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
Page 85
Wiring the VAC LINE (IPL) Connector
Line Interface Module (IPL connector)
1 2 3 4
L3
L2
L1
VAC LINE (IPL) Connector
2094-AL09, -ALxxS, -BLxxS, and -XL75S-Cx
Three-phase Supply IPL Pin Signal
L1 4 L1
L2 3 L2
L3 2 L3
Connecting the Kinetix 6000 Drive System 85
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
Recommended
Wire Size
2
(AWG)
mm
2.5-25
(14-4)
Strip Length
mm (in.)
16.0
(0.63)
Tor que Value
Nm (lb-in)
2.7
(24)
1
VAC LINE (IPL) Connector
2094-BL02
Three-phase Supply IPL Pin Signal
L1 1 L1
L2 2 L2
L3 3 L3
4
Recommended
Wire Size
2
(AWG)
mm
4.0
(12)
Strip Length
mm (in.)
10.0
(0.38)
Tor que Value
Nm (lb-in)
1.5 - 1.8
(13.2 - 15.9)
Publication 2094-UM001A-EN-P — September 2006
Page 86
86 Connecting the Kinetix 6000 Drive System
Wiring the VAC LOAD (OPL) Connector
Line Interface Module (OPL connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
1 2 3 4
L3
L2
L1
IMPORTANT
VAC LOAD (OPL) Connector (2094-ALxxS, -BLxxS, or -XL75S-Cx)
Three-phase Supply OPL Pin Signal
L1 4 L1’
L2 3 L2’
L3 2 L3’
1
VAC LOAD (OPL) Connector (2094-AL09)
Three-phase Supply OPL Pin Signal
L1 1 L1’
L2 2 L2’
L3 3 L3’
Line interface modules (2094-ALxxS, -BLxxS, and -XL75S-Cx)
are capable of connecting to two IAMs, providing each IAM has
its own line filter and the maximum current specification is not
exceeded.
Refer to Power Wiring Examples on page 194 for an example of
the LIM wired to two IAMs.
Recommended Wire Size
2
(AWG)
mm
2.5-25
(14-4)
Recommended Wire Size
mm2 (AWG)
2.5-25
(14-4)
Strip Length
mm (in.)
16.0
(0.63)
Strip Length
mm (in.)
16.0
(0.63)
Tor que Value
Nm (lb-in)
2.7
(24)
Tor que Value
Nm (lb-in)
2.7
(24)
Three-phase Supply OPL Pin Signal
L1 4 L1’
L2 3 L2’
L3 2 L3’
Publication 2094-UM001A-EN-P — September 2006
4
VAC LOAD (OPL) Connector (2094-BL02)
Recommended Wire Size
2
(AWG)
mm
4.0
(12)
1
Strip Length
mm (in.)
10.0
(0.38)
Tor que Value
Nm (lb-in)
1.5 - 1.8
(13.2 - 15.9)
Page 87
Connecting the Kinetix 6000 Drive System 87
Wiring the Control Power Output (CPL) Connector
Line Interface Module (CPL connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
Control Power Output (CPL) Connector
2094-ALxxS, -BLxxS, -XL75S-Cx
CPL Pin Signal
1CTRL 1
2CTRL 2
Control Power Output (CPL) Connector
2094-AL09 and -BL02
CPL Pin Signal
2L1
1L2/N
Recommended
Wire Size
2
(AWG)
mm
0.2-4.0
(24-10)
Recommended
Wire Size
2
mm
(AWG)
2.5
(14)
Strip Length
mm (in.)
7.0
(0.28)
Strip Length
mm (in.)
10.0
(0.38)
CTRL 2
CTRL 1
1 2
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
Page 88
88 Connecting the Kinetix 6000 Drive System
Wiring the Auxiliary Power Output (P2L) Connector
Line Interface Module (P2L connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
Auxiliary Power Output (P2L) Connector
2094-ALxxS, -BLxxS, -XL75S-Cx
P2L Pin Signal
1AUX1_L1
2AUX1_L2
3AUX2_L1
4AUX2_L2
Recommended
Wire Size
2
(AWG)
mm
0.2-4.0
(24-10)
Strip Length
mm (in.)
7.0
(0.28)
AUX2_L2
AUX2_L1
AUX1_L2
AUX1_L1
1 2 3 4
Tor que Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
Page 89
Wiring the Brake Power Output (24V dc) Connector
Line Interface Module (24V connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
Brake Power Output (24V dc) Connector
2094-ALxxS, -BLxxS, -XL75S-Cx
P1L Pin Signal
1IO_PWR2
2IO_COM2
3IO_PWR2
4IO_COM2
5IO_PWR2
6IO_COM2
Connecting the Kinetix 6000 Drive System 89
WR2
IO_P
IO_COM2
WR2
IO_P
IO_COM2
WR2
IO_P
IO_COM2
1 2 3 4 5 6
Recommended
Wire Size
2
(AWG)
mm
0.08-1.5
(28-16)
Strip Length
mm (in.)
7.0
(0.28)
Tor que Value
Nm (lb-in)
0.22-0.25 (1.9-2.2)
Brake Power Output (24V dc) Connector
2094-AL09 and -BL02
Recommended
PSL Pin Signal
1 MBRK PWR
2 MBRK COM
3 MBRK PWR
4 MBRK COM
Wire Size
2
mm
(AWG)
2.5
(14)
Strip Length
mm (in.)
10.0
(0.38)
Tor que Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
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90 Connecting the Kinetix 6000 Drive System
Wiring the IAM/AM Connectors
This section provides examples and wiring tables to assist you in
making connections to the integrated axis module (IAM) connectors.
Wiring the Control Power (CPD) Connector
This example applies to an integrated axis module (IAM), leader IAM,
or follower IAM.
Integrated Axis Module (CPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
CTRL 2
1 2
CTRL 1
IMPORTANT
LIM models (2094-AL75S and BL75S) will supply up to eight
axes. LIM models (2094-XL75S-Cx) will supply up to sixteen
axes.
IMPORTANT
Source the 230V IAM control power from the three-phase input
power (line-to-line). Supplying 230V control power from any
other source requires an isolation transformer. If used, do not
ground either output leg of the isolation transformer.
Refer to Control Power Input on page 65 for more information
and IAM Wiring Example (without LIM) on page 196 for the
interconnect drawing.
Control Power (CPD) Connector
CPL Connector (LIM) or Other Single-phase Input
2094-ALxxS, -BLxxS,
-XL75S-Cx
CPL Pin Signal CPL Pin Signal CPD Pin Signal
1 CTRL 1 2 L1 1 CTRL 2
2 CTRL 2 1 L2/N 2 CTRL 1
2094-AL09 and -BL02
CPD Connector (IAM)
Recommended
Wire Size
2
(AWG)
mm
2.5 (14) 10 (0.38)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
Page 91
Connecting the Kinetix 6000 Drive System 91
Wiring the Input Power (IPD) Connector
This example applies to an integrated axis module (IAM) or leader
IAM (dc common bus).
Integrated Axis Module (IPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
DC-
1 2 3 4 5 6
DC+
L3
L2
L1
Input Power (IPD) Connections
OPL Connector (LIM) or Other Three-phase Input
2094-AL09
2094-BL02, -ALxxS, -BLxxS,
or -XL75S-Cx
OPL Pin Signal OPL Pin Signal IPD Pin Signal
1 L1’ 4 L1’ 6 L1
2 L2’ 3 L2’ 5 L2
3 L3’ 2 L3’ 4 L3
413
N/A
IPD Connector
(IAM or leader IAM)
2DC+
1DC-
Termination Specifications
Integrated Axis Module
Cat. No.
Input VAC
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-AC16-Mxx-S 10 (8)
230V ac
2094-AC32-Mxx-S 25 (4)
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-BC04-Mxx-S 10 (8)
460V ac
2094-BC07-Mxx-S 25 (4)
Recommended
Wire Size
2
mm
(AWG)
Strip Length
mm (in.)
2.5 (14) 10 (0.38)
16 (0.63)
4.0 (12) 10 (0.38)
16 (0.63)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
2.4 - 3.0
(21.6 - 26.5)
1.2 - 1.5
(10.6 - 13.2)
2.4 - 3.0
(21.6 - 26.5)
Publication 2094-UM001A-EN-P — September 2006
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92 Connecting the Kinetix 6000 Drive System
This example applies to a follower IAM (dc common bus).
Integrated Axis Module (IPD connector)
Input Power (IPD) Connections
IPD Pin Signal
6N.C.
5N.C.
4N.C.
DC-
1 2 3 4 5 6
DC+
L3
L2
L1
IPD Connector
(IAM or follower IAM)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
3
2DC+
1DC-
IMPORTANT
Do not connect three-phase input power to the follower IAM.
Termination Specifications
Integrated Axis Module
Cat. No.
Input VAC
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-AC16-Mxx-S 10 (8)
230V ac
2094-AC32-Mxx-S 25 (4)
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-BC04-Mxx-S 10 (8)
460V ac
2094-BC07-Mxx-S 25 (4)
Recommended
Wire Size
mm
2.5 (14) 10 (0.38)
4.0 (12) 10 (0.38)
2
(AWG)
Strip Length
mm (in.)
16 (0.63)
16 (0.63)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
2.4 - 3.0
(21.6 - 26.5)
1.2 - 1.5
(10.6 - 13.2)
2.4 - 3.0
(21.6 - 26.5)
Publication 2094-UM001A-EN-P — September 2006
Page 93
Connecting the Kinetix 6000 Drive System 93
Wiring the Contactor Enable (CED) Connector
This example applies to any integrated axis module (IAM), leader
IAM, or follower IAM.
Integrated Axis Module (CPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
1 2
CONT EN-
CONT EN+
ATTENTION
Wiring the contactor enable relay is required. To avoid personal
injury or damage to the drive, wire the contactor enable relay
into your safety control string.
Refer to Contactor Enable Relay on page 63.
In common bus configurations, the contactor enable (CED)
connections for leader and follower drives must be wired in
series to the safety control string.
For interconnect diagrams, refer to Wiring Examples beginning
on page 192.
Contactor Enable (CED) Connector
LIM I/O (IOL) Connector or
Other Control String
2094-ALxxS, -BLxxS,
-XL75S-Cx
IO_COM1 IO_COM 1 CONT ENCOIL_E2 COIL_A2 2 CONT EN+
(1)
The actual gauge of the contactor enable wiring depends on the system configuration. Consult your machine builder, the NEC, and applicable local codes.
2094-AL09 and -BL02
CED Pin Signal
Recommended
Wire Size
2
mm
(AWG)
(1)
2.5 (14)
Strip Length
mm (in.)
10 (0.38)
Tor que Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
Publication 2094-UM001A-EN-P — September 2006
Page 94
94 Connecting the Kinetix 6000 Drive System
Wiring the Safe-off (SO) Connector
This example applies to any integrated axis module (IAM) or axis
module (AM) equipped with the safe-off (SO) connector.
Integrated Axis Module (CED connector)
Kinetix 6000 IAM/AM
(Kinetix 6000 AM is shown)
1
1
2
3
Safe-off
(SO) Connector
4
5
67
8
9
Motion Allowed Jumper
Wiring Plug Header
Each IAM and AM ships with the (9-pin) wiring plug header and
motion allowed jumper installed in the safe-off connector. With the
motion allowed jumper installed, the safe-off feature is not used.
Pinouts for the safe-off (SO) connector are shown on page 52.
IMPORTANT
Pins SO-8 and -9 (24V+) are only used by the motion allowed
jumper. When wiring to the wiring plug header, the 24V supply
must come from an external source.
Safe-off (SO) Connector
Publication 2094-UM001A-EN-P — September 2006
CED Pin Signal
1FDBK2+
2FDBK23FDBK1+
4FDBK15 SAFETY ENABLE2+
6 SAFETY ENABLE7 SAFETY ENABLE1+
824V +
924V_COM
Recommended
Wire Size
mm2 (AWG)
0.75 (18)
(stranded wire
with ferrule)
1.5 (16)
(solid wire)
Strip Length
mm (in.)
7.0 (0.275) 0.235 (2.0)
Torque Value
Nm (lb-in)
To wire the safe-off connector in single axis or multi-axis
configurations, refer to the Kinetix Safe-off Feature Safety Reference
Manual, publication GMC-RM002.
Page 95
Cable Shield Clamp
Connecting the Kinetix 6000 Drive System 95
Wiring the Motor Power (MP) Connector
This example applies to axis modules (AM) and the inverter section of
integrated axis modules (IAM).
Integrated Axis Module/Axis Module (MP connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
W
V
U
1 2 3 4
Cable Shield Terminations
Factory supplied motor power cables for MP-Series, TL-Series,
1326AB, F-, and Y-Series motors are shielded, and the braided cable
shield must terminate at the drive during installation. A small portion
of the cable jacket must be removed to expose the shield braid. The
exposed area must be clamped (using the clamp provided) on top of
the IAM or AM and the power wires terminated in the motor power
(MP) connector plug.
SHOCK HAZARD
IMPORTANT
To avoid hazard of electrical shock, ensure shielded power
cables are grounded at a minimum of one point for safety.
For TL- and Y-Series motors, also connect the 152 mm (6.0 in.)
termination wire to the closest earth ground.
Refer to Pigtail Terminations on page 100 for more information.
Publication 2094-UM001A-EN-P — September 2006
Page 96
96 Connecting the Kinetix 6000 Drive System
Motor Power Cables with Three-phase Wires Only
Motor Motor Catalog Number
MP-Series Low Inertia
MPL-A/B3xxx, -A/B4xxx, -A/B45xxx,
-A/B5xxx, -B6xxx, -B8xxx, -B9xxx, S/M
MP-Series Integrated Gear MPG-A/BxxxxS/M
Motor Power Cable
Catalog Number
2090-XXNPMP-xxSxx
1326AB (M2L/S2L) 1326AB-Bxxxx-M2L/S2L
TL-Series TL-Axxxx-H 2090-XXNPT-16Sxx
F-Series F-xxxx 2090-XXNPHF-xxSxx
These cables only contain the three-phase wires and the motors have
a separate connector for brake connections. Thermal switch wires are
included in the feedback cable.
IMPORTANT
Motor Power Terminations (three-phase wires only)
No drive-end preparation is required for these cables.
Motor Cable
Shield Clamp
Cable Clamp
(with tie wrap)
CTRL 2
CTRL 1
DCDC+
L3
L2
L1
CONT ENCONT EN+
W
V
1 2 3 4
U
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
RX
TX
DPI
Motor Power (MP) Connector Plug
BAUD
RATE
The cable shield clamp shown above is mounted to an IAM. Cables
attach to the clamp on each AM in the same way.
IMPORTANT
Securing the cable shield in the clamp with a tie wrap is
recommended to improve stress relief.
Publication 2094-UM001A-EN-P — September 2006
Page 97
Connecting the Kinetix 6000 Drive System 97
Motor Power Cables with Three-phase and Brake Wires
Motor Motor Catalog Number
Motor Power Cable
Catalog Number
MP-Series Low Inertia MPL-A/B15xxx and MPL-A/B2xxx V/E
2090-XXNPMF-xxSxxMP-Series Food Grade MPF-A/BxxxxS/M
MP-Series Stainless Steel MPS-A/BxxxxS/M
Y-S erie s Y- xxxx 2090-XXNPY-16Sxx
These MP-Series brake wires have a shield braid (shown below as
gray) that folds back under the cable clamp before the conductors are
attached to the motor brake (BC) connector. Y-Series brake wires are
not shielded and do not require routing under the cable clamp.
The thermal switch wires for the MP-Series motors are included in the
feedback cable.
Refer to Axis Module/Motor Wiring Examples beginning on page 204
for interconnect diagrams.
IMPORTANT
No drive-end preparation is required for these cables.
Refer to page 99 for drive-end cable pinouts.
Motor Power Terminations (three-phase and brake wires)
MP-Series Cable Brake Wires
Y-Series brake wires are not
shielded and do not require
routing under the cable clamp.
The cable shield clamp shown above is mounted to an IAM. Cables
attach to the clamp on each AM in the same way.
CTRL 2
CTRL 1
DCDC+
L3
L2
L1
CONT ENCONT EN+
Motor Cable
Shield Clamp
(with tie wrap)
MBRK -
MBRK +
DBRK DBRK +
RX
DPI
W
V
U
COM
PWR
1 2 3 4
1 2 3 4 5 6
TX
BAUD
RATE
Motor Power
(MP) Connector
Resistive/Motor Brake
(BC) Connector
IMPORTANT
Securing the cable shield in the clamp with a tie wrap is
recommended to improve stress relief.
Publication 2094-UM001A-EN-P — September 2006
Page 98
98 Connecting the Kinetix 6000 Drive System
Motor Power Cables with Three-phase, Brake, and Thermal Switch Wires
Low-profile motor feedback connector
(2090-K6CK-D15MF) pins 16, 17, and S
provide filtering for 1326-CPx1-xxx cables
(refer to page 111 for an illustration).
Motor Motor Catalog Number
Motor Power Cable
Catalog Number
1326AB (resolver) 1326AB-Bxxxx-21 1326-CPx1-xxx
The 1326AB (resolver) power cable contains the three-phase wires,
brake wires, and thermal switch wires. To improve the EMC
performance of your system, route the wires as shown.
IMPORTANT
Drive-end preparation is required for these cables.
Refer to page 99 for drive-end pinouts and cable preparation.
Motor Power Terminations (three-phase, brake, and thermal switch wires)
MF-16
MF-17
MF-S
Thermal Switch
Wires
Terminal Block (mounted on DIN rail)
Refer to page 28 for treatment of painted panels.
Cable Clamp
Thermal Switch Wires
Keep wires separated
as much as possible.
CTRL 1
CTRL 2
DCDC+
L3
L2
L1
CONT ENCONT EN+
(with tie wrap)
MBRK -
MBRK +
DBRK +
RX
DPI
PWR
DBRK -
COM
W
V
U
TX
1 2 3 4
1 2 3 4 5 6
BAUD
RATE
Motor Power
(MP) Connector
Resistive/Motor Brake
(BC) Connector
The cable shield clamp shown above is mounted to an IAM. Cables
attach to the clamp on each AM in the same way.
IMPORTANT
Securing the cable shield in the clamp with a tie wrap is
recommended to improve stress relief.
Publication 2094-UM001A-EN-P — September 2006
Page 99
Connecting the Kinetix 6000 Drive System 99
Shield Clamp Cable Preparation (1326-CPx1-xxx)
Cable Pinouts (2090-XXNPY-16Sxx, and 2090-XXNPMF-xxSxx)
Strip Length 10 mm (0.375 in.)
Outer Insulation
Motor Power Cable
Exposed Braid
25.4 mm (1.0 in.)
1326AB (resolver) Motors
(1326-CPx1-xxx cable)
9
Black
Thermal
switch
5
4
6
3
2
1
wires
Black
Black
Brake
wires
Black
Black
Black
Motor
Power
Wires
Black Black
Grn/Yel
Y-Series Motors
(2090-XXNPY-xxSxx cable)
N/A
Black
7
9
3
2
1
Black
Black
Black
Grn/Yel
Brake
wires
Motor
Power
Wires
MPL-A/B15xx, MPL- A/B2xx,
MPF-A/B and MPS-A/B Motors
(2090-XXNPMF-xxSxx cable)
1
White
2
Red
White
BR+
Black
BR-
U
Brown
Black
V
W
Blue
Grn/Yel
105 mm (4.1 in.)
130 mm (5.1 in.)
Refer to Axis Module/Motor Wiring Examples beginning on page 204
for interconnect diagrams.
Motor Power (MP) Connector
Servo Motor MP Connector (IAM/AM)
1326AB (resolver)
and Y-Series
1 / Black U / Brown 1 U
2 / Black V / Black 2 V
3 / Black W / Blue 3 W
Green/Yellow
1326AB (M2L/S2L), F-, TL-,
and MP-Series
Green/Yellow
MP Pin Signal
4
Spare
wire
set
Brake
wires
Motor
Power
Wires
Termination Specifications
IAM/AM
Cat. No.
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-AMP5-S, -AM01-S, -AM02-S,
-BMP5-S, -BM01-S, and -BM02-S
2094-AC16-Mxx-S
2094-AC32-Mxx-S
2094-AM03-S, -AM05-S
2094-BC04-Mxx-S
2094-BC07-Mxx-S
2094-BM03-S, -BM05-S
Recommended
Wire Size
2
mm
(AWG)
Motor power
cable depends on
Strip Length
mm (in.)
10 (0.38)
motor/drive
combination.
6 (10) max
10 (0.38)
25 (4) max 16 (0.63)
Publication 2094-UM001A-EN-P — September 2006
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
1.2 - 1.5
(10.6 - 13.2)
2.4 - 3.0
(21.6 - 26.5)
Page 100
100 Connecting the Kinetix 6000 Drive System
Pigtail Terminations
TL- and Y-Series motors have a short pigtail cable which connects to
the motor, but is not shielded. The preferred method for grounding
the TL- and Y-Series motor power cable on the motor side is to
expose a section of the cable shield and clamp it directly to the
machine frame. The motor power cable also has a 150 mm (6.0 in.)
shield termination wire with a ring lug that connects to the closest
earth ground. Use this method in addition to the cable clamp. The
termination wire may be extended to the full length of the motor
pigtail if necessary, but it is best to connect the supplied wire directly
to ground without lengthening.
Pigtail Terminations
Motor Power Cable
Machine Frame
Cable Braid Clamped
to Machine Frame.
(1)
Remove paint from machine frame to ensure proper HF-bond between machine frame and motor case, shield
clamp, and ground stud.
(1)
(1)
Connectors
150 mm (6.0) Termination
Pigtail Cable
TL-Series or
Y-S erie s
Motor
(1)
Publication 2094-UM001A-EN-P — September 2006
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