Download 2094-IN002A-EN-P Kinetix 6000 Integration Manual

Over 100 years cumulative experience
24 hour rush turnaround / technical support service
Established in 1993
The leading independent repairer of servo motors and drives in North America.
Visit us on the web:
www.servo-repair.com
www.servorepair.ca
www.ferrocontrol.com
www.sandvikrepair.com
www.accuelectric.com
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For 24/7 repair services :
USA: 1 (888) 932 - 9183
Canada: 1 (905) 829 -2505
Emergency After hours: 1 (416) 624 0386
Servicing USA and Canada
Kinetix 6000 Multi-Axis
Servo Drive
(Catalog Numbers
2094-AC05-MP5, -AC05-M01, -AC09-M02
-AC16-M03, -AC32-M05
2094-BC01-MP5, -BC01-M01, -BC02-M02
-BC04-M03, -BC07-M05
2094-BC01-MP5-S, -BC01-M01-S,
-BC02-M02-S, -BC04-M03-S, -BC07-M05-S
2094-AMP5, -AM01, -AM02, -AM03, -AM05
2094-BMP5, -BM01, -BM02, -BM03, -BM05
2094-PRS1, -PRS2, -PRS3, -PRS4, -PRS5,
-PRS6, -PRS7, -PRS8
2094-PR1, -PR2, -PR4, -PR6, -PR8
2094-PRF
2094-AL09, -AL75S
2094-BL02, -BL75S
2094-XL75S-C1
2094-XL75S-C2
2094-BSP2)
Integration Manual
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1
available from your local Rockwell Automation sales office or online at
http://www.rockwellautomation.com/literature) 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.
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
• recognize the consequence
SHOCK HAZARD
Labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may
be present.
BURN HAZARD
Labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be
dangerous temperatures.
Allen-Bradley, A-B, ControlLogix, and Kinetix are registered trademarks of Rockwell Automation.
DriveExplorer, RSLogix, RSLogix 5000, SoftLogix, and SCANport are trademarks of Rockwell Automation.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
Who Should Use this Manual . . . . . . . . . . . . .
Purpose of this Manual . . . . . . . . . . . . . . . . .
Contents of this Manual . . . . . . . . . . . . . . . . .
Product Receiving and Storage Responsibility .
Related Documentation . . . . . . . . . . . . . . . . .
Conventions Used in this Manual . . . . . . . . . .
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P-1
P-1
P-1
P-2
P-2
P-3
P-4
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . .
General Startup Precautions . . . . . . . . . . . . . . . . . . .
Understand IAM/AM Connectors . . . . . . . . . . . . . . .
Integrated Axis Module/Axis Module Connectors .
Locate IAM Connectors and Indicators . . . . . . . . . . .
Locate AM Connectors and Indicators . . . . . . . . . . . .
Understand SM Connectors . . . . . . . . . . . . . . . . . . .
Locate Shunt Module Connectors . . . . . . . . . . . .
Understand LIM Connectors and Indicators . . . . . . . .
Line Interface Module Connectors . . . . . . . . . . . .
Locate SERCOS Interface Fiber-Optic Connectors . . .
Configure Your Kinetix 6000 . . . . . . . . . . . . . . . . . .
Configure Your Integrated Axis Module. . . . . . . .
Configure Your Axis Module(s) . . . . . . . . . . . . . .
Configure Your Logix SERCOS interface Module . . . .
Configure Your Logix Controller . . . . . . . . . . . . .
Configure Your Logix Module . . . . . . . . . . . . . . .
Configure Your Kinetix 6000 Modules . . . . . . . . .
Configure the Motion Group . . . . . . . . . . . . . . . .
Configure Axis Properties . . . . . . . . . . . . . . . . . .
Download Your Program . . . . . . . . . . . . . . . . . .
Apply Power to Your Kinetix 6000 . . . . . . . . . . . . . .
Apply Power to Your Kinetix 6000 (with LIM) . . .
Apply Power to Your Kinetix 6000 (without LIM).
Test and Tune Your Axes. . . . . . . . . . . . . . . . . . . . .
Test Your Axes. . . . . . . . . . . . . . . . . . . . . . . . . .
Tune Your Axes . . . . . . . . . . . . . . . . . . . . . . . . .
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1-1
1-1
1-2
1-2
1-3
1-4
1-5
1-5
1-6
1-6
1-9
1-9
1-10
1-15
1-16
1-16
1-17
1-19
1-23
1-24
1-25
1-26
1-26
1-30
1-33
1-33
1-36
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2-1
2-2
2-2
2-3
2-8
2-8
2-8
Chapter 1
Commission Your Kinetix 6000
Chapter 2
Troubleshoot Your Kinetix 6000
i
Chapter Objectives. . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . .
General Troubleshooting . . . . . . . .
Error Codes . . . . . . . . . . . . . . .
Troubleshoot IAM/AM Status LEDs .
Drive Status LED . . . . . . . . . . .
Comm Status LED. . . . . . . . . . .
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Publication 2094-IN002E-EN-P — September 2005
ii
Table of Contents
Bus Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshoot SM Status LEDs . . . . . . . . . . . . . . . . . . . . .
General Shunt Module Troubleshooting . . . . . . . . . . .
Bus Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Fault LED . . . . . . . . . . . . . . . . . . . . . . .
Shunt Fault LED . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshoot LIM Status LEDs . . . . . . . . . . . . . . . . . . . .
Troubleshoot RBM Status LEDs . . . . . . . . . . . . . . . . . . . .
24V dc Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . .
230V ac Auxiliary Power Status LED . . . . . . . . . . . . .
Troubleshoot General System Problems . . . . . . . . . . . . .
Understand Logix/Drive Fault Behavior. . . . . . . . . . . . . .
Supplemental Troubleshooting Information. . . . . . . . . . .
Tools for Changing Parameters . . . . . . . . . . . . . . . . .
Using Analog Test Points to Monitor System Variables
Replace Kinetix 6000 System Components. . . . . . . . . . . .
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Modules from the Power Rail. . . . . . . . . . . . . . .
Replace Power Rail Modules. . . . . . . . . . . . . . . . . . . . . .
Remove the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . .
Replace the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . .
Remove the Line Interface Module . . . . . . . . . . . . . . . . .
Replace the Line Interface Module . . . . . . . . . . . . . . . . .
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. 2-9
2-10
2-10
2-11
2-11
2-11
2-12
2-12
2-12
2-13
2-14
2-16
2-19
2-19
2-20
2-22
2-22
2-23
2-24
2-25
2-26
2-27
2-28
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. A-1
. A-1
. A-3
. A-8
A-13
A-14
A-14
A-16
A-24
A-26
A-26
A-27
A-28
A-28
A-29
A-34
Appendix A
Interconnect Diagrams
Publication 2094-IN002E-EN-P — September 2005
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . .
Kinetix 6000 Interconnect Diagram Notes . . . . .
Power Interconnect Diagrams. . . . . . . . . . . . . .
DC Common Bus Interconnect Diagrams . . . . .
Shunt Module Interconnect Diagrams . . . . . . . .
1336 Active Shunt Input Fuse Specifications .
1336 Active Shunt Fault Relay Specifications
AM/Motor Interconnect Diagrams . . . . . . . . . . .
Controlling a Brake Example . . . . . . . . . . . . . .
System Block Diagrams . . . . . . . . . . . . . . . . . .
IAM/AM Inverter Block Diagram . . . . . . . . .
IAM Converter Block Diagram . . . . . . . . . . .
Safe-Off Feature Block Diagram. . . . . . . . . .
SM Block Diagram . . . . . . . . . . . . . . . . . . .
LIM Block Diagrams . . . . . . . . . . . . . . . . . .
RBM Block Diagrams . . . . . . . . . . . . . . . . .
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Table of Contents
iii
Appendix B
Upgrade Your Kinetix 6000
Firmware
Chapter Objectives. . . . . . . . . . . . . . . . . . . . .
Upgrade Drive Firmware Using DriveExplorer
Before You Begin. . . . . . . . . . . . . . . . . . .
Select Axis Modules to Upgrade . . . . . . . .
HyperTerminal Configuration . . . . . . . . . .
Flash Your Firmware . . . . . . . . . . . . . . . .
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B-1
B-1
B-1
B-1
B-4
B-5
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . .
Understand Safety Precautions . . . . . . . . . . . . . . . . .
Safety Standards for Reference . . . . . . . . . . . . . .
Background on Safety Design . . . . . . . . . . . . . . .
Stop Categories . . . . . . . . . . . . . . . . . . . . . . . . .
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . .
Control Reliability . . . . . . . . . . . . . . . . . . . . . . . .
Resistive Brake Module Interconnect Diagram Notes .
Resistive Brake Module Interconnect Diagrams . . . . .
Set the RBM Delay Time Using DriveExplorer . . . . . .
Remove SERCOS Communication . . . . . . . . . . . .
Set the RBM Delay Time Parameter . . . . . . . . . . .
Save the Delay Time Parameter to Non-Volatile
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnect SERCOS Communication . . . . . . . . . .
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C-1
C-1
C-2
C-2
C-3
C-3
C-4
C-5
C-5
C-6
C-14
C-14
C-15
Appendix C
Integrate Resistive Brake
Modules
with Kinetix 6000 Drives
. . . . C-16
. . . . C-17
Appendix D
DC Common Bus Applications
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculate Total Bus Capacitance . . . . . . . . . . . . .
Calculate Additional Bus Capacitance . . . . . . . . .
Kinetix 6000 Capacitance Values . . . . . . . . . . . . .
Common Bus Capacitance Example . . . . . . . . . .
Set the Additional Bus Capacitance Parameter. . . . . .
Remove SERCOS Communication . . . . . . . . . . . .
Set the Additional Bus Capacitance Parameter . . .
Save the Add Bus Cap Parameter to Non-Volatile
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnect SERCOS Communication . . . . . . . . . .
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D-1
D-1
D-2
D-3
D-3
D-4
D-5
D-5
D-6
. . . . . D-7
. . . . . D-8
Publication 2094-IN002E-EN-P — September 2005
iv
Table of Contents
Publication 2094-IN002E-EN-P — September 2005
Preface
Introduction
Who Should Use this
Manual
Read this preface to familiarize yourself with the rest of the manual.
This preface contains the following topics:
•
Who Should Use this Manual
•
Purpose of this Manual
•
Contents of this Manual
•
Product Receiving and Storage Responsibility
•
Related Documentation
•
Conventions Used in this Manual
This manual is intended for engineers or programmers directly
involved in the operation, field maintenance, and integration of the
Kinetix 6000 multi-axis servo drive with the SERCOS interface module.
If you do not have a basic understanding of the Kinetix 6000, contact
your local Allen-Bradley representative for information on available
training courses before using this product.
Purpose of this Manual
1
This manual provides the startup, configuration, and troubleshooting
procedures for the Kinetix 6000. The purpose of this manual is to
assist you in the integration of your Kinetix 6000 servo drive with the
ControlLogix 1756-MxxSE SERCOS interface module or SoftLogix
1784-PM16SE SERCOS PCI card.
Publication 2094-IN002E-EN-P — September 2005
P-2
Contents of this Manual
Refer to the following listing for the descriptive contents of this
installation manual.
Chapter
Product Receiving and
Storage Responsibility
Title
Contents
Preface
Describes the purpose, background, and scope of
this manual. Also specifies the audience for
whom this manual is intended.
Chapter 1
Commission Your Kinetix 6000
Provides steps to follow when configuring your
Kinetix 6000, the Logix SERCOS interface
module, and when applying power to the Kinetix
6000 for the first time.
Chapter 2
Troubleshoot Your Kinetix 6000
Provides diagnostic aids that help isolate
problems with your drive and Kinetix 6000
removal/replacement procedures.
Appendix A
Interconnect Diagrams
Provides interconnect diagrams between the
Kinetix 6000 and the Line Interface Module,
Shunt Module, Resistive Brake Module and
servo motors.
Appendix B
Upgrade Your Kinetix 6000
Firmware
Provides steps to follow when you need to
upgrade (flash) your IAM and AM firmware.
Appendix C
Integrate Resistive Brake
Modules with Kinetix 6000
Drives
Provides safety precautions, interconnect
diagrams, and procedures specific to configuring
the RBM with the Kinetix 6000.
Appendix D
DC Common Bus Applications
Explains how to calculate capacitance values
and set the Add Bus Cap parameter for DC
common bus applications.
You, the customer, are responsible for thoroughly inspecting the
equipment before accepting the shipment from the freight company.
Check the item(s) you receive against your purchase order. If any
items are obviously damaged, it is your responsibility to refuse
delivery until the freight agent has noted the damage on the freight
bill. Should you discover any concealed damage during unpacking,
you are responsible for notifying the freight agent. Leave the shipping
container intact and request that the freight agent make a visual
inspection of the equipment.
Store the product in its shipping container prior to installation. If you
are not going to use the equipment for a period of time, store using
the following guidelines.
Publication 2094-IN002E-EN-P — September 2005
•
Use a clean, dry location
•
Maintain an ambient temperature range of -40 to 70° C
(-40 to 158° F)
•
Maintain a relative humidity range of 5% to 95%, non-condensing
•
Store it where it cannot be exposed to a corrosive atmosphere
•
Store it in a non-construction area
P-3
Related Documentation
The following documents contain additional information concerning
related Allen-Bradley products. To obtain a copy, contact your local
Allen-Bradley office, distributor, or download them from
www.rockwellautomation.com/literature.
For
Read This Document
Catalog Number
The instructions needed for the installation and wiring of the Kinetix
6000
Kinetix 6000 Installation Manual
2094-IN001
Installation instructions for the LIM and removal/replacement
procedures for selected internal LIM components
Kinetix 6000 Line Interface Module Installation
Instructions
2094-IN005
Information on wiring and troubleshooting your Kinetix 6000 safety
drive
Kinetix Safe-Off Feature Safety Reference Manual
GMC-RM002
A description and specifications for the 2094 family including motors
and motor accessories
Kinetix Motion Control Selection Guide
GMC-SG001
Drive and motor sizing with application analysis software
Motion Analyzer CD
(v4.1 or above)
PST-SG003
Kinetix 6000 user documentation and CAD files
Kinetix 6000 User Documentation and CAD Files CD
2094-CL001
More detailed information on the use of ControlLogix motion features
and application examples
ControlLogix Motion Module Programming Manual
1756-RM086
ControlLogix SERCOS interface module installation instructions
SERCOS interface Module Installation Instructions
1756-IN572
SoftLogix SERCOS interface PCI card installation instructions
16 Axis PCI SERCOS interface Card Installation
Instructions
1784-IN041
The instructions needed to program a motion application
Logix5000 Controllers Motion Instructions
Reference Manual
1756-RM007
Information on configuring and troubleshooting your ControlLogix
SERCOS and analog motion modules
Logix5000 Motion Modules User Manual
1756-UM006
Information on configuring and troubleshooting your SoftLogix PCI
card
SoftLogix Motion Card Setup and Configuration
Manual
1784-UM003
Information on the installation and wiring of Bulletin 2090 Resistive
Brake Modules
Resistive Brake Module Installation Instructions
2090-IN009
Information on proper handling, installing, testing, and
troubleshooting fiber-optic cables
Fiber-Optic Cable Installation and Handling
Instructions
2090-IN010
Information, examples, and techniques designed to minimize system
failures caused by electrical noise
System Design for Control of Electrical Noise
GMC-RM001
For declarations of conformity (DoC) currently available from Rockwell
Automation
Rockwell Automation Product Certification website
www.ab.com/
certification/ce/docs
An article on wire sizes and types for grounding electrical equipment
National Electrical Code
Published by the National
Fire Protection Association
of Boston, MA.
A glossary of industrial automation terms and abbreviations
Allen-Bradley Industrial Automation Glossary
AG-7.1
Publication 2094-IN002E-EN-P — September 2005
P-4
Conventions Used in this
Manual
Publication 2094-IN002E-EN-P — September 2005
The following conventions are used throughout this manual.
•
Bulleted lists such as this one provide information, not procedural
steps
•
Numbered lists provide sequential steps or hierarchical
information
•
Words that you type or select appear in bold
•
When we refer you to another location, the section or chapter
name appears in italics
•
Acronyms for the Kinetix 6000 components, shown in the table
below, are used throughout this manual.
Kinetix 6000 Component
Catalog Numbers
Acronym
Power Rail
2094-PRx
PR
Power Rail (slim)
2094-PRSx
PRS
Power Rail Slot Filler
2094-PRF
PRF
Integrated Axis Module
2094-xCxx-Mxx
IAM
Axis Module
2094-xMxx
AM
Line Interface Module
2094-xLxx and -xLxxS-xx
LIM
Shunt Module
2094-BSP2
SM
Resistive Brake Module
2090-XBxx-xx
RBM
Chapter
1
Commission Your Kinetix 6000
Chapter Objectives
This chapter provides you with information to apply power and
configure your Kinetix 6000. This chapter includes:
•
General Startup Precautions
•
Understand IAM/AM/SM and LIM Connectors
•
Locate Connectors and Indicators
•
Locate SERCOS Interface Fiber-Optic Connectors
•
Configure Your Kinetix 6000
•
Configure Your Logix SERCOS interface Module
•
Apply Power to Your Kinetix 6000
•
Test and Tune Your Axes
Note: Some of the procedures in this chapter include information
regarding integration with other products.
General Startup
Precautions
The following precautions pertain to all of the procedures in this
chapter. Be sure to read and thoroughly understand them before
proceeding.
ATTENTION
ATTENTION
1
This product contains stored energy devices. To
avoid hazard of electrical shock, verify that all
voltages on the system bus network have been
discharged before attempting to service, repair or
remove this unit. Only qualified personnel familiar
with solid state control equipment and safety
procedures in publication NFPA 70E or applicable
local codes should attempt this procedure.
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.
Publication 2094-IN002E-EN-P — September 2005
1-2
Commission Your Kinetix 6000
Understand IAM/AM
Connectors
The following table provides a brief description of the Kinetix 6000
IAM/AM connectors.
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 (male)
IAM/AM
AF
Auxiliary Feedback
15-pin high-density D-shell (female)
IAM/AM
CPD
Control Input Power (drive)
2-position connector housing
IAM
DC Bus and VAC Input Power (drive)
230V
6-position connector housing
IAM
DC Bus and VAC Input Power (drive)
460V
6-position connector housing
IAM
CED
Contactor Enable
2-position connector housing
IAM
MP
Motor Power
4-position connector housing
IAM/AM
BC
Resistive/Motor Brake
6-position connector housing
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
IPD
Publication 2094-IN002E-EN-P — September 2005
Commission Your Kinetix 6000
Locate IAM Connectors and
Indicators
1-3
Use the figure below to locate the Integrated Axis Module connectors
and indicators. Although the physical size of the 2094-BCxx-Mxx
(460V) IAM is larger than the 2094-ACxx-Mxx (230V) IAM, the location
of the connectors and indicators is identical.
Figure 1.1
Kinetix 6000 Integrated Axis Modules (2094-ACxx-Mxx and -BCxx-Mxx)
Integrated Axis Module, top view
(2094-BM01-MP5-S is shown)
Motor Cable
Shield Clamp
CONT ENCONT EN+
MBRK MBRK +
COM
PWR
DBRK DBRK +
RX
TX
DPI
Motor Power
(MP) Connector
1 2 3 4 5 6
L3
L2
L1
W
V
U
1 2 3 4
CTRL 1
1 2 3 4 5 6 7 8 9
Safe-Off
(SO) Connector
(present only on the 2094-BCxx-Mxx-S)
DCDC+
1 2
Contactor Enable
(CED) Connector
CTRL 2
1 2 3 4 5 6
DC Bus / AC Input Power
(IPD) Connector
1 2
Control Power
(CPD) Connector
Motor/Resistive Brake
(BC) Connector
BAUD
RATE
SERCOS Baud Rate
and Optical Power Switches
SERCOS Transmit (Tx) Connector
DPI Connector
SERCOS Receive (Rx) Connector
Integrated Axis Module, front view
(2094-AC05-M01 is shown)
SERCOS
Node Address Switch
Seven Segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
Mounting Screw
Note: Power, feedback, and I/O connectors are shown, however for
wiring information, refer to the Kinetix 6000 Multi-Axis Servo
Drive Installation Manual (publication 2094-IN001).
Publication 2094-IN002E-EN-P — September 2005
1-4
Commission Your Kinetix 6000
Locate AM Connectors and
Indicators
Use the figure below to locate the Axis Module connectors and
indicators. Although the physical size of the 2094-BMxx (460V) AM is
larger than the 2094-AMxx (230V) AM, the location of the connectors
and indicators is identical.
Figure 1.2
Kinetix 6000 Axis Modules (2094-AMxx and -BMxx)
W
V
U
1 2 3 4 5 6 7 8 9
Safe-Off
(SO) Connector
(present only on the 2094-BMxx-S)
RX
1 2 3 4
Motor Cable
Shield Clamp
MBRK -
Motor Power
(MP) Connector
1 2 3 4 5 6
Axis Module, top view
(2094-BMP5-S is shown)
MBRK +
COM
PWR
DBRK DBRK +
TX
Motor/Resistive Brake
(BC) Connector
BAUD
RATE
SERCOS Baud Rate
and Optical Power Switches
SERCOS Transmit (Tx) Connector
SERCOS Receive (Rx) Connector
Axis Module, front view
(2094-AM01 is shown)
Seven Segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
Mounting Screw
Note: Power, feedback, and I/O connectors are shown, however for
wiring information, refer to the Kinetix 6000 Multi-Axis Servo
Drive Installation Manual (publication 2094-IN001).
Publication 2094-IN002E-EN-P — September 2005
Commission Your Kinetix 6000
Understand SM Connectors
1-5
Use the table below and Figure 1.3 to locate the Shunt Module
connectors and indicators.
Locate Shunt Module Connectors
Designator
Description
Connector
RC
External Shunt Resistor Connector
3-position connector housing
TS
External Thermal Switch Connector
2-position connector housing
Figure 1.3
Kinetix 6000 Shunt Modules (2094-BSP2)
Shunt Module, top view
TS2
TS1
1 2
COL
INT
DC+
1 2 3
Motor Cable
Shield Clamp
External Shunt Resistor
(RC) Connector
External Thermal Switch
(TS) Connector
Shunt Module, front view
Shunt Fault LED
Over-Temp Fault LED
Bus Status LED
Mounting Screw
Note: Power connectors are shown, however for wiring information,
refer to the Kinetix 6000 Multi-Axis Servo Drive Installation
Manual (publication 2094-IN001).
Publication 2094-IN002E-EN-P — September 2005
1-6
Commission Your Kinetix 6000
Understand LIM Connectors
and Indicators
Use the tables below and figures 1.4 and 1.5 to locate the Line
Interface Module connectors.
Line Interface Module Connectors
The following table describes the Line Interface Module connectors
used with catalog numbers 2094-AL75S, -BL75S, and -XL75S-Cx.
1
Designator
Description
Connector
IOL
Status I/O (LIM)
21-pin (plugable) terminal block
IPL
VAC LINE Input Power (LIM)
4-position plug/header
OPL
VAC LOAD Output Power
4-position plug/header
P1L
Brake and I/O Power Output (24V dc)
6-position plug/header
P2L
Auxiliary Power Output (230V ac)
4-position plug/header
CPL
Control Power Output (LIM)
2-position plug/header
APL 1
Auxiliary Power Input (LIM)
2-position plug/header
Auxiliary Power Input (APL) connector is only present on the 2094-XL75S-Cx model.
The following table describes the Line Interface Module connectors
used with catalog numbers 2094-AL09 and -BL02.
Publication 2094-IN002E-EN-P — September 2005
Designator
Description
Connector
IOL
Status I/O (LIM)
26-pin high-density D-shell
IPL
VAC LINE Input Power (LIM)
4-position terminals
OPL
VAC LOAD Output Power
4-position terminals
PSL
Brake and I/O Power Output (24V dc)
4-position plug/header
CPL
Control Power Output (LIM)
2-position plug/header
Commission Your Kinetix 6000
1-7
Use the figure below to locate the Line Interface Module connectors
and indicators.
Figure 1.4
Kinetix 6000 Line Interface Modules (2094-AL09 and -BL02)
L2
L1
PE
1
L3
1
L2 1
L1 1
1 2 3 4
MBRK PWR
MBRK COM
MBRK PWR
MBRK COM
4321
195-264 VAC LINE
50/60 Hz
L3
195-264 VAC LOAD
50/60 Hz
PE
24 VDC BRAKE SUPPLY
1 2 3 4
VAC Line
(IPL) Connector
230 VAC LOAD
L1
L2/N
1 2
Line Interface Module,
top view
(2094-AL09 is shown)
Control Power Load
(CPL) Connector
VAC Load
(OPL) Connector
24 VDC Brake Power (PSL) Connector
Line Interface Module,
front view
(2094-AL09 is shown)
Brake Power Status LED
MAIN VAC
AUX VAC
BRAKE - I/O VAC
CB1
CB2
CB3
I/O Power Status LED
I/O (IOL) Connector
Main
VAC
Control/AUX
VAC
Line Interface Module
200/230V AC
2094-AL09
20A Output
Brake - I/O
VAC
Publication 2094-IN002E-EN-P — September 2005
1-8
Commission Your Kinetix 6000
Use the figure below to locate the Line Interface Module connectors
and indicators.
Figure 1.5
Kinetix 6000 Line Interface Modules (2094-AL75S, -BL75S, and -XL75S-Cx)
1 2
CONTROL VAC
Control Power Output (CPL) Connector
1 2 3 4
L1
230 VAC SUPPLY
230V ac Auxiliary Power Output (P2L) Connector
24 VDC SUPPLY
L2N
1 2
24V dc Brake Power Output (P1L) Connector
1
L3
2
L2
3
VAC Line
(IPL) Connector
AUX2
AUX2
L1
AUX1
AUX1
4
195-265 VAC LINE, 50/60 Hz
CTRL2
CTRL1
1
I/O_COM
L3'
I/O_PWR
2
L2'
3
L1'
4
VAC Load
(OPL) Connector
195-265 VAC LOAD, 50/60 Hz
I/O_COM
I/O_PWR
I/O_COM
I/O_PWR
12 3 4 5 6
Auxiliary Power Input
(APL) Connector 1
Line Interface Module, top view
(2094-XL75S-Cx is shown)
I/O Power
Status LED
Main VAC
OFF
CB1
ON
MAIN VAC
I/O (IOL) Connector
IOL Connector
(as viewed from side)
CB2
CB3
Brake-I/O
VAC
Fuse
Block
Control/AUX
VAC
Line Interface Module, front view
(2094-XL75S-Cx is shown)
1
Publication 2094-IN002E-EN-P — September 2005
Auxiliary Power Input (APL) connector is only present on the 2094-XL75S-Cx model.
Commission Your Kinetix 6000
Locate SERCOS Interface
Fiber-Optic Connectors
1-9
Use the figure below to locate the SERCOS interface fiber-optic
connectors. The fiber-optic ring is connected using the SERCOS
Receive and Transmit connectors.
Note: Plastic cable is available in lengths up to 32 m (105.0 ft). Glass
cable is available in lengths up to 200 m (656.7 ft).
Figure 1.6
ControlLogix and SoftLogix SERCOS Connector Locations
SERCOS interfaceTM
ABCDE
F 1
45
23 6 7
RSLogix 5000
89
OK
0
CP
ControlLogix
1756-MxxSE SERCOS
interface Module
OK
SoftLogix
1784-PM16SE SERCOS interface PCI Card
(as viewed from the back of your PC)
CP
TX
SERCOS Transmit Connector, Tx
Tx (rear)
Front View
RX
Rx (front)
SERCOS Receive Connector, Rx
Bottom View
SERCOS Receive Connector, Rx (front)
SERCOS Transmit Connector, Tx (rear)
Configure Your Kinetix 6000
These procedures assume you have completed mounting, wiring, and
connecting your SERCOS interface module and Kinetix 6000 drive as
described in the Kinetix 6000 Multi-Axis Servo Drive Installation
Manual (publication 2094-IN001).
The procedures in this section apply to Kinetix 6000 drive
components and describe how to:
• Configure your Kinetix 6000 IAM and AM(s)
• Configure your SERCOS interface module using RSLogix 5000
software
• Download your program to your Logix controller
• Apply power to your Kinetix 6000 drive components
• Test and tune your motor using RSLogix 5000 software
These procedures assume you have connected the fiber optic cables
between your IAM (2094-xCxx-Mxx, inverter section), axis modules
(2094-xMxx), and the ControlLogix chassis with 1756-MxxSE interface
module or personal computer with 1784-PM16SE PCI card.
Publication 2094-IN002E-EN-P — September 2005
1-10
Commission Your Kinetix 6000
Configure Your Integrated Axis Module
To configure your IAM:
1. Verify that there is no power applied to the IAM and that the
SERCOS fiber-optic cables are plugged into the Tx and Rx
connectors. To verify your fiber-optic cable connections, refer to
the Kinetix 6000 Multi-Axis Servo Drive Installation Manual
(publication 2094-IN001).
2. Set the base node address for the IAM by setting the SERCOS
Node Address switch. Valid node addresses are 01-99. The left
hand switch sets the most significant digit (MSD) and the right
hand switch sets the least significant digit (LSD). Refer to the table
below for switch operation. Refer to for switch location.
To
Press
Increment the (MSD/LSD) node address
The plus (+) switch.
Decrement the (MSD/LSD) node address The minus (-) switch.
Figure 1.7
Setting the Base Address Switches
Decrements MSD
MSD
Increments MSD
Decrements LSD
LSD
Increments LSD
Setting the base node address on the IAM determines the node
address for the IAM inverter. Node addressing for all slot locations
on the same power rail increment (from the IAM inverter) left to
right.
IMPORTANT
IMPORTANT
After setting the base node address, always cycle
control power to initialize the IAM.
When two or more IAMs are connected to the
same SERCOS interface module, each node
address must be unique.
Refer to figures 1.9, 1.10, and 1.11 for examples
of how node addresses are assigned.
Publication 2094-IN002E-EN-P — September 2005
Commission Your Kinetix 6000
1-11
Refer to Figure 1.8 for an example of the fiber-optic ring connections
between the Kinetix 6000 drive(s) and the SoftLogix PCI card.
Although Figure 1.8 only illustrates the SERCOS fiber-optic ring with
the SoftLogix PCI card, node addressing for SoftLogix is done the
same way as shown in the three ControlLogix examples.
0
3456 72
ABCDE
Figure 1.8
Fiber-Optic Ring Connection
F 1
89
OK
CP
TX
Transmit
Receive
SoftLogix
1784-PM16SE SERCOS
interface PCI Card
RX
SERCOS fiber-optic ring
Receive
Transmit
Kinetix 6000
Receive
Transmit
Kinetix 6000
Figure 1.9
Node Addressing Example 1
1756-MxxSE SERCOS
interface Module
SERCOS interfaceTM
CP
OK
ControlLogix Chassis
Tx (rear)
Rx (front)
Transmit
Receive
SERCOS Fiber-Optic ring
Receive
Receive
Transmit
Transmit
Kinetix 6000
System 2
(2-axis power rail)
Kinetix 6000
System 1
(6-axis power rail)
17 = AM (axis 2) node address
16 = IAM (axis 1) base node address
15 = Slot Filler node address
14 = Shunt Module node address
13 = AM (axis 4) node address
12 = AM (axis 3) node address
11 = AM (axis 2) node address
10 = IAM (axis 1) base node address
In the example above, Kinetix 6000 (6-axis) System 1 power rail
contains one IAM, three AMs, one SM, and one slot filler module.
The shunt module and slot filler slots are assigned a node address,
but they do not use it.
Kinetix 6000 (2-axis) System 2 power rail contains one IAM and
one AM. The base node address of the IAM (system 2) must be set
for an address of ≥16 or ≤8.
Publication 2094-IN002E-EN-P — September 2005
1-12
Commission Your Kinetix 6000
IMPORTANT
Do not position axis modules to the right of
shunt or slot filler modules. The added distance
between non-adjacent axes can increase
electrical noise and impedance, and requires
longer fiber-optic cable lengths.
Figure 1.10
Node Addressing Example 2
1756-MxxSE SERCOS
interface Module 1
1756-MxxSE SERCOS
interface Module 2
SERCOS interfaceTM
CP
SERCOS interfaceTM
OK
CP
OK
ControlLogix Chassis
ControlLogix Chassis
Tx (rear)
Tx (rear)
Rx (front)
Rx (front)
Transmit
Receive
Transmit
Receive
SERCOS Fiber-Optic rings
Transmit
Receive
Transmit
Receive
Kinetix 6000
(8-axis power rail)
08 = Slot Filler node address
07 = AM (axis 7) node address
06 = AM (axis 6) node address
05 = AM (axis 5) node address
04 = AM (axis 4) node address
03 = AM (axis 3) node address
02 = AM (axis 2) node address
01 = IAM (axis 1) base node address
In the example above, SERCOS interface module 1 controls axes
1 to 4 and module 2 controls axes 5 to 7. The slot filler module is
assigned a node address, but does not use it.
Note: You can mount the two SERCOS interface modules in two
separate ControlLogix chassis (as shown above) or you can
mount them in the same chassis.
Utilizing two SERCOS interface modules to control axes
from a single Kinetix 6000 power rail allows you to reduce
the cycle times.
IMPORTANT
Publication 2094-IN002E-EN-P — September 2005
Slot Filler modules must be used to fill any
unoccupied slot on the power rail. However, the
slot fillers may also be removed and replaced by
an axis or shunt module in the future.
Commission Your Kinetix 6000
1-13
Figure 1.11
Node Addressing Example 3
1756-MxxSE SERCOS
interface Module
SERCOS interfaceTM
CP
OK
ControlLogix Chassis
Tx (rear)
Rx (front)
Transmit
Receive
SERCOS Fiber-Optic ring
Transmit
Receive
Kinetix 6000
(8-axis power rail)
08 = Slot Filler node address
07 = AM (axis 4) node address
06 = Not Used (AM right most slot)
05 = AM (axis 3) node address
04 = Not Used (AM right most slot)
03 = AM (axis 2) node address
02 = Not Used (IAM right most slot)
01 = IAM (axis 1) base node address
In the example above, the Kinetix 6000 (8-axis) power rail
contains a double-wide IAM, two double-wide AMs, one
single-wide AM, and one slot filler module. The slot filler module
is assigned a node address, but does not use it.
The left-most slot of a double-wide module determines the node
address. So, in the example above, node addresses 02, 04, and 06
(the right-most slots of the double-wide modules) are not used.
IMPORTANT
Slot Filler modules must be used to fill any
unoccupied slot on the power rail. However, the
slot fillers may also be removed and replaced by
an axis or shunt module in the future.
Publication 2094-IN002E-EN-P — September 2005
1-14
Commission Your Kinetix 6000
3. Set the SERCOS baud rate using DIP switches 2 and 3, as shown in
Figure 1.12. Refer to the table below for baud rate switch settings.
For this baud rate
Set switch 2
Set switch 3
4M baud
OFF
ON
8M baud
ON
OFF
4. Set the SERCOS optical power level to High using DIP switch 1, as
shown in Figure 1.12. Refer to the table below for optical power
level switch setting.
For this optical power level
Set switch 1
Low
OFF
High
ON
Figure 1.12
SERCOS Baud Rate and Optical Power DIP Switches
DIP switches set for
8M baud applications
(high power setting)
3
1
2
3
ON
OFF
2
ON
OFF
1
DIP switches set for
4M baud applications
(high power setting)
Integrated Axis Module, top view
(2094-ACxx-Mxx)
Switch in OFF position
Note: Switch numbers as seen on the IAM
are upside down in this orientation.
SERCOS Baud Rate
and Optical Power Switches
Publication 2094-IN002E-EN-P — September 2005
Switch numbers shown above
are in ON position
Switch
turned around for clarity.
Commission Your Kinetix 6000
1-15
Configure Your Axis Module(s)
This procedure assumes you have configured your IAM. Use the
following procedure to configure your axis module(s). In this
procedure you will set the baud rate and optical power level switches
for your IAM and each AM.
IMPORTANT
The node address for each axis module is
determined by the base node address switch setting
on the IAM. Refer to Figure 1.9.
To configure your Axis Module(s):
1. Verify that there is no power applied to the IAM and that the
SERCOS fiber-optic cables are plugged into the Tx and Rx
connectors. To verify your fiber-optic cable connections, refer to
the Kinetix 6000 Multi-Axis Servo Drive Installation Manual
(publication 2094-IN001).
2. Set the SERCOS baud rate using DIP switches 2 and 3, as shown in
Figure 1.12 (page 1-14). Refer to the table below for the baud rate
switch settings.
For this baud rate
Set switch 2
Set switch 3
4M baud
OFF
ON
8M baud
ON
OFF
3. Set the optical power level to High using DIP switch 1, as shown
in Figure 1.12. Refer to the table below for optical power level
switch setting.
For this optical power level
Set switch 1
Low
OFF
High
ON
Publication 2094-IN002E-EN-P — September 2005
1-16
Commission Your Kinetix 6000
Configure Your Logix
SERCOS interface Module
This procedure assumes that you have wired your Kinetix 6000 system
and have configured the Kinetix 6000 baud rate and optical power
switches.
IMPORTANT
In order for the Kinetix 6000 to communicate with
the SERCOS interface module (indicated by the three
LEDs on the module going solid green), your
RSLogix 5000 software must be version 11.0 or
above.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the
appropriate publication.
For
Refer to this Document
Publication Number
Detailed information on configuring and
troubleshooting your ControlLogix motion module
Logix5000 Motion Modules User
Manual
1756-UM006
Detailed information on configuring and
troubleshooting your SoftLogix PCI card
SoftLogix Motion Card Setup and
Configuration Manual
1784-UM003
If you have already configured your Logix module using one of the
setup and configuration manuals listed above, go directly to Apply
Power to Your Kinetix 6000 (page 1-26). If not, go to Configure Your
Logix Controller beginning below.
Configure Your Logix Controller
To configure your Logix controller:
1. Apply power to your Logix chassis/PC containing the SERCOS
interface module and open your RSLogix 5000 software.
2. Select New in the File menu. The New Controller window opens.
•
Select controller type
•
Select RSLogix 5000 revision
•
Name the file
•
Select the Logix chassis size
•
Select the Logix processor slot
3. Select OK.
4. Select Controller Properties in the edit menu. The Controller
Properties window opens.
Publication 2094-IN002E-EN-P — September 2005
Commission Your Kinetix 6000
1-17
5. Select the Date and Time tab.
6. Check the box Make this controller the Coordinated System
Time master.
IMPORTANT
Only one ControlLogix processor can be
assigned as the Coordinated System Time master.
7. Select OK.
Configure Your Logix Module
To configure your Logix module:
1. Right-click on I/O Configuration in the explorer window and
select New Module. The Select Module window opens.
2. Expand the Motion category and select 1756-MxxSE,
-L60M03SE, or 1784-PM16SE as appropriate for your actual
hardware configuration.
Publication 2094-IN002E-EN-P — September 2005
1-18
Commission Your Kinetix 6000
3. Select OK. The New Module window opens. Your new module
appears under the I/O Configuration folder in the explorer
window.
•
Name the module
•
Select the slot where your module resides (left most slot = 0)
•
Select an Electronic Keying option (select Disable Keying if
unsure)
•
Check the box Open Module Properties.
4. Select OK. The Module Properties window opens.
5. Select the SERCOS Interface tab and reference the table below.
Logix SERCOS Module Number of Axes
Publication 2094-IN002E-EN-P — September 2005
1756-M03SE or
1756-L60M03SE
up to 3
1756-M08SE
up to 8
1756-M16SE or
1784-PM16SE
up to 16
Data Rate
4 or 8 Mbits/s
Commission Your Kinetix 6000
1-19
6. Select Data Rate, Cycle Time and Optical Power settings.
•
Ensure the Data Rate setting matches DIP switches 2 and 3
(baud rate) as set on the IAM and AM(s), or use the Auto
Detect setting.
•
Set the Cycle Time according to the table below.
Data Rate
4 Mbits/s
Number of Axes
Cycle Time
up to 2
0.5 ms
up to 4
1 ms
up to 8
2 ms
No support for axes 9 to 16
8 Mbits/s
up to 4
0.5 ms
up to 8
1 ms
up to 16
2 ms
Note: The number of axes/module is limited to the number of
axes as shown in step 5.
•
Ensure the Optical Power setting (high or low) matches DIP
switch 1 as set on the IAM and AM(s).
•
Transition to Phase default setting is 4 (phase 4). The
Transition to Phase setting will stop the ring in the phase
specified.
7. Select OK.
8. Repeat steps 1-7 for each Logix module.
Configure Your Kinetix 6000 Modules
To configure your Kinetix 6000 modules:
1. Right-click on the new Logix module you just created and select
New Module. The Select Module window opens.
2. Select your 2094-xCxx-Mxx (IAM) or 2094-xMxx (AM) as
appropriate for your actual hardware configuration.
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Commission Your Kinetix 6000
3. Select OK. The Module Properties window opens.
•
Name the module
•
Set the Node address
Note: Set node address in the software to match the node
setting on the drive. Refer to Configure Your Integrated
Axis Module, step 2, on page 1-10.
•
Select an Electronic Keying option
•
Check the box Open Module Properties
4. Select OK.
5. Select the Associated Axes tab.
6. Select the New Axis button. The New Tag window opens.
•
Name the axis
•
Select AXIS_SERVO_DRIVE as the Data Type
7. Select OK. The axis appears under the Ungrouped Axes folder in
the explorer window.
8. Assign your axis to the node address (as shown in the window
below).
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Commission Your Kinetix 6000
1-21
With drive firmware version 1.80 (or above) and RSLogix 5000
software version 13 (or above), it is possible to configure the
auxiliary axis feedback port as a Feedback Only axis. With this
feature, each IAM (inverter) or AM can be configured to appear as
two axes/nodes on the SERCOS ring. The base node is the servo
axis utilizing the motor feedback, and the base node (plus 128) is
a feedback only axis utilizing the auxiliary feedback port (as
shown below).
If an axis is associated to the auxiliary axis node, then the Axis
Configuration on the General tab of the Axis Properties page is set
to Feedback Only (as shown below).
9. Select OK.
10. Select the Power tab.
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Commission Your Kinetix 6000
11. Select the Bus Regulator Catalog Number or other as appropriate
for your actual hardware configuration.
If your IAM is
Configured as an IAM or
Leader IAM (common bus) 1
Configured as a Follower IAM 2
And your hardware configuration
includes this shunt option
Then select
Internal shunts only
Internal or <none>
Bulletin 2094 (rail mounted) shunt module
2094-BSP2
Bulletin 1394 passive shunt module
(connected to the 2094-BSP2)
1394-SRxxxx
Bulletin 1336 active shunt module
Internal or <none>
N/A. Shunts are disabled on Follower IAM
CommonBus Follow
1
Drive will not accept Internal, <none>, 2094-BSP2, or 1394-SRxxxx selection if DC Bus voltage is present without
having three-phase power applied.
2
Drive will not accept CommonBus Follow selection if three-phase power is applied.
ATTENTION
IMPORTANT
IMPORTANT
To avoid damage to your Bulletin 1394 external
shunt module, verify that the proper 230V or
460V fuse is installed prior to applying power.
Refer to the Kinetix 6000 Multi-Axis Servo Drive
Installation Instructions (publication 2094-IN001)
for fuse specifications.
When configured to use the Bulletin 1394 or
2094 shunt modules, the IAM bus regulator
capacity attribute displays the shunt module or
passive shunt module utilization instead of the
IAM internal shunt resistor utilization.
DC Common Bus applications must calculate
Total Bus Capacitance and Additional Bus
Capacitance and set the Add Bus Cap parameter
(x:x:x599) using DriveExplorer software. Refer to
Appendix D for the procedures.
12. Select OK.
13. Repeat steps 1-9 for each 2094-xMxx Axis Module (AM).
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Commission Your Kinetix 6000
1-23
Configure the Motion Group
To configure the motion group:
1. Right-click Motion Groups in the explorer window and select New
Motion Group. The New Tag window opens.
2. Name the new motion group.
3. Select OK. New group appears under the Motion Groups folder.
4. Right-click on the new motion group and select Properties. The
Motion Group Properties window opens.
5. Select the Axis Assignment tab and move your axes (created
earlier) from Unassigned to Assigned.
6. Select the Attribute tab and edit the default values as appropriate
for your application.
7. Select OK.
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Commission Your Kinetix 6000
Configure Axis Properties
To configure axis properties:
1. Right-click on an axis in the explorer window and select
Properties. The Axis Properties window opens.
2. Select the Drive/Motor tab.
•
Set the Kinetix 6000 Amplifier (2094-xCxx-Mxx)
•
Set the Motor Catalog Number
•
Set Loop Configuration to Position Servo
•
Drive Enable Input Checking, when checked (default), means
a hard drive enable input signal is required. Uncheck to
remove that requirement.
Note: For amplifier and motor catalog numbers refer to the
amplifier and motor name plate.
3. Select the Motor Feedback tab and verify the Feedback Type
shown is appropriate for your actual hardware configuration.
4. Select the Units tab and edit default values as appropriate for your
application.
5. Select the Conversion tab and edit default values as appropriate
for your application.
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1-25
6. Select the Fault Actions tab and click on the Set Custom Stop
Action... tab. The Custom Stop Action Attributes window opens.
The Custom Stop Action Attributes window allows you to set
delay times for servo motors and resistive brake modules. For
recommended motor brake delay times, refer to the Kinetix
Motion Control Selection Guide (publication GMC-SG001).
•
Set the Brake Engage Delay Time
•
Set the Brake Release Delay Time
•
Set the Resistive Brake Contact Delay time (0 - 1000 ms range)
Note: The recommended delay time for 2090-XB33-xx and
-XB120-xx resistive brake modules is 71 ms.
Note: If you are using RSLogix 5000 v12 or lower, refer to Set the
RBM Delay Time Using DriveExplorer on page C-14.
•
Select Close
7. Select OK.
8. Repeat steps 1-7 for each axis module.
9. Verify your Logix program and save the file.
Download Your Program
After completing the Logix configuration you must download your
program to the Logix processor.
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Commission Your Kinetix 6000
Apply Power to Your
Kinetix 6000
Use the table below to determine where to begin applying power to
your Kinetix 6000.
If your Kinetix 6000 system
Then
Includes a (2094-xLxx or -xLxxS-xx) LIM
Go to Apply Power to Your Kinetix 6000 (with
LIM)
Does not include a (2094-xLxx or -xLxxS-xx) LIM
Go to Apply Power to Your Kinetix 6000 (without
LIM)
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.
Apply Power to Your Kinetix 6000 (with LIM)
This procedure assumes that you have wired and configured your
Kinetix 6000 (including the LIM) and your SERCOS interface module.
IMPORTANT
Follow this procedure if your Kinetix 6000 system
includes a Line Interface Module (LIM).
To apply power to your Kinetix 6000 system:
1. Ensure CB1, CB2, and CB3 on the LIM are in the OFF position
(refer to figures 1.4 and 1.5 for the location of the CB1, CB2, and
CB3).
2. Disconnect the load to the motor(s).
ATTENTION
To avoid personal injury or damage to
equipment, disconnect the load to the motor(s).
Ensure each motor is free of all linkages when
initially applying power to the system.
3. Apply three-phase input power to the LIM VAC Line connector.
4. Set CB3 on the LIM to the ON position.
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5. Observe the Brake Power Status LED on the LIM (2094-xLxx only).
Refer to Figure 1.4 for the location of the Brake Power Status LED.
If the Brake Power Status
LED is
Status
Do This
Solid green
Brake power is ready
Go to step 6.
Not solid green
Brake power fault
Go to Troubleshoot LIM Status LEDs
on page 2-12.
6. Observe the I/O Power Status LED on the LIM. Refer to Figure 1.4
(2094-xLxx) or Figure 1.5 (2094-xLxxS-xx) for the location of the
I/O Power Status LED.
If the I/O Power Status
LED is
Status
Do This
Solid green
I/O power is ready
Go to step 7.
Not solid green
I/O power fault
Go to Troubleshoot LIM Status LEDs
on page 2-12.
7. Set CB2 on the LIM to the ON position.
8. Set CB1 on the LIM to the ON position.
9. Verify the Hardware Enable Input signal (IOD pin 2) for each axis
is at 0 volts.
If the Hardware Enable
Input signal is
Then
0 volts
Go to step 10.
24 volts
1. Remove connection
between IOD-1 and IOD-2.
2. Go to step 10.
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Commission Your Kinetix 6000
10. Observe the IAM/AM front panel logic power LED as shown in the
figure below.
Figure 1.13
Logic Power and Status LED Display
Seven Segment Fault Status LED
Logic Power LED
If the Logic Power LED Then
is
ON
Go to step 11.
Not ON
1. Check your control power
connections.
2. Repeat step 10.
11. Observe the IAM/AM front panel seven segment status LED
display as shown in Figure 1.13.
Note: The seven segment LED will first flash the SERCOS node
address, then cycle through phases until final configuration
(phase 4) is reached.
If
Is
Status
Do This
Actively cycling
(phase 0)
The drive is looking for a closed SERCOS
ring. Wait for phase 1 or take corrective
action until you reach phase 1.
Check fiber-optic
connections.
Displaying a fixed 1 The drive is looking for active nodes.
Wait for phase 2 or take corrective action
(phase 1)
until you reach phase 2.
Check node
addressing.
Check program
The
drive
is
configuring
nodes
for
motor and drive
The seven segment Displaying a fixed 2
communication. Wait for phase 3 or take configuration
status LED on your (phase 2)
corrective action until you reach phase 3. against installed
2094-xCxx-Mxx IAM
hardware.
or
2094-xMxx AM
Check motor
Displaying a fixed 3 The drive is configuring device specific
parameters. Wait for phase 4 or take
catalog number
(phase 3)
corrective action until you reach phase 4. against selection.1
Displaying a fixed 4
The drive is configured and active.
(phase 4)
Go to step 12.
Flashing an E
followed by two
numbers
Go to Error Codes
on page 2-3.
1
Publication 2094-IN002E-EN-P — September 2005
Drive is faulted.
You can get diagnostic information from the module by highlighting the module name in RSLogix 5000. A Pseudo
Key Failure often indicates that the motor selection does not match the motor installed.
Commission Your Kinetix 6000
1-29
12. Observe the Drive Status LED.
If the Drive Status LED is
Status
Do This
Off
Normal condition
Go to step 13.
Steady red
Drive is faulted
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
13. Observe the Comm Status LED.
If the Comm Status LED is
Status
Do This
Flashing green
Establishing communication
Wait for steady green.
with network
Steady green
Communication is ready
Go to step 14.
Off
No ring present
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
14. Observe the Bus Status LED.
If the Bus Status LED is
Status
Do This
1. Verify Hardware Enable Input
(IOD-2) is open.
Axis is enabled when status
should be disabled
Steady green
2. Verify MSO instruction is not
commanded in RSLogix 5000.
3. Return to Apply Power to Your
Kinetix 6000 (with LIM) on
page 1-26.
Flashing green 1
Bus is up, axis is disabled
(normal status)
Go to step 15.
Off
DC bus is not present
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
1
The Follower IAM has a 2.5 second delay after DC Bus voltage is applied before the Bus Status LED begins
flashing. This provides the common bus leader time to complete pre-charge.
15. Observe the three SERCOS LEDs on the SERCOS module.
If the three SERCOS LEDs are
Status
Do This
Flashing green and red
Establishing communication
Wait for steady green on all three
LEDs.
Steady green
Communication ready
Go to Test and Tune Your Axes.
SERCOS module is faulted
Go to the appropriate Logix
motion module setup and
configuration manual for specific
instructions and troubleshooting.
Not flashing green and red/
not steady green
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Commission Your Kinetix 6000
Apply Power to Your Kinetix 6000 (without LIM)
This procedure assumes that you have wired and configured your
Kinetix 6000 and SERCOS interface module.
IMPORTANT
Follow this procedure if your Kinetix 6000 system
does not include a Line Interface Module (LIM).
To apply power to your Kinetix 6000 system:
1. Disconnect the load to the motor(s).
ATTENTION
To avoid personal injury or damage to
equipment, disconnect the load to the motor(s).
Ensure each motor is free of all linkages when
initially applying power to the system.
2. Apply (95-264V ac) control power to the IAM (CPD connector)
and observe the logic power LED as shown in the figure below.
Figure 1.14
Logic Power and Status LED Display
Seven Segment Fault Status LED
Logic Power LED
If the Logic Power LED Then
is
ON
Go to main step 3.
Not ON
1. Check your control power
connections.
2. Repeat main step 2.
Note: The seven segment LED will first flash the SERCOS node
address, then cycle through phases until final configuration
(phase 4) is reached.
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1-31
3. Apply 195-265V ac (230V) or 324-528V ac (460V) input power to
the IAM (IPD connector) and observe the front panel seven
segment Status LED display as shown in Figure 1.14.
If
Is
Status
Do This
Actively cycling
(phase 0)
The drive is looking for a closed SERCOS
ring. Wait for phase 1 or take corrective
action until you reach phase 1.
Check fiber-optic
connections.
The drive is looking for active nodes.
Displaying a fixed 1
Wait for phase 2 or take corrective action
(phase 1)
until you reach phase 2.
Check node
addressing.
Check program
The
drive
is
configuring
nodes
for
motor and drive
The seven segment Displaying a fixed 2
communication.
Wait
for
phase
3
or
take
configuration
status LED on your (phase 2)
corrective action until you reach phase 3. against installed
2094-xCxx-Mxx IAM
hardware.
or
2094-xMxx AM
Check motor
The drive is configuring device specific
Displaying a fixed 3
parameters. Wait for phase 4 or take
catalog number
(phase 3)
corrective action until you reach phase 4. against selection.1
Displaying a fixed 4
The drive is configured and active
(phase 4)
Go to step 4.
Flashing an E
followed by two
numbers
Go to Error Codes
on page 2-3.
1
Drive is faulted
You can get diagnostic information from the module by highlighting the module name in RSLogix 5000. A Pseudo
Key Failure often indicates that the motor selection does not match the motor installed.
4. Observe the Drive Status LED.
If the Drive Status LED is
Status
Do This
Off
Normal condition
Go to step 5.
Steady red
Drive is faulted
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
5. Observe the Comm Status LED.
If the Comm Status LED is
Status
Do This
Flashing green
Establishing communication
Wait for steady green.
with network
Steady green
Communication is ready
Go to step 6.
Off
No ring present
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
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Commission Your Kinetix 6000
6. Observe the Bus Status LED.
If the Bus Status LED is
Status
Do This
1. Verify Hardware Enable Input
(IOD-2) is open.
DC bus is present. Axis is
enabled when status should
be disabled.
Steady green
2. Verify MSO instruction is not
commanded in RSLogix 5000.
3. Return to Apply Power to Your
Kinetix 6000 (without LIM) on
page 1-30.
Flashing green 1
Bus is up, axis is disabled
(normal status)
Go to step 7.
Off
DC bus is not present
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
1
The Follower IAM has a 2.5 second delay after DC Bus voltage is applied before the Bus Status LED begins
flashing. This provides the common bus leader time to complete pre-charge.
7. Observe the three SERCOS LEDs on the SERCOS module.
If the three SERCOS LEDs are
Status
Do This
Flashing green and red
Establishing communication
Wait for steady green on all three
LEDs.
Steady green
Communication ready
Go to Test and Tune Your Axes.
SERCOS module is faulted
Go to the appropriate Logix
motion module setup and
configuration manual for specific
instructions and troubleshooting.
Not flashing green and red/
not steady green
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Commission Your Kinetix 6000
Test and Tune Your Axes
1-33
This procedure assumes that you have configured your Kinetix 6000,
your SERCOS interface module, and applied power to the system.
Before proceeding with testing and tuning your axes,
verify that the IAM and AM status LEDs are as
described in the table below.
IMPORTANT
Status LED
Must be
Status
Drive
Off
Normal condition
Comm
Steady green
Communication is ready
Bus
Flashing green
Bus is up, axis is disabled (normal status)
Seven Segment
Displaying a fixed 4 (phase 4)
The drive is configured and active.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the
appropriate publication.
For
Refer to this Document
Publication Number
Detailed information on configuring and
troubleshooting your ControlLogix motion module
Logix5000 Motion Modules User
Manual
1756-UM006
Detailed information on configuring and
troubleshooting your SoftLogix PCI card
SoftLogix Motion Card Setup and
Configuration Manual
1784-UM003
If you have already tested and tuned your Logix module using one of
the setup and configuration manuals listed above, you are finished
commissioning your Kinetix 6000 system. If not, go to Test Your Axes
beginning below.
Test Your Axes
To test your axes:
1. Verify the load was removed from each axis.
2. Right-click on an axis in your Motion Group folder in the explorer
window and select Axis Properties. The Axis Properties window
appears.
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Commission Your Kinetix 6000
3. Select the Hookup tab.
4. Select 2.0 as the number of revolutions for the test (or another
number more appropriate for your application).
This Test
Performs this Test
Test Marker
Verifies marker detection capability
as you rotate the motor shaft.
Test Feedback
Verifies feedback connections are
wired correctly as you rotate the
motor shaft.
Test Command &
Feedback
Verifies motor power and feedback
connections are wired correctly as
you command the motor to rotate.
Also, allows you to define polarity.
5. Apply Hardware Enable Input signal (IOD-2) for the axis you are
testing.
ATTENTION
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To avoid personal injury or damage to
equipment, apply 24V ENABLE signal (IOD-2)
only to the axis you are testing.
Commission Your Kinetix 6000
1-35
6. Select the Test (Marker/Feedback/Command & Feedback) button
to verify connections. The Online Command window opens.
Follow the on-screen test instructions. When the test completes,
the Command Status changes from Executing to Command
Complete.
7. Select OK.
8. The Online Command - Apply Test window opens (Feedback and
Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.
9. Select OK.
If
Then
Your test completes successfully, this window 1. Select OK.
appears:
2. Remove Hardware Enable Input
signal (IOD-2).
3. Go to Tune Your Axes.
1. Select OK.
Your test failed, this widow appears:
2. Verify the Bus Status LED turned
solid green during the test.
3. Verify that the Hardware Enable
Input signal (IOD-2) is applied to
the axis you are testing.
4. Verify conversion constant entered
in the Conversion tab.
5. Return to step 6 and run the test
again.
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Commission Your Kinetix 6000
Tune Your Axes
To tune your axes:
1. Verify the load is still removed from the axis being tuned.
ATTENTION
To reduce the possibility of unpredictable motor
response, tune your motor with the load
removed first, then re-attach the load and
perform the tuning procedure again to provide
an accurate operational response.
2. Select the Tune tab.
3. Enter values for Travel Limit and Speed. In this example, Travel
Limit = 5 and Speed = 10.
Note: Actual value of programmed units depend on your
application.
4. Select setting for Direction (Forward Uni-directional is default).
5. Check Tune boxes as appropriate for your application.
6. Apply Hardware Enable Input signal (IOD-2) for the axis you are
tuning.
ATTENTION
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To avoid personal injury or damage to
equipment, apply 24V ENABLE signal (IOD-2)
only to the axis you are tuning.
Commission Your Kinetix 6000
1-37
7. Select the Start Tuning button to auto-tune your axis. The Online
Command - Tune Servo window opens. When the test completes,
the Command Status changes from Executing to Command
Complete.
8. Select OK. The Tune Bandwidth window opens.
Note: Actual bandwidth values (Hz) depend on your application
and may require adjustment once motor and load are
connected.
Record your bandwidth data for future reference.
9. Select OK.
10. The Online Command - Apply Tune window opens. When the test
completes, the Command Status changes from Executing to
Command Complete.
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Commission Your Kinetix 6000
11. Select OK.
If
Then
Your test completes successfully, this window
appears:
1. Select OK.
2. Remove the Hardware Enable
Input signal (IOD-2) applied
earlier.
3. Go to step 12.
Your test failed, this widow appears:
1. Select OK.
2. Make an adjustment to motor
velocity.
3. Refer to appropriate Logix motion
module setup and configuration
manual for more information.
4. Return to step 7 and run the test
again.
12. Repeat Test and Tune Your Axes for each axis.
Publication 2094-IN002E-EN-P — September 2005
Chapter
2
Troubleshoot Your Kinetix 6000
Chapter Objectives
1
This chapter provides a description of maintenance and
troubleshooting activities for the Kinetix 6000. This chapter includes:
•
Safety Precautions
•
General Troubleshooting
•
Troubleshoot IAM/AM Status LEDs
•
Troubleshoot SM Status LEDs
•
Troubleshoot LIM Status LEDs
•
Troubleshoot RBM Status LEDs
•
Troubleshoot General System Problems
•
Understand Logix/Drive Fault Behavior
•
Supplemental Troubleshooting Information
•
Replace Kinetix 6000 System Components
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2-2
Troubleshoot Your Kinetix 6000
Safety Precautions
Observe the following safety precautions when troubleshooting your
Kinetix 6000 drive.
ATTENTION
DC bus capacitors may retain hazardous voltages
after input power has been removed, but will
normally discharge in several seconds. Before
working on the drive, measure the DC bus voltage to
verify it has reached a safe level or wait the full time
interval listed on the warning on the front of the
drive. Failure to observe this precaution could result
in severe bodily injury or loss of life.
Do not attempt to defeat or override the drive fault
circuits. You must determine the cause of a fault and
correct it before you attempt to operate the system. If
you do not correct a drive or system malfunction, it
could result in personal injury and/or damage to
equipment as a result of uncontrolled machine
system operation.
If you use an oscilloscope (or chart recorder) for
troubleshooting, you must properly ground it. The
oscilloscope chassis can be at a potentially fatal
voltage if you do not properly ground it. Always
connect the oscilloscope chassis to an earth ground.
General Troubleshooting
Refer to the Error Codes section to identify problems, potential causes,
and appropriate actions to resolve the problems. If problems persist
after attempting to troubleshoot the system, please contact your
Allen-Bradley representative for further assistance. To determine if
your Kinetix 6000 drive has an error, refer to the table below.
If the Logic Power LED is ON and the
Status LED display on your
2094-xCxx-Mxx-x IAM
All drives
Publication 2094-IN002E-EN-P — September 2005
Is
Then
Actively cycling segments in a full circle
Your Kinetix 6000 drive is ready, but SERCOS
communications is not available.
Displaying a fixed 4
Your Kinetix 6000 drive is ready.
Flashing an E followed by two numbers
Your Kinetix 6000 drive has an error. Proceed
to the section Error Codes.
Troubleshoot Your Kinetix 6000
2-3
Error Codes
The following list of problematic symptoms (no error code shown)
and problems with assigned error codes is designed to help you
resolve problems.
When a fault is detected, the 7-segment LED will display an E
followed by the flashing of the two-digit error code, one digit at a
time. This is repeated until the problem is cleared.
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom is
Power (PWR) indicator not
ON
Motor jumps when first
enabled
E00
E04
BusUndervoltage
Fault
(Blown fuse)
MotorOvertemp
Fault
(Motor Overtemp)
Potential Cause is
Possible Resolution is
No AC power or auxiliary logic power.
Verify AC control power is applied to the
Kinetix 6000.
Internal power supply malfunction.
Call your Allen-Bradley representative to
return module for repair.
• Check motor wiring.
Motor wiring error.
• Run Hookup test in RSLogix 5000.
Incorrect motor chosen.
Verify the proper motor is selected.
Digital I/O not working
correctly
I/O power supply disconnected.
Verify connections and I/O power source.
A blown fuse was detected
on the inverter PCB
Blown fuse.
Call your Allen-Bradley representative to
return module for repair.
• High motor ambient temperature
and/or
• Operate within (not above) the
continuous torque rating for the
ambient temperature
40 °C (104 °F) maximum.
Motor thermal switch
tripped
• Excessive current
• Lower ambient temperature, increase
motor cooling.
Motor wiring error.
Check motor wiring at MF connector on the
IAM/AM.
Incorrect motor selection.
Verify the proper motor has been selected.
Motor cables shorted.
Verify continuity of motor power cable and
connector.
Motor winding shorted internally.
Disconnect motor power cables from the
motor. If the motor is difficult to turn by
hand, it may need to be replaced.
• Check for clogged vents or defective
fan.
Kinetix 6000 temperature too high.
E05
DriveOvercurrent
Fault
(Power Fault)
Self-protection of the
Intelligent Power Module
(IPM) is indicating a major
power related fault
condition.
• Ensure cooling is not restricted by
insufficient space around the unit.
• Verify ambient temperature is not too
high.
Operation above continuous power rating
and/or product environmental ratings.
• Operate within the continuous power
rating.
• Reduce acceleration rates.
Kinetix 6000 has a short circuit,
overcurrent, or failed component.
Remove all power and motor connections,
and preform a continuity check from the DC
bus to the U, V, and W motor outputs. If a
continuity exists, check for wire fibers
between terminals, or send drive in for
repair.
Publication 2094-IN002E-EN-P — September 2005
2-4
Error
Code
E06
E07
Troubleshoot Your Kinetix 6000
Fault Message
RSLogix (HIM)
Problem or Symptom is
HardOvertravel
Fault
(+/- Hard Overtravel)
Axis moved beyond the
physical travel limits in the Dedicated overtravel input is inactive.
positive/negative direction.
MotFeedbackFault
(Motor Feedback Loss)
The feedback wiring is open, shorted, or missing.
Potential Cause is
Possible Resolution is
• Check wiring.
• Verify motion profile.
• Verify axis configuration in software.
• Check motor encoder wiring.
• Run Hookup test in RSLogix 5000.
• Verify voltage level of the incoming AC
power.
E09
BusUndervoltage
Fault
(Bus Undervoltage)
With three-phase power
present, the DC bus
voltage is below limits.
DC bus voltage fell below
the undervoltage limit
while an axis on the
follower power rail was
enabled.
• DC bus voltage for 460V system is
below 275V
• DC bus voltage for 230V system is
below 137V
DriveOvervoltage
Fault
(Bus Overvoltage)
The DC bus voltage is
above limits.
• Install an uninterruptible power supply
(UPS) on your AC input.
Disable follower axis before removing
power.
Excessive regeneration of power.
E10
• Check AC power source for glitches or
line drop.
When the motor is driven by an external
mechanical power source, it may
regenerate too much peak energy
through the Kinetix 6000’s power supply.
The system faults to save itself from an
overload.
• DC bus voltage for 460V system is
over 820V
• DC bus voltage for 230V system is
over 410V
• Change the deceleration or motion
profile.
• Use a larger system (motor and Kinetix
6000).
• Install shunt module.
Verify input is within specifications.
• Verify the Hall wiring at the MF
connector on the IAM/AM.
MotFeedbackFault
(Illegal Hall State)
State of Hall feedback
inputs is incorrect.
E16
Softovertravel
Fault
(+/- Software
Overtravel)
Axis position exceeded maximum software setting.
• Verify overtravel settings are
appropriate.
E18
OverSpeedFault
(Overspeed Fault)
Motor speed has exceeded 150% of maximum rated speed. The 100%
trip point is dictated by the lesser of the user velocity limits or the
motor rated base speed.
• Check cables for noise.
E11
Bad connections.
• Verify 5V power supply to the encoder.
• Verify motion profile.
• Check tuning.
• Increase the feed forward gain.
• Increase following error limit or time.
E19
PositionErrorFault
(Follow Error)
Position error limit was exceeded.
• Check position loop tuning.
• Verify sizing of system.
• Verify mechanical integrity of system
within specification limits.
• Use shielded cables with twisted pair
wires.
E20
MotFeedbackFault
(Mtr Fdbk AQB)
Motor Encoder State Error
The motor encoder encountered an
illegal transition.
• Route the feedback away from
potential noise sources.
• Check the system grounds.
• Replace the motor/encoder.
E21
AuxFeedbackFault
(Aux Feedback Comm)
Communication was not established with an intelligent encoder.
Publication 2094-IN002E-EN-P — September 2005
Verify auxiliary encoder wiring.
Troubleshoot Your Kinetix 6000
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom is
Potential Cause is
2-5
Possible Resolution is
• Verify motor selection.
E30
MotFeedbackFault
(Motor Feedback Comm)
• Verify the motor supports automatic
identification.
Communication was not established with an intelligent encoder.
• Verify motor encoder wiring.
• Check motor power wiring.
E34
GroundShortFault
(Ground Fault)
Excessive ground current in
the converter was
detected.
Wiring error.
• Check input power wiring (refer to
Kinetix 6000 Installation Manual,
publication 2094-IN001).
Motor internal ground short.
Replace motor.
Internal malfunction.
Disconnect motor power cable from drive
and enable drive with current limit set to 0.
If fault clears, then a wiring error or motor
internal problem exists. If fault remains,
call your A-B representative.
• Remove ground from control power
input.
• Wire control power to use main power
as shown in Figure A.3.
Grounded control power terminal
(applies to 230V systems only)
• Add isolation transformer for control
power.
E35
DriveUndervoltage
Fault
(Pre-charge Fault)
Converter pre-charge cycle
failed.
Low AC input voltage.
Check input AC voltage on all phases.
Internal malfunction.
Call your A-B representative.
• Reduce acceleration rates.
• Reduce duty cycle (ON/OFF) of
commanded motion.
E36
DriveOvertemp
Fault
(System
Overtemperature)
Converter thermal switch
tripped.
• Increase time permitted for motion.
Excessive heat exists in the power
circuitry.
• Use larger Kinetix 6000 converter.
• Check for clogged vents or defective
fan.
• Ensure cooling is not restricted by
insufficient space around the unit.
E37
PowerPhaseLoss
Fault
(Phase Loss Flt)
E38
SERCOSFault
(SERCOS Ring Flt)
• One or more phases of the input AC power is missing.
• Check input AC voltage on all phases.
• Axis was enabled when main (3-phase) power was removed.
• Common bus follower axis was enabled when DC bus power was
removed.
• Disable axis before removing power.
The SERCOS ring is not
active after being active
and operational.
Check that fiber-optic cable is present and
connected properly.
Cable disconnected.
• Verify that there are no impediments to
motion at startup, such as hard limits.
E39
DriveHardFault
(Self Sense Flt)
Self-sensing Commutation
Startup Error
Motion required for self-sensing startup
commutation was obstructed.
• Increase self-sensing current if high
friction or load conditions exist.
• Check motor or encoder wiring using
wiring diagnostics.
E43
DriveEnableInput
Fault
(Drive Enable Flt)
Missing Drive Enable Input
Signal
• An attempt was made to enable the
axis through software while the Drive
Enable hardware input was inactive.
• The Drive Enable input transitioned
from active to inactive while the axis
was enabled.
• Disable the Drive Enable Input fault.
• Verify that Drive Enable hardware input
is active whenever the drive is enabled
through software.
Publication 2094-IN002E-EN-P — September 2005
2-6
Troubleshoot Your Kinetix 6000
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom is
E49
DriveHardFault
(Safe-Off HW Flt)
For symptom, cause, and resolution of this error code, refer to the Kinetix Safe-Off Feature Safety Reference Manual
(publication GMC-RM002). Applies to IAM (2094-xCxx-Mxx-S) and AM (2094-xMxx-S) with Safe-Off feature.
E50
SERCOSFault
(SERCOS Same ADDR)
Duplicate node address detected on SERCOS ring.
Verify that each SERCOS drive is assigned
a unique node address.
E54
DriveHardFault
(Ifbk HW Fault)
Current feedback hardware fault detected.
Replace the module
E60
DriveHardFault
(Unknown Axis)
Illegal ID bits detected
Replace the module
Potential Cause is
Possible Resolution is
• Use shielded cables with twisted pair
wires.
E61
AuxFeedbackFault
(Aux Fdbk AQB)
Auxiliary Encoder State
Error
The auxiliary encoder encountered an
illegal transition.
• Route the feedback away from
potential noise sources.
• Check the system grounds.
• Replace the motor/encoder.
Check the motor feedback cable
connectors/wiring to the IAM/AM and
motor.
E62
AuxFeedbackFault
(Aux Fdbk Loss)
The feedback wiring is open, shorted, or missing.
E63
AuxFeedbackNoise
(Aux Fdbk Noise)
Noise on auxiliary
feedback cable.
E64
MotorFeedbackNoise
(Mtr Fdbk Noise)
Noise on motor feedback
cable.
E65
No Fault Message
(condition indicated
by on-screen
message)
(Hookup Fault)
Hookup procedure failed
E66
No Fault Message
(condition indicated
by on-screen
message)
(Atune Flt)
Autotune procedure failed
E67
DriveHardFault
(Task init)
Operating system failed
Software initialization fault detected due
to hardware failure.
E68
DriveHardFault
(SCANport Comm)
DPI communication failed
The DPI device or cable is faulty.
E69
DriveHardFault
(Objects Init)
Non-volatile memory is corrupt due to control board hardware failure.
Load default parameters, save to
non-volatile memory, and recycle power or
reset the drive.
E70
DriveHardFault
(NV Mem Init)
Non-volatile memory is corrupt due to control board software error.
Load default parameters, save to
non-volatile memory, and recycle power or
reset the drive.
E71
DriveHardFault
(Memory Init)
RAM or Flash memory validation failure
• Verify grounding.
Recommended grounding, per
installation instructions, has not been
followed.
• Route feedback cable away from noise
sources.
• Refer to System Design for Control of
Electrical Noise Reference Manual
(publication GMC-RM001).
• Check motor power/feedback wiring.
Motor or feedback device malfunction.
• Refer to on-screen message for
resolution.
• Check motor power/feedback wiring.
Motor or feedback device malfunction.
• Refer to on-screen message for
resolution.
• Perform Hookup in RSLogix 5000.
• Consult RSLogix 5000 help screen.
Publication 2094-IN002E-EN-P — September 2005
• Cycle power.
• If fault persists, replace module.
Check DPI connections.
• Cycle power.
• If fault persists, replace module.
Troubleshoot Your Kinetix 6000
Error
Code
E72
E73
Fault Message
RSLogix (HIM)
DriveOvertemp
Fault
(Drive Overtemp)
Communicate
(Backplane Comm)
Problem or Symptom is
Inverter thermal switch
tripped
Potential Cause is
Possible Resolution is
The fan on the IAM or an AM failed.
Replace the failed module.
The cabinet ambient temperature is
above rating.
Check the cabinet temperature.
The machine duty cycle requires an RMS
current exceeding the continuous rating
of the controller.
Change the command profile to reduce
speed or increase time.
The airflow access to the Kinetix 6000 is
limited or blocked.
Check airflow and re-route cables away
from the Kinetix 6000.
Power rail CAN communications failed.
Check module for proper mount.
Power rail connection shorted or open.
Check power rail and module for foreign
objects.
2-7
• Check for proper motor sizing.
E74
DriveOvercurrent
Fault
(Bus OverCurrent)
• Check/replace transmission device.
Motor or transmission malfunction.
DC link current exceeds
rating.
• Check/replace motor.
• Check for proper IAM sizing.
IAM not properly sized.
• Install larger kW rated IAM.
• Use a properly sized shunt or modify
duty cycle of the application.
E75
DriveOvervoltage
Fault
(Shunt Time Out)
E76
DriveHardFault
(Can Init)
DPI hardware initialization
fault detected.
E77
DriveHardFault
(Module Mismatch)
Either 230V AM is installed on power rail with 460V IAM, or 460V AM
is installed on power rail with 230V IAM.
E78
DriveHardFault
(SERCOS Init)
Control hardware fault detected.
E79
DriveOvervoltage
Fault
(Shunt Module Flt)
The IAM, AM, or SM has exceeded its shunt resistor continuous rating. • System uses internal shunt and
requires external shunt for additional
capacity.
• Reset System.
• If fault persists, replace system
module.
Control board hardware failure.
Replace mismatched module.
• Cycle power.
• If fault persists, replace module.
SM Temperature Fault LED
status is Steady Red
Refer to Temperature Fault LED on page 2-11.
SM Shunt Fault LED status
is Steady Red
Refer to Shunt Fault LED on page 2-11.
Module missing from power rail.
• Install missing module on power rail.
• Fill empty slot with slot filler module.
E80
DriveHardFault
(CPLD FLT)
Control hardware fault detected.
Replace module.
E81
DriveHardFault
(Common Bus FLT)
Follower IAM detected AC input power being applied.
Remove AC input power connections from
Follower IAM.
E90
DriveHardFault
(Pre-charge Timeout FLT)
Pre-charge resistor power exceeds the resistor rating.
Allow resistor to cool.
All
others RESERVED
Call your local Allen-Bradley
representative.
Publication 2094-IN002E-EN-P — September 2005
2-8
Troubleshoot Your Kinetix 6000
Troubleshoot IAM/AM
Status LEDs
Drive Status LED
Use the table below for troubleshooting the Drive Status LED on your
Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).
If the Drive Status
LED is
Status is
Potential Cause is
Possible Resolution is
Off
Normal, no faults
N/A
N/A
Steady Red
Drive faulted
Seven-segment LED displays error code
Refer to the section Error Codes and continue
troubleshooting.
Comm Status LED
Use the table below for troubleshooting the Comm Status LED on your
Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).
If the Comm Status
LED is
Status is
Potential Cause is
Possible Resolution is
Steady Green
Communication ready
No faults or failures.
N/A
System is still in the process of establishing
SERCOS communication.
Wait for steady green LED status.
Node address setting on the drive module
does not match SERCOS controller
configuration.
Verify proper node switch setting.
Loose fiber-optic connection.
Verify proper fiber-optic cable connections.
Broken fiber-optic cable.
Replace fiber-optic cable.
Receive fiber-optic cable connected to
SERCOS transmit connector and vice versa.
Check proper SERCOS fiber-optic cable
connections.
Flashing Green
Off
Establishing
communication
No communication 1
1
Publication 2094-IN002E-EN-P — September 2005
Refer to Fiber Optic Cable Installation and Handling Instructions (publication 2090-IN010) for more information.
Troubleshoot Your Kinetix 6000
2-9
Bus Status LED
Use the table below for troubleshooting the Bus Status LED on your
Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).
If the Bus Status LED is Status is
Steady Green
Flashing Green
Bus power is present, axis enabled.
No faults or failures.
Bus power is present, axis disabled.
No faults or failures.
Condition
Normal when:
• 24V is applied to Hardware Enable Input (IOD-2).
• MSO instruction is commanded in RSLogix 5000 software.
Normal when:
• 24V is not applied to Hardware Enable Input (IOD-2).
• MSO instruction is not commanded in RSLogix 5000 software.
• Normal when bus power is not applied.
Bus power not present.
Off
• Fault exists, refer to seven segment Error Code and General Troubleshooting
beginning on page 2-2.
• Follower IAM is not configured as Common Bus Follower in RSLogix 5000.
Bus power is present in Follower IAM.
• After DC bus voltage is applied, a 2.5 second delay before the LED begins
flashing green is normal operation to provide common bus leader time to
complete pre-charge.
Publication 2094-IN002E-EN-P — September 2005
2-10
Troubleshoot Your Kinetix 6000
Troubleshoot SM Status
LEDs
Each of the shunt module LEDs provide specific troubleshooting
information, as described in Bus Status LED, Temperature Fault LED,
and Shunt Fault LED.
IMPORTANT
Use of the Kinetix 6000 (rail mounted) shunt module
(catalog number 2094-BSP2), requires IAM/AM
firmware revision 1.068 or above.
General Shunt Module Troubleshooting
Shunt Module Faults are
Under these Conditions
Latched
Until fault condition is corrected and cleared.
• Using RSLogix MASR, MAFR, MGSR commands or the HIM (red
stop button).
• Only after the DC bus is discharged (SM Bus Status LED is
flashing).
Cleared
• Drive must be configured with 2094-BSP2 or Bulletin 1394 external
shunt module.
IAM/AM Internal Shunts
are
Under these Conditions
• When the 2094-BSP2 shunt module is used on a 230V system.
• When either 230V or 460V system is configured with a Bulletin
1394 external shunt module.
Disabled (for DC Bus
regulation)
• When configured in common bus follower mode.
Enabled to discharge the
DC Bus
Drive (IAM or IAM Leader) three-phase power is removed.
Disabled from discharging
the DC bus
When configured in common bus follower mode.
IMPORTANT
Under some fault conditions, two reset commands
may be required to clear drive and SM faults.
The following table applies when all three SM LEDs are flashing.
Status is
Potential Cause is
Possible Resolution is
All three SM status LEDs
flash simultaneously
Shunt module hardware failure
• Cycle power
• If problem persists, replace shunt module
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
2-11
Bus Status LED
Use the table below for troubleshooting the Bus Status LED on your
Kinetix 6000 SM (2094-BSP2).
If the Bus Status
LED is
Status is
Flashing
Normal condition when control power is applied and bus voltage is less than
60V dc.
N/A
Steady Green
Normal condition when control power is applied and bus voltage is greater
than 60V dc.
N/A
Off
Control power is not present
Replace shunt module.
Potential Cause is
Internal power supply failure
Possible Resolution is
Temperature Fault LED
Use the table below for troubleshooting the Temperature Fault LED on
your Kinetix 6000 SM (2094-BSP2).
If the Temp Fault
LED is
Status is
Off
Normal condition
Potential Cause is
Possible Resolution is
N/A
SM internal temperature
exceeds operating
temperature specification
Shunt module fan failed
Replace shunt module.
Shunt module temperature exceeds rating
• Allow shunt module to cool.
• Reset faults.
• Verify IAM bus regulator configuration.
External temperature switch is open
• Allow shunt module to cool.
• Reset faults.
• Verify IAM bus regulator configuration.
TS jumper is not present
Install jumper.
Steady Red
External over temperature
condition
Shunt Fault LED
Use the table below for troubleshooting the Shunt Fault LED on your
Kinetix 6000 SM (2094-BSP2).
If the Shunt Fault
LED is
Status is
Off
Normal condition
Steady Red
Shorted internal or external
shunt resistor
Potential Cause is
Possible Resolution is
N/A
Mis-wired shunt jumper or other short on RC
connector
Mis-wired (shorted) external shunt wiring
• Correct mis-wire (shorted) condition
• If problem persists, replace shunt module
Publication 2094-IN002E-EN-P — September 2005
2-12
Troubleshoot Your Kinetix 6000
Troubleshoot LIM Status
LEDs
The following troubleshooting table applies to the following Line
Interface Module status LEDs:
•
•
•
24V Power status LED (2094-AL75S, -BL75S, and -XL75S-Cx)
Brake Power status LED (2094-AL09 and -BL02)
I/O Power status LED (2094-AL09 and -BL02)
If the Status LED is
Status is
Potential Cause is
Possible Resolution is
Steady Green
Normal, 24V power enabled
N/A
N/A
• 24V power disabled
(2094-AL75S, -BL75S, and
XL75S-Cx)
CB3 is open
Off
• Brake power disabled
(2094-AL09, and -BL02)
24V polarity is
reversed at the load
• I/O power disabled
(2094-AL09, and -BL02)
Troubleshoot RBM Status
LEDs
• Set breaker to on position.
• If breaker continues to trip, call your Allen-Bradley
representative to return module for repair.
• Correct polarity.
• If polarity is correct and LED is not steady green, call your
Allen-Bradley representative to return module for repair.
The Resistive Brake Module (RBM) contactor status LED is visible from
the front of the RBM. Use the table below for troubleshooting the
RBM status LEDs.
24V dc Status LED
The 24V dc Status LED is on when 24V is applied between COIL_A1
and COIL_A2 (e.g. a Brake Enable signal is received from the drive).
If the Status LED is
Steady Green
RBM Contactor Status is
Potential Cause is
Possible Resolution is
Contactor engaged
(direct connection between drive and
motor)
No faults or failures
N/A
Contactor disengaged
(no connection between drive and
motor)
Contactor failure
• Monitor CONSTAT_41/42 status to verify lack of
drive/motor power (output is NC).
• Contact A-B representative.
• Verify ground wiring.
Blinking Green
(audible clicking)
Contactor rapidly engaging/
disengaging
Off
(intended)
Off
(unintended)
Contactor disengaged
(connection open between drive and
motor)
Recommended grounding
not followed
• Route wires away from noise sources.
Control circuit improperly
wired
Verify control wiring and programming.
No faults or failures
N/A
• +24V supply is off.
+24V not applied between
COIL_A1 and COIL_A2
• Verify wiring.
• Drive not enabled.
• Contact A-B representative.
T1 (Fault) thermostat open
Publication 2094-IN002E-EN-P — September 2005
• Refer to System Design for Control of Electrical Noise
Reference Manual (publication GMC-RM001).
Duty cycle exceeded, allow RBM to cool.
Troubleshoot Your Kinetix 6000
2-13
230V ac Auxiliary Power Status LED
Note: The 230V ac Auxiliary Power Status LED only applies to
2090-XB120-xx RBMs.
The 230V ac Status LED is on when 230V ac is applied to L1 and L2
(TB4) and the contactor is engaged by applying 24V dc across
COIL_A1 and COIL_A2 (e.g. a Brake Enable signal is received from
the drive).
If 230V Status LED
is
Contactor Status is
Potential Cause is
Possible Resolution is
Contactor Engaged
No faults or failures
(direct connection between drive and motor)
Steady Green
Contactor Disengaged
(no connection between drive and motor)
N/A
• Monitor CONSTAT_41/42 status to
verify lack of drive/motor power
(output is NC).
Contactor failure
• Contact A-B representative.
• Verify ground wiring.
• Route wires away from noise
sources.
Grounding
Blinking Green
(audible clicking)
• Refer to System Design for Control of
Electrical Noise Reference Manual
(publication GMC-RM001).
Contactor rapidly engaging/disengaging
• Check VAC loading.
• Check VAC source.
230V ac is varying
• Verify wiring.
Off
(intended)
Contactor Engaged
Control circuit improperly wired
Verify control wiring and programming.
Contactor failure
(contacts welded together)
• Monitor CONSTAT_41/42 status to
verify lack of drive/motor power
(output is NC).
• Contact A-B representative.
Contactor Disengaged
No faults or failures
N/A
Contactor Engaged
Contactor failure
(contacts welded together)
• Monitor CONSTAT_41/42 status to
verify lack of drive/motor power
(output is NC).
Off
(unintended)
Contactor Disengaged
• Contact A-B representative.
LED failure
• Contact A-B representative.
+24V signal not functioning properly
Refer to 24V dc Status LED
troubleshooting table on page 2-12.
Contactor failure (coil damaged)
Contact A-B representative.
No 230V ac signal
• Verify wiring.
• Verify 230V ac source.
Publication 2094-IN002E-EN-P — September 2005
2-14
Troubleshoot Your Kinetix 6000
Troubleshoot General
System Problems
Condition
Axis or System is unstable
Use the tables below for troubleshooting general system faults. For a
list of Bulletin 1756 product manuals, refer to Related Documentation
in the Preface.
Potential Cause is
Possible Resolution is
The position feedback device is incorrect or open.
Check wiring.
Unintentionally in torque mode.
Check to see what primary operation mode
was programmed.
Motor tuning limits are set too high.
Run Tune in RSLogix 5000.
Position loop gain or position controller accel/decel rate is
improperly set.
Run Tune in RSLogix 5000.
Improper grounding or shielding techniques are causing noise to
be transmitted into the position feedback or velocity command
lines, causing erratic axis movement.
Check wiring and ground.
Motor Select limit is incorrectly set (servo motor is not matched
to axis module).
Notch filter or output filter may be required
(refer to Axis Properties window, Output tab
in RSLogix 5000).
Torque Limit limits are set too low.
Verify that current limits are set properly.
Incorrect motor selected in configuration.
Select the correct motor and run Tune in
RSLogix 5000 again.
The system friction torque is excessive.
Available current is insufficient to supply the correct accel/decel
rate.
• Check motor size vs. application need.
• Review servo system sizing.
Check motor size vs. application need.
• Check motor size vs. application need.
• Review servo system sizing.
Acceleration limit is incorrect.
Verify limit settings and correct them, as
necessary.
Velocity Limit limits are incorrect.
Verify limit settings and correct them, as
necessary.
The axis cannot be enabled for 1.5 seconds after disabling.
Disable the axis, wait for 1.5 seconds, and
enable the axis.
Enable signal has not been applied or the enable wiring is
incorrect.
The motor wiring is open.
Motor does not respond to a
Velocity Command
• Run Tune in RSLogix 5000.
Mechanical resonance
The system inertia is excessive.
You cannot obtain the motor
acceleration/deceleration
that you want
• Check setups.
The motor thermal switch has tripped.
• Check the controller.
• Check the wiring.
Check the wiring.
• Check for a fault.
• Check the wiring.
The motor has malfunctioned.
Repair or replace the motor.
The coupling between motor and machine has broken (i.e., the
motor moves, but the load/machine doesn’t).
Check and correct the mechanics.
Primary operation mode is set incorrectly.
Check and properly set the limit.
Velocity or current limits are set incorrectly.
Check and properly set the limit(s).
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
Condition
Potential Cause is
2-15
Possible Resolution is
• Verify grounding.
Recommended grounding per installation instructions have not
been followed.
Presence of noise on
Command or motor feedback
signal wires
No Rotation
• Refer to System Design for Control of
Electrical Noise (publication
GMC-RM001).
• Verify grounding.
Line frequency may be present.
• Route wire away from noise sources.
Variable frequency may be velocity feedback ripple or a
disturbance caused by gear teeth or ballscrew balls etc. The
frequency may be a multiple of the motor power transmission
components or ballscrew speeds resulting in velocity
disturbance.
• Decouple the motor for verification.
The motor connections are loose or open.
Check motor wiring and connections.
Foreign matter is lodged in the motor.
Remove foreign matter.
The motor load is excessive.
Verify the servo system sizing.
The bearings are worn.
Return the motor for repair.
• Check and improve mechanical
performance of the gearbox, ballscrew,
etc.
• Check brake wiring and function.
The motor brake is engaged (if supplied).
Motor Overheating
• Route wire away from noise sources.
• Return the motor for repair.
The motor is not connect to the load.
Check coupling.
The duty cycle is excessive.
Change the command profile to reduce accel/
decel or increase time.
The rotor is partially demagnetized causing excessive motor
current.
Return the motor for repair.
Motor tuning limits are set too high.
Run Tune in RSLogix 5000 again.
• Remove the loose parts.
• Return motor for repair.
Loose parts are present in the motor.
• Replace motor.
Abnormal Noise
Erratic Operation - Motor
locks into position, runs
without control or with
reduced torque
Through bolts or coupling is loose.
Tighten bolts.
The bearings are worn.
Return motor for repair.
Mechanical resonance
Notch filter may be required (refer to Axis
Properties window, Output tab in RSLogix
5000).
Motor power phases U and V, U and W, or V and W reversed.
Check and correct motor power wiring.
Sine, Cosine or Rotor leads are reversed in the feedback cable
connector.
Check and correct motor feedback wiring.
Sine, Cosine, Rotor lead sets of resolver feedback are reversed.
Check and correct motor feedback wiring.
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Troubleshoot Your Kinetix 6000
Understand Logix/Drive
Fault Behavior
This section provides the drive fault actions and indicates whether the
fault action is programmable.
The following drive fault action definitions apply:
Drive Fault Action
Definition
Shutdown
The drive disables and the contactor enable relay opens. Uncontrolled
stop, motor coasts to a stop.
Disable Drive
The drive is disabled. Uncontrolled Stop, motor coasts to a stop.
Stop Motion
Logix configuration for velocity loop Kp/Ki is followed. When zero speed is
reached or stopping time is exceeded, the drive is disabled.
Note: Stopping time and stopping torque are configurable parameters in
RSLogix 5000.
Status Only
Drive continues to operate. Status is provided by 7-Segment Fault Status
LED, Drive Status LED, and DPI (if used).
Fault Message RSLogix
(HIM)
Error
Code
Description
Drive Fault
Action
RSLogix
Programmable
Fault Action?
BusUndervoltageFault
(Blown fuse)
E00
A blown fuse was detected in the inverter pcb.
SHUTDOWN
N
STOP
Y
The motor thermal switch was tripped.
Note: Firmware I2t protection does not generate a fault, rather it
dynamically folds back current when 110% of motor rating is
reached. Setting the Motor Thermal fault action to Status Only
will bypass this function.
MotorOvertempFault
(Motor Overtemp)
E04
DriveOvercurrentFault
(Power Fault)
E05
An instantaneous over-current was detected in the inverter power
section.
SHUTDOWN
N
HardOvertravelFault
(+/- Hard Overtravel)
E06
Axis moved beyond the physical travel limits in the positive/negative
direction. This fault can be configured for status only.
STOP
Y
MotFeedbackFault
(Motor Feedback Loss)
E07
The feedback wiring is open, shorted or missing.
DISABLE
N
SHUTDOWN
N
With 3 phase present, the DC bus voltage is below limits. The trip
point is 275V and 137V DC for 460V/230V drives respectively.
BusUndervoltageFault
(Bus Under Voltage)
E09
DriveOvervoltageFault
(Bus Overvoltage)
E10
The DC bus voltage is above limits. The trip point is 820V and 410V
DC for 460V/230V drives respectively.
SHUTDOWN
N
MotFeedbackFault
(Illegal Hall State)
E11
State of Hall feedback inputs in incorrect.
DISABLE
N
SoftovertravelFault
(+/- Software Overtravel)
E16
Axis position exceeded maximum software setting in the positive/
negative direction. This fault can be configured for status only.
STOP
Y
OverSpeedFault
(Overspeed Fault)
E18
Axis speed has reached 150% of the maximum rated setting. The
100% trip point is dictated by the lesser of the user velocity limits or
the motor rated base speed.
DISABLE
N
PositionErrorFault
(Follow Error)
E19
Axis position error limit has been exceeded. This fault can be
configured for status only.
STOP
Y
DC bus voltage is below limits when any axis on common bus
follower power rail was enabled.
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
2-17
Fault Message RSLogix
(HIM)
Error
Code
Description
Drive Fault
Action
RSLogix
Programmable
Fault Action?
MotFeedbackFault
(Mtr Fdbk AQB)
E20
Motor encoder has encountered an illegal state transition.
DISABLE
N
AuxFeedbackFault
(Aux Feedback Comm)
E21
Communication was not established with an intelligent (i.e.
Stegmann) encoder on the Auxiliary feedback port.
STOP
N
MotFeedbackFault
(Motor Feedback Comm)
E30
Communication was not established with an intelligent (i.e.
Stegmann) encoder on the Motor feedback port.
STOP
N
GroundShortFault
(Ground Fault)
E34
Excessive ground current in the converter was detected.
SHUTDOWN
N
DriveUndervoltageFault
(Precharge Fault)
E35
The converter pre-charge cycle has failed.
SHUTDOWN
N
DriveOvertempFault
(System Overtemperature)
E36
Converter internal temperature limit exceeded.
SHUTDOWN
N
• One or more phases of the input AC power is missing.
PowerPhaseLossFault
(Phase Loss Flt)
E37
• Axis was enabled when main (3-phase) power was removed.
SERCOSFault
(SERCOS Ring Flt)
E38
The SERCOS ring is not active after being active and operational.
STOP
N
DriveHardFault
(Self Sense Flt)
E39
Self-sensing commutation fault detected
DISABLE
N
DriveEnableInputFault
(Drive Enable Flt)
E43
Generated when Enable input switches off when drive is enabled.
STOP
Y
DriveHardFault
(Safe-Off HW Flt)
E49
Safe-off function mismatch. Drive will not allow motion. Refer to the
Kinetix Safe-Off Feature Safety Reference Manual (publication
GMC-RM002) for more information. Applies to IAM
(2094-xCxx-Mxx-S) and AM (2094-xMxx-S) with Safe-Off feature.
SHUTDOWN
N
SERCOSFault
(SERCOS Same ADDR)
E50
Duplicate node address detected on SERCOS ring.
STOP
N
DriveHardFault
(Ifbk HW Fault)
E54
Current feedback hardware fault detected.
SHUTDOWN
N
DriveHardFault
(Unknown Axis)
E60
Invalid module type identified by firmware during power on
SHUTDOWN
N
AuxFeedbackFault
(Aux Fdbk AQB)
E61
Auxiliary encoder has encountered an illegal state transition.
DISABLE
N
AuxFeedbackFault
(Aux Fdbk Loss)
E62
The feedback wiring is open, shorted or missing.
DISABLE
N
AuxFeedbackNoise
(Aux Fdbk Noise)
E63
Presence of noise on auxiliary feedback cable.
MotorFeedbackNoise
(Mtr Fdbk Noise)
DISABLE
Y
E64
Presence of noise on motor feedback cable.
No Fault Message
(condition indicated by
on-screen message)
(Hookup Fault)
E65
Hookup procedure failed
DISABLE
N
• Common bus follower axis was enabled when DC bus power was
removed.
SHUTDOWN/ STOP N
Publication 2094-IN002E-EN-P — September 2005
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Troubleshoot Your Kinetix 6000
Fault Message RSLogix
(HIM)
Error
Code
Description
Drive Fault
Action
RSLogix
Programmable
Fault Action?
No Fault Message
(condition indicated by
on-screen message)
(Atune Flt)
E66
Autotune procedure failed
DISABLE
N
DriveHardFault
(Task init)
E67
Operating System Failed
SHUTDOWN
N
DriveHardFault
(SCANport Comm)
E68
DPI Communication Failed
STOP
N
DriveHardFault
(Objects Init)
E69
Non-Volatile Memory attribute out of range
SHUTDOWN
N
DriveHardFault
(NV Mem Init)
E70
Non-Volatile Memory Corrupted
SHUTDOWN
N
DriveHardFault
(Memory Init)
E71
RAM or Flash memory validation failure.
SHUTDOWN
N
Inverter temperature limit exceeded.
DriveOvertempFault
(Drive Overtemp)
E72
Note: Firmware I2t protection does not generate a fault, rather it
dynamically folds back current when 110% of drive rating is
reached.
SHUTDOWN
Y
Communicate
(Backplane Comm)
E73
Power Rail Backplane CAN communications failed
STOP
N
DriveOvercurrentFault
(Bus OverCurrent)
E74
The converter has exceeded its converter rating.
SHUTDOWN
N
DriveOvervoltageFault
(Shunt Time Out)
E75
The IAM, AM, or SM has exceeded its shunt resistor continuous
rating.
Note: SHUTDOWN for IAM, DISABLE for AM. IAM also provides
fault handling for Shunt Module.
SHUTDOWN
N
DriveHardFault
(Can Init)
E76
Either DPI or Backplane CAN initialization failure
SHUTDOWN
N
DriveHardFault
(Module Mismatch)
E77
Generated by IAM if the power rating of one of the AM’s on the
power rail does not match with IAM input power rating
SHUTDOWN
N
DriveHardFault
SERCOS Init
E78
Control hardware fault detected
SHUTDOWN
N
DriveOvervoltageFault
(Shunt Module Flt)
E79
Power Rail mounted Shunt Module Fault. Displayed on IAM
7-segment fault status LED.
SHUTDOWN
N
HardwareFault
(CPLD FLT)
E80
Control hardware fault detected
SHUTDOWN
N
HardwareFault
(Common Bus FLT)
E81
Common Bus Follower IAM detected AC input power being applied.
SHUTDOWN
N
HardwareFault
(Pre-charge Timeout FLT)
E90
Pre-charge resistor power exceeds the resistor rating.
SHUTDOWN
N
RESERVED
All
Others
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
Supplemental
Troubleshooting
Information
2-19
This section provides information for accessing and changing
parameters not accessible through RSLogix 5000 software.
Tools for Changing Parameters
Most parameters are accessible through RSLogix 5000 software.
Alternatives to RSLogix 5000 software for changing parameters include
the DPI compatible Human Interface Module (HIM) and
DriveExplorer software. Refer to the table below for catalog numbers.
Method
DriveExplorer
HIM
Description
Catalog Number
Firmware Revision
DriveExplorer Software 1
9306-4EXP02ENE
2.01 or later
Serial to SCANport Adapter
1203-SSS (Series B)
3.004 or later
Full Numeric LCD HIM
20-HIM-A3 2
N/A
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Compatible catalog numbers include all 20-HIM-Ax.
Changing Parameters Using DriveExplorer
To navigate using DriveExplorer, refer to the figure below. In this
example, the I/O Interface group folder is open, the Analog Outputs
parameter is selected, and the parameter elements are displayed in the
box to the right.
IMPORTANT
Parameters are read-only when SERCOS ring is
active. You must break SERCOS ring to change
parameters.
To save changes, perform a non-volatile save (NVS)
prior to cycling power.
Figure 2.1
DriveExplorer Example
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Troubleshoot Your Kinetix 6000
Changing Parameters Using the HIM
When using the HIM to monitor or change parameters, use the up and
down arrows (∧ and ∨ ) to arrive at selections. Refer to the
instructions that came with your HIM for more information.
To monitor or change parameters using the HIM:
1. Select parameter. Press ↵ .
2. Select I/O AM1 Group (for IAM). Press ↵ .
3. Select Analog Outputs. Press ↵ .
•
Analog Output 1 is displayed. Press ↵ .
•
For Analog Output 2 use arrows to select. Press ↵ .
4. Press Sel.
5. Enter parameter number. Press ↵ .
Using Analog Test Points to Monitor System Variables
There are two analog output test points accessible from the IOD
26-pin connector on each IAM and AM (refer to figures and 1.2 for
connector locations).
IOD Pin
Description
Signal
23
Analog Output 0
DAC0
24
Analog Output Common
DAC_COM
25
Analog Output 1
DAC1
26
Analog Output Common
DAC_COM
Figure 2.2
Pin Orientation for 26-pin I/O (IOD) Connector
26-pin IAM/AM
I/O Connector
Pin 26
Pin 19
Pin 18
Pin 9
Pin 1
Pin 10
Refer to the Kinetix 6000 Multi-Axis Servo Drive Installation Manual
(publication 2094-IN001) for analog output specifications.
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
2-21
Parameters begin with a variable to identify a specific axis by slot
number, as follows:
•
IAM = 0 for parameters 0-999
•
1st AM = 1 for parameters 1000-1999
•
2nd AM = 2 for parameters 2000-2999 and so on...
•
7th AM = 7 for parameter 7000-7999
Use the two analog output test points to monitor system variables, as
shown in the table below.
Controlling Parameter
Scale Parameter
Analog
Output
Parameter Number1
Default Value1
Parameter Number1
Default Value
1
x681
xx40
x682
0.0060
2
x683
xx84
x684
0.1000
1
x = slot number
The value entered in Scale Parameter will scale the analog output so
that you can get a full scale reading of the specific parameter for the
dynamic range or values you are testing.
To monitor dynamic system variables on analog outputs, use the
values shown in the table below.
Attribute
Parameter Number4
Velocity Feedback1
xx40
Velocity Commanded1
xx36
Torque Feedback2
xx84
Torque Commanded2
xx80
Following Error3
x189
1
Velocity Command and Feedback scaling value is 0.25V = 1000 rpm (using default scaling).
2
Torque Command and Feedback scaling value is 0.25V = 100% rated motor current or amplifier rating (whichever
is less) using default scaling.
3
Output scaling is dependant on feedback device and drive resolution.
4
x = slot number
Publication 2094-IN002E-EN-P — September 2005
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Troubleshoot Your Kinetix 6000
Replace Kinetix 6000
System Components
Use these procedures to:
•
Determine what you need to replace modules
•
Remove a module from the Power Rail
•
Install a replacement Power Rail module
•
Remove the Power Rail
•
Install a replacement Power Rail
•
Remove the Line Interface Module
•
Install a replacement Line Interface Module
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.
Before You Begin
Before you replace modules, be sure to have the following:
Publication 2094-IN002E-EN-P — September 2005
•
A flat blade screw driver
•
A small flat blade screw driver, 3.5 mm (0.14 in.)
•
Voltmeter
Troubleshoot Your Kinetix 6000
Remove Modules from the
Power Rail
2-23
To remove module(s) from the power rail:
1. Verify that all control and input power has been removed from the
system.
ATTENTION
To avoid shock hazard or personal injury, assure
that all power has been removed before
proceeding. This system may have multiple
sources of power. More than one disconnect
switch may be required to de-energize the
system.
2. Allow five minutes for the DC bus to completely discharge before
proceeding.
ATTENTION
This product contains stored energy devices. To
avoid hazard of electrical shock, verify that all
voltage on capacitors has been discharged before
attempting to service, repair, or remove this unit.
You should only attempt the procedures in this
document if you are qualified to do so and are
familiar with solid-state control equipment and
the safety procedures in publication NFPA 70E.
3. Label and remove all connectors from the module (IAM, AM, or
SM) you are removing. To identify each connector, refer to
Commission Your Kinetix 6000 (pages 1-3 to 1-5).
Note: The Slot Filler module has no connectors aside from the
connections to the power rail.
4. Remove the motor cable from the cable shield clamp, as shown in
the figure below.
Figure 2.3
Depressing the Spring Clamp
Vertical Cable Clamp
Orientation Example
Use flat blade screwdriver with
3.5 mm (0.14 in.) tip to depress
spring and remove cable.
Motor
Cable
Horizontal Cable Clamp
Orientation Example
Cable Clamp
Cable Clamp
Screwdriver tip in slot
Vent holes on top of IAM/AM
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2-24
Troubleshoot Your Kinetix 6000
5. Loosen the mounting screw (bottom center of each module).
6. Grasp top and bottom of the module with both hands and gently
pull the module away from the connectors enough to clear the
guide pin(s) (module will pivot on top bracket). Lift the bracket
out of the power rail slot and remove module from the power rail.
Figure 2.4
Removing Module from Power Rail
Guide Pin(s)
Integrated Axis Module
(side view)
Power Rail
(side view)
Replace Power Rail
Modules
To replace the power rail module(s):
1.
If you are
Then
Replacing a power rail module on
the existing power rail
Go to step 3.
Replacing a power rail module on a
new power rail
Go to step 2.
2. Prepare to mount your replacement module by removing the
protective boots from the power rail connector.
3. Hang the mounting bracket from the slot on the power rail.
IMPORTANT
Power rail must be in vertical orientation before
replacing modules or pins may not seat properly.
4. Align the guide pin(s) on the power rail with the guide pin hole(s)
in the back of the module (refer to Figure 2.4).
Note: The IAM can have two or three power rail connectors and
guide pins, the AM can have one or two, all other modules
have only one connector and one guide pin.
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
2-25
5. Use 2.26 N-m (20 lb-in.) torque to tighten the mounting screw.
6. Re-connect the module connectors.
7. Re-apply power to the system.
8. Verify that the system is operating properly.
Note: Because IAM and AM parameters reside in the RSLogix 5000
software, you do not need to perform any tuning or setup
procedures.
Remove the Power Rail
This procedure assumes you have disconnected all power from the
power rail modules and removed all modules from the power rail.
To remove the power rail:
1. Disconnect the braided grounding strap from the grounding stud
on the right side of the power rail, as shown in the figures below.
Figure 2.5
Removing Ground Strap (2094-PRx)
Braided Ground Strap
100 mm (3.9 in.)
Bonded Cabinet Ground
Figure 2.6
Removing Ground Strap (2094-PRSx)
Braided Ground Strap
100 mm (3.9 in.)
Bonded Cabinet Ground
2. Loosen the mounting bolts (removing the bolts is not necessary).
3. Lift the power rail up and off of the mounting bolts.
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Troubleshoot Your Kinetix 6000
Replace the Power Rail
This procedure assumes you do not need to change the location of
the power rail on the panel and you intend to reuse the mounting
bolts of the power rail you just removed.
IMPORTANT
ATTENTION
If you need to change the location of the power rail,
or if you are installing a power rail designed for
additional or fewer modules than you removed, refer
to the Kinetix 6000 Multi-Axis Servo Drive
Installation Manual (publication 2094-IN001) for
complete installation instructions.
To avoid damage to Power Rail during installation,
do not remove the protective boots until the module
for each slot is ready for mounting.
To replace the power rail:
1. Align the replacement power rail over the existing mounting bolts.
IMPORTANT
To improve the bond between the power rail and
subpanel, construct your subpanel out of zinc
plated (paint-free) steel.
2. Tighten the mounting bolts.
3. Re-attach the braided grounding strap to the power rail grounding
stud (refer to figures 2.5 and 2.6).
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000
Remove the Line Interface
Module
2-27
To remove the Line Interface Module (LIM):
1. Verify that all input power has been removed from the LIM.
ATTENTION
To avoid shock hazard or personal injury, assure
that all power has been removed before
proceeding. This system may have multiple
sources of power. More than one disconnect
switch may be required to de-energize the
system.
2. Allow five minutes for the DC bus to completely discharge before
proceeding.
ATTENTION
To avoid hazard of electrical shock, verify that all
voltage on the capacitors has been discharged
before attempting to service, repair, or remove
this unit. This product contains stored energy
devices. You should only attempt the procedures
in this document if you are qualified to do so and
familiar with solid-state control equipment and
the safety procedures in publication NFPA 70E.
3. Label and remove all connectors and wires from the LIM. To
identify each connector, refer to page 1-6.
4. Loosen the mounting bolts (removing the bolts is not necessary).
5. Lift the LIM up and off of the mounting bolts.
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Troubleshoot Your Kinetix 6000
Replace the Line Interface
Module
This procedure assumes you do not need to change the location of
the LIM on the panel and you intend to reuse the mounting bolts of
the LIM you just removed.
IMPORTANT
If you need to change the location of the LIM, refer
to the Kinetix 6000 Multi-Axis Servo Drive
Installation Manual (publication 2094-IN001) for
complete installation instructions.
1. Align the replacement LIM over the existing mounting bolts.
IMPORTANT
To improve the bond between the LIM and
subpanel, construct your subpanel out of zinc
plated (paint-free) steel.
2. Tighten the mounting bolts.
3. Re-connect the LIM wires and connectors. To locate wires and
connectors, refer to page 1-6.
4. Re-apply power to the LIM.
5. Verify that the LIM is operating properly.
Publication 2094-IN002E-EN-P — September 2005
Appendix
A
Interconnect Diagrams
Chapter Objectives
This appendix contains the following interconnect diagrams:
• Power Interconnect Diagrams
• DC Common Bus Interconnect Diagrams
• Shunt Module Interconnect Diagrams
• AM/Motor Interconnect Diagrams
• Controlling a Brake Example
• System Block Diagrams
Kinetix 6000 Interconnect
Diagram Notes
This section provides interconnect diagram notes to assist you in
wiring the Kinetix 6000 system. The notes apply to the interconnect
diagrams on the pages that follow.
ATTENTION
1
The National Electrical Code and local electrical
codes take precedence over the values and methods
provided. Implementation of these codes is the
responsibility of the machine builder.
Publication 2094-IN002E-EN-P — September 2005
A-2
Interconnect Diagrams
Note
Information
1
For power wiring specifications, refer to Kinetix 6000 Installation Manual (publication 2094-IN001).
2
For input fuse and circuit breaker sizes, refer to Kinetix 6000 Installation Manual (publication 2094-IN001).
3
For AC line filter specifications, refer to Kinetix 6000 Installation Manual (publication 2094-IN001).
4
Terminal block is required to make connections.
5
2094-BCxx-Mxx (460V) IAM requires step down transformer for single-phase control power input. 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.
6
LIM models 2094-AL75S and -BL75S can supply a maximum of eight axes. LIM models 2094-XL75S-Cx can supply a maximum of sixteen axes. For
common bus systems with more than sixteen axes, multiple LIMs (or control power transformers) are required.
7
Contactor coil (M1) needs integrated surge suppressors for AC coil operation.
8
Drive Enable input must be opened when main power is removed, or a drive fault will occur. A delay of at least 1.0 second must be observed
before attempting to enable the drive after main power is restored.
9
Cable shield clamp must be used in order to meet CE requirements. No external connection to ground required.
10
Jumper is factory set, indicating grounded system at user site. Ungrounded sites must jumper the bleeder resistor to prevent high electrostatic
buildup. Refer to Kinetix 6000 Installation Manual (publication 2094-IN001) for more information.
11
12
ATTENTION
ATTENTION
Implementation of safety circuits and risk assessment is the responsibility of the
machine builder. Please reference international standards EN 1050 and EN 954
estimation and safety performance categories. For more information refer to
Understanding the Machinery Directive (publication SHB-900).
Wiring the Contactor Enable relay is required. To avoid injury or damage to the
drive, wire the Contactor Enable relay into your safety control string. The
recommended minimum wire size for wiring the safety circuit to the contactor
enable connector is 1.5 mm2 (16 AWG).
13
The Kinetix 6000 axis module referenced is either an individual axis module (2094-xMxx) or the same axis module that resides within an
integrated axis module (2094-xCxx-Mxx).
14
For motor cable specifications, refer to the Kinetix Motion Control Selection Guide (publication GMC-SG001).
15
Wire colors are for flying lead cable (2090-XXNFxx-Sxx) and may vary from the premolded connector cable (2090-UXNFBxx-Sxx).
16
Y-Series feedback cables have a drain wire that must be folded back under the Low Profile connector clamp.
17
Only the MPG-Bxxx encoder uses the +5V dc supply. MPL-Bxxx encoders use the +9V dc supply.
18
Brake wires on MPF/MPS-A/B5xx motors are labeled plus (+) and minus (-). All other MP-Series Food Grade and Stainless Steel motor brake
wires are labeled F and G.
19
Refer to Kinetix 6000 Installation Manual (publication 2094-IN001) for input fuse specifications. Current requirements are for master only shunt
applications. For master/slave applications you must multiply the current requirement by the number of shunt units.
20
Refer to Kinetix 6000 Installation Manual (publication 2094-IN001) for fault relay specifications. This normally closed contact (TTL compatible) is
closed when 115V ac is applied and opens when a shunt fault or loss of power occurs.
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams
Power Interconnect
Diagrams
A-3
The interconnect wiring for an IAM is shown beginning below.
In the configuration below the IAM has input power, brake power,
and the start/stop string wired from a LIM (2094-AL09 or -BL02). The
2094-xLxx LIM contains an AC line filter, so an external filter is not
required.
Figure A.1
IAM Power Interconnect Diagram (IAM with LIM)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
Power Rail
Ground Stud
Bonded Cabinet
Ground Bus*
Note 9
Cable Shield
Clamp
Kinetix 6000
LINE INTERFACE MODULE
2094-AL09 or -BL02
Single-Phase (CPL) Output
195-264V ac RMS
Notes 1
4
L2
L1
1
2
1
2
1
2
VAC LINE Three-Phase (IPL) Input
195-264V ac RMS
or 324-528V ac RMS
Note 1
L3
L2
L1
Ground
VAC LOAD 3-Phase (OPL) Output
195-264V ac RMS
or 324-528V ac RMS
Note 1
3
5
L2'
6
L1'
MBRK_PWR
24V dc Output
(PSL) Connector
4
L3'
MBRK_COM
MBRK_PWR
MBRK_COM
Control Power
(CPD) Connector
CTRL 2
CTRL 1
Motor Power
(MP) Connector
W
V
U
I/O (IOL)
Connector
Note 11, 12
IO_COM
COIL_A2
1
L3
L2
DC Bus
and
3-Phase
Input (IPD)
Connector
L1
1
2
3
4
MBRK -
Motor/Resistive
Brake (BC) Connector
24-26
COM
PWR
DBRK -
STOP *
COIL_A1
2
DCDC+
MBRK +
IO_PWR
Three-Phase
Motor Power
Connections
Note 14
3
DBRK +
13
20-22
1
4
2
CONT ENCONT EN+
Contactor Enable
(CED) Connector
Note 12
6
BR-
5
BR+
Motor Brake
Connections
4
3
2
BR-
1
BR+
Resistive Brake
Connections
* INDICATES USER SUPPLIED COMPONENT
Publication 2094-IN002E-EN-P — September 2005
A-4
Interconnect Diagrams
In the configuration below two IAMs have input power, brake power,
and the start/stop string wired from the same LIM (2094-AL75S,
-BL75S, or -XL75S-Cx). The 2094-xL75S-xx LIM does not contain an AC
line filter, so an external filter is added between the LIM and IAM.
Figure A.2
IAM Power Interconnect Diagram (IAM with LIM)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(IAM_1)
Bonded Cabinet
Ground Bus*
Note 9
Power Rail
Ground Stud
Cable Shield
Clamp
Kinetix 6000
LINE INTERFACE MODULE
2094-AL75S, -BL75S, or -XL75S-Cx
4
Control Power CTRL 2 1
Single-Phase (CPL) Output
2
195-264V ac RMS CTRL 1
Note 1
Note 4
1
2
To CPD connector,
IAM_2
Note 6
1
2
1
VAC LINE
3-Phase (IPL) Input
195-264V ac RMS
or 324-528V ac RMS
Note 1
2
3
4
VAC LOAD
3-Phase (OPL) Output
195-264V ac RMS
or 324-528V ac RMS
Note 1
L3
L2
L1
1
L3'
L2'
L1'
W
V
Motor Power
(MP) Connector
Note 4
2
3
Three-Phase
AC Line Filter
Note 3
3
4
4
5
6
CTRL 2
CTRL 1
DCDC+
L3
L2
U
Control Power
(CPD) Connector
Three-Phase
Motor Power
Connections
Note 14
3
2
1
DC Bus
and
3-Phase
Input (IPD)
Connector
L1
To IPD connector,
IAM_2
Auxiliary Power
Single-Phase (APL) Input
93-121V ac RMS
or 196-253V ac RMS
(This connector is present
only on the 2094-XL75S-Cx)
Note 1
1
2
L1
L2/N
IO_PWR2
IO_COM2
24V dc (P1L) Output
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
1
2
To BC connector, IAM_2
3
4
5
6
Motor Brake
Connections
MBRK MBRK +
Motor/Resistive
Brake (BC) Connector
IO_PWR1
1, 3, 5
COM
PWR
DBRK DBRK +
I/O (IOL)
Connector
Note 11, 12
STOP *
COIL_E1
IO_COM1
COIL_E2
* INDICATES USER SUPPLIED COMPONENT
Publication 2094-IN002E-EN-P — September 2005
6
BR-
5
BR+
4
3
2
BR-
1
BR+
Resistive Brake
Connections
7
2, 4, 6
1
8
2
CONT ENCONT EN+
Contactor Enable
(CED) Connector
Note 12
To CED connector, IAM_2
Interconnect Diagrams
A-5
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(IAM_2)
Power Rail
Ground Stud
Bonded Cabinet
Ground Bus*
Note 9
Cable Shield
Clamp
4
Motor Power
(MP) Connector
1
From CPL connector, LIM
2
1
2
3
From OPL connector, LIM
Three-Phase
AC Line Filter
Note 3
4
5
6
CTRL 2
CTRL 1
DCDC+
L3
Control Power
(CPD) Connector
W
V
U
L1
Motor/Resistive
Brake (BC) Connector
COM
PWR
DBRK DBRK +
2
1
L2
MBRK +
1
2
DC Bus
and
3-Phase
Input (IPD)
Connector
MBRK -
From IOL connector, LIM
and CED connector, IAM_1
Three-Phase
Motor Power
Connections
Note 14
3
CONT ENCONT EN+
6
BR-
5
BR+
Motor Brake
Connections
4
3
From P1L connector, LIM
2
BR-
1
BR+
Resistive Brake
Connections
Contactor Enable
(CED) Connector
Note 12
Publication 2094-IN002E-EN-P — September 2005
A-6
Interconnect Diagrams
The configuration on this page does not include a LIM. You must
supply input power components. The diagram below is preferred
because one three-phase line filter is utilized by both control power
and main input power connections. The three-phase line filter is wired
upstream of fusing and the M1 contactor.
Wiring the Contactor Enable relay is required. To
avoid injury or damage to the drive, wire the
Contactor Enable relay into your safety control string.
ATTENTION
Figure A.3
IAM Power Interconnect Diagram (IAM without LIM - Preferred)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet Ground Bus *
Power Rail
Ground Stud
Chassis
Note 9
1
Single-Phase Input
95-264V ac RMS
Notes 1, 2
2
Input Fusing *
CTRL 2
CTRL 1
Control Power
(CPD) Connector
Cable Shield
Clamp
4
Isolation
Transformer *
Notes 5, 6
Motor Power
(MP) Connector
W
V
U
1
2
DCDC+
3
Three-Phase
AC Line Filter
Note 3
Three-Phase Input
195-264V ac RMS
or 324-528V ac RMS
Notes 1, 2
4
5
6
L3
L2
L1
Input Fusing * M1 *
Notes 7, 8
DC Bus
and
3-Phase
Input (IPD)
Connector
MBRK MBRK +
Motor/Resistive
Brake (BC) Connector
COM
PWR
DBRK DBRK +
Notes 7, 12
1
2
24V ac/dc
or
120V ac
50/60 Hz
STOP *
START *
CONT ENCONT EN+
Three-Phase
Motor Power
Connections
Note 14
3
2
1
6
BR-
5
BR+
4
Motor Brake
Connections
User Supplied
24V dc (1.2A maximum)
3
2
BR-
1
BR+
Resistive Brake
Connections
Contactor Enable
(CED) Connector
Note 12
CR1 *
M1 *
CR1 *
CR1 *
Refer to Attention statement (Note 11)
Publication 2094-IN002E-EN-P — September 2005
Ground Jumper
Note 10
* INDICATES USER SUPPLIED COMPONENT
Interconnect Diagrams
A-7
The configuration on this page does not include a LIM. You must
supply input power components. The diagram below is not preferred
because two line filters are required. The single-phase and
three-phase line filters are wired downstream of fusing and the M1
contactor.
Wiring the Contactor Enable relay is required. To
avoid injury or damage to the drive, wire the
Contactor Enable relay into your safety control string.
ATTENTION
Figure A.4
IAM Power Interconnect Diagram (IAM without LIM - Alternate)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet Ground Bus *
Power Rail
Ground Stud
Chassis
Single-Phase Input
95-264V ac RMS
Notes 1, 2
1
Single-Phase
AC Line Filter
Note 3
Input Fusing *
2
Note 9
CTRL 2
CTRL 1
Control Power
(CPD) Connector
Cable Shield
Clamp
Isolation
Transformer *
Note 5
4
Motor Power
(MP) Connector
1
2
Note 4
DCDC+
3
Three-Phase
AC Line Filter
Note 3
Three-Phase Input
195-264V ac RMS
or 324-528V ac RMS
Notes 1, 2
Input Fusing *
4
5
6
L3
L2
DC Bus
and
3-Phase
Input (IPD)
Connector
MBRK -
L1
MBRK +
Motor/Resistive
Brake (BC) Connector
COM
PWR
DBRK -
24V ac/dc
or
120V ac
50/60 Hz
STOP *
1
START *
V
U
M1 *
Notes 7, 8
Notes 7, 12
W
CONT EN2
CONT EN+
Contactor Enable
(CED) Connector
Note 12
DBRK +
Three-Phase
Motor Power
Connections
Note 14
3
2
1
6
BR-
5
BR+
4
Motor Brake
Connections
User Supplied
24V dc (1.2A maximum)
3
2
BR-
1
BR+
Resistive Brake
Connections
CR1 *
M1 *
CR1 *
CR1 *
Refer to Attention statement (Note 11)
Ground Jumper
Note 10
* INDICATES USER SUPPLIED COMPONENT
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
Three-Phase Input from LIM
or input power contactor (M1)
195-264V ac RMS
or 324-528V ac RMS
Notes 1, 2, 7, 8
2
1
6
5
4
3
2
1
2
1
Contactor Enable
(CED) Connector
Note 12
Motor/Resistive
Brake (BC) Connector
Note 9
W
V
U
1
2
6
5
4
1
N.C.
N.C.
N.C.
2
Three-Phase
Motor Power
Connections
Note 14
3
2
1
2
1
3
4
5
6
1
2
3
4
Wire the Leader and Follower IAM
contactor enable terminals in series
with the safety control string or LIM I/O.
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
DC Bus
and
3-Phase
Input (IPD)
Connector
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
W
V
U
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
* INDICATES USER SUPPLIED COMPONENT
Contactor Enable
(CED) Connector
Note 12
Motor/Resistive
Brake (BC) Connector
Note 9
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
DC Bus
and
3-Phase
Input (IPD)
Connector
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
1
2
3
4
5
6
1
2
3
4
Three-Phase
Motor Power
Connections
Note 14
DC Common Bus
Interconnect Diagrams
Single-Phase Input
95-264V ac RMS
Notes 1, 2
Bonded Cabinet
Ground Bus*
Kinetix 6000
COMMON BUS LEADER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus*
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-ACxx-Mxx or -BCxx-Mxx
A-8
Interconnect Diagrams
The interconnect wiring for common bus configurations is shown
beginning below. The example on this page shows a Kinetix 6000
Leader IAM and Follower IAM connected via the DC common bus.
Figure A.5
Leader IAM with Single Follower IAM Power Interconnect Diagram
Three-Phase
AC Line Filter
Note 3
IMPORTANT
R
S
Customer
supplied
120V ac
M1 *
Note 7
MC
Line
Reactors
T1
S1
R1
T
S
R
G
CR1*
L3
PR3
MC2
Refer to Attention statement (Note 11)
Stop *
Start *
CR1*
2
MC1
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
DC Bus
and
3-Phase
Input (IPD)
Connector
Contactor Enable
(CED) Connector
Note 12
Motor/Resistive
Brake (BC) Connector
CONT ENCONT EN+
Note 9
W
V
U
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
Power Rail
Ground Stud
+24V_PWR
I/O (IOD)
ENABLE
3 +24V_COM Connector
2
1
6
5
1
Note 12
Motion Control I/O
N.C.
N.C.
N.C.
4
3
2
1
2
1
PR2
+24V dc
PWR
P
N
Single-Phase Input
95-264V ac RMS
Notes 1, 2
PR1
L3 AUX
L2 AUX
COM
RDY
TB3
DCDC+
L2
TB2
L1 AUX
TB1
L1
TB1
8720MC
REGENERATIVE
POWER SUPPLY
8720MC-RPSxxx
Bonded Cabinet
Ground Bus*
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-BCxx-Mxx
1
2
3
4
5
6
1
2
3
4
Three-Phase
Motor Power
Connections
Note 14
Use a push-button circuit (instead of a SPST toggle switch) in series with the contactor enable string
(between the 8720MC-RPS and Kinetix 6000) to allow a drive fault to remove the DC bus power, and
to prevent the drive from applying DC bus power without the user’s input after clearing a drive fault.
T
E/N
Bonded Cabinet
Ground Bus*
Harmonic
Filter
To Motor Fan
Varistor
Motor Fan Fusing*
Input Fusing *
Three-Phase Input (+10/-15%)
380V ac RMS, 50 Hz
or 460V ac RMS, 60 Hz
Notes 1, 2
Interconnect Diagrams
A-9
In the figure below, the 8720MC-RPS regenerative power supply and
Kinetix 6000 (460V) Follower IAM are shown.
Figure A.6
Non-Kinetix 6000 Leader Drive with Single Follower IAM Power Diagram
Publication 2094-IN002E-EN-P — September 2005
A-10
Interconnect Diagrams
In the figure below, a Kinetix 6000 Leader IAM is connected to two
Follower IAMs via the DC common bus.
Figure A.7
Leader IAM with Multiple Follower IAM Diagram
To Follower
DC Bus Connections
To Follower
Control Power
Connections
Kinetix 6000
COMMON BUS LEADER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
Power Rail
Ground Stud
Note 9
Cable Shield
Clamp
Single-Phase Input
95-264V ac RMS
Notes 1, 2
1
2
Control Power
(CPD) Connector
CTRL 2
CTRL 1
4
Note 4
1
2
3
Three-Phase Input from LIM
or input power contactor (M1)
195-264V ac RMS
or 324-528V ac RMS
Notes 1, 2, 7, 8
4
5
6
Motor Power
(MP) Connector
DCDC+
L3
L2
DC Bus
and
3-Phase
Input (IPD)
Connector
L1
W
V
U
MBRK MBRK +
COM
Motor/Resistive
Brake (BC) Connector
PWR
DBRK DBRK +
1
2
CONT ENCONT EN+
3
2
1
Three-Phase
Motor Power
Connections
Note 14
6
5
4
3
2
1
Contactor Enable
(CED) Connector
Note 12
To Follower
Control Circuit
Connections
Wire the Leader and Follower IAM
contactor enable terminals in series
with the safety control string or LIM I/O.
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams
A-11
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
Power Rail
Ground Stud
Note 9
Cable Shield
Clamp
Note 4
1
From Leader
Control Power
Connections
2
Control Power
(CPD) Connector
CTRL 2
CTRL 1
4
Note 4
1
From Leader
DC Bus Connections
2
3
DC Bus Fusing *
Note 2
N.C.
N.C.
N.C.
4
5
6
Motor Power
(MP) Connector
DCDC Bus
and
3-Phase
Input (IPD)
Connector
DC+
L3
L2
L1
W
V
U
MBRK MBRK +
6
5
2
DBRK +
2
1
Three-Phase
Motor Power
Connections
Note 14
3
PWR
DBRK -
1
2
4
COM
Motor/Resistive
Brake (BC) Connector
3
1
Contactor Enable
(CED) Connector
Note 12
CONT ENCONT EN+
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
Power Rail
Ground Stud
Note 9
Cable Shield
Clamp
1
2
1
2
3
DC Bus Fusing *
Note 2
N.C.
N.C.
N.C.
4
5
6
Control Power
(CPD) Connector
CTRL 2
CTRL 1
Motor Power
(MP) Connector
DCDC+
L3
L2
4
DC Bus
and
3-Phase
Input (IPD)
Connector
L1
W
V
U
MBRK MBRK +
COM
Motor/Resistive
Brake (BC) Connector
PWR
DBRK DBRK +
From Leader
Control Circuit
Connections
1
2
CONT ENCONT EN+
3
2
1
Three-Phase
Motor Power
Connections
Note 14
6
5
4
3
2
1
Contactor Enable
(CED) Connector
Note 12
* INDICATES USER SUPPLIED COMPONENT
Publication 2094-IN002E-EN-P — September 2005
A-12
Interconnect Diagrams
In the figure below, a non-Kinetix 6000 leader drive and Kinetix 6000
Follower IAM are shown.
Figure A.8
Non-Kinetix 6000 Leader Drive with Single Follower IAM Power Diagram
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus*
Power Rail
Ground Stud
Non-Kinetix 6000
COMMON BUS LEADER
Note 9
Cable Shield
Clamp
Bonded Cabinet
Ground Bus*
Ground Stud
Single-Phase Input
95-264V ac RMS
Notes 1, 2
DC Bus
Connections
DCDC+
1
2
1
Pre-charge
Circuitry*
2
3
DC Bus Fusing*
N.C.
N.C.
N.C.
4
5
6
Control Power
(CPD) Connector
CTRL 2
CTRL 1
DCDC+
L3
L2
L1
DC Bus
Connections
4
Motor Power
(MP) Connector
W
V
U
Ground
3-Phase
Input (IPD)
Connector
MBRK MBRK +
Three-Phase Input
from LIM or input
power contactor (M1)
Notes 1, 2, 7, 8
L3
Motor/Resistive
Brake (BC) Connector
L2
L1
COM
PWR
DBRK DBRK +
1
2
DRIVE OKDRIVE OK+
Contactor Enable
Wire the Leader and Follower IAM
contactor enable terminals in series
with the safety control string or LIM I/O.
Publication 2094-IN002E-EN-P — September 2005
CONT ENCONT EN+
Contactor Enable
(CED) Connector
Note 12
* INDICATES USER -SUPPLIED COMPONENT
3
2
1
6
5
4
3
2
1
Three-Phase
Motor Power
Connections
Note 14
Interconnect Diagrams
Shunt Module Interconnect
Diagrams
A-13
In the figure below, the Kinetix 6000 Shunt Module is shown wired for
internal shunt operation. This is the factory default jumper setting.
Figure A.9
Internal Shunt Module Interconnect Diagram
Kinetix 6000
SHUNT MODULE
2094-BSP2
External Shunt Resistor
(RC) Connector
COL
INT
DC+
External Thermal Switch
(TS) Connector
TS2
TS1
3
2
1
2
1
In the figure below, the Kinetix 6000 shunt module is shown wired
with an external passive shunt resistor.
IMPORTANT
Only passive shunts with a thermal switch are wired
to the TS connector on the Kinetix 6000 shunt
module. If your external passive shunt does not have
a thermal switch, leave the factory installed jumper
in place on the TS connector.
Figure A.10
External Passive Shunt Module Interconnect Diagram
EXTERNAL PASSIVE
SHUNT RESISTOR
Kinetix 6000
SHUNT MODULE
2094-BSP2
3
External Shunt Resistor
(RC) Connector
COL
INT
DC+
External Thermal Switch
(TS) Connector
TS2
2
TS1
1
2
COL
1
DC+
Resistor
Thermal
Switch
Publication 2094-IN002E-EN-P — September 2005
A-14
Interconnect Diagrams
In the figure below, the Kinetix 6000 IAM (without the LIM) is shown
wired with a Bulletin 1336 external active shunt.
Figure A.11
External Active Shunt Module Interconnect Diagram
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-xCxx-Mxx
1
(–) Slave In
3
(–) Master Out
4
DC Bus
Connections
DC-
1
5
DC+
2
6
3
Three-Phase
Input (IPD)
Connections
L3
4
L2
5
L1
6
Input Fusing*
Note 19
Single-Phase Input
115V ac RMS
50/60 Hz
(+) Slave In
2
TB1
(+) Master Out
(–) DC Bus
(+) DC Bus
1
2
TB3
3
Fault Relay Note 20
4
1336 Master
Shunt chassis
ground screw
Contactor Enable
(CED) Connector
1
CONT EN2
CONT EN+
Refer to Attention statement (Note 11)
CR1*
Note 12
CR1*
M1*
24V ac/dc
or
120V ac
50/60 Hz
CR1*
* INDICATES USER SUPPLIED COMPONENT
START*
STOP*
Notes 7, 12
1336 Active Shunt Input Fuse Specifications
Active Shunt Module
1336-
Description
Input Current
Requirements
Kx005 or Kx010
Input current requirement to power logic for fault
contact operation.
0.05A
KB050
Input current requirement to power fan and logic for
fault contact operation.
0.65A
1336 Active Shunt Fault Relay Specifications
Parameter
Description
120V ac
30V ac
On State Current
Current flow when the contact is closed
0.6A
2.0A
On State Resistance
Contact resistance (maximum)
50 mOhms
50 mOhms
Off State Voltage
Voltage across the contacts when the relay is open
120V ac
30V ac
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams
A-15
In the figure below, the Kinetix 6000 IAM is shown (without a LIM)
wired with a Bulletin 1336 external active shunt (master) and two
slave units.
Figure A.12
External Active Shunt Module Interconnect Diagram
Kinetix 6000
INTEGRATED AXIS MODULE
2094-xCxx-Mxx
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
DC Bus
Connections
DC-
1
DC+
2
(+) Master Out
Note 4
5
6
(–) DC Bus
1
2
3
4
TB1
(+) DC Bus
3
Three-Phase
Input (IPD)
Connections
L3
L2
L1
4
1
5
2
6
3
TB3
Fault Relay Note 20
4
1336 Master
Shunt chassis
ground screw
Contactor Enable
(CED) Connector
Note 12
CONT ENCONT EN+
1
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
2
(+) Slave In
Notes 7, 12
24V ac/dc
or
120V ac
50/60 Hz
(–) Slave In
STOP*
(–) Master Out
START*
CR1*
M1*
(+) Master Out
5
CR1*
6
CR1*
Refer to Attention statement (Note 11)
(–) DC Bus
1
2
3
4
TB1
(+) DC Bus
Note 4
1
2
TB3
3
Fault Relay Note 20
4
1336 Slave
Shunt chassis
ground screw
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
(+) Master Out
5
6
1
Single-Phase Input
115V ac RMS
50/60 Hz
2
Input Fusing*
Note 19
* INDICATES USER SUPPLIED COMPONENT
Note 4
(–) DC Bus
1
2
3
4
TB1
(+) DC Bus
TB3
3
4
Fault Relay Note 20
Shunt chassis
ground screw
1336 Slave
Publication 2094-IN002E-EN-P — September 2005
A-16
Interconnect Diagrams
AM/Motor Interconnect
Diagrams
This section contains the motor power, brake, and feedback signal
interconnect diagrams between an Axis Module and MP-Series,
1326AB, or F-, H-, N-, and Y-Series servo motors.
In the figure below, the Kinetix 6000 axis module (460V) is shown
connected to MP-Series Low Inertia and Integrated Gear (460V)
motors.
Figure A.13
Axis Module to MP-Series (460V) Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
MPL-B and MPG-B (460V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
Motor Feedback
(MF) Connector
4
3
2
1
Green/Yellow
1/Blue
D
2/Black
C
B
3/Brown
A
W
GND
V
Three-Phase
U Motor Power
2090-XXNPMP-xxSxx
Motor Power Cable
Note 14
Motor Feedback
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
2090-UXNBMP-18Sxx Brake Cable
Note 14
6
Black
C
BR-
5
White
A
BR+
4
COM
User Supplied
24V dc (1.2A max.)
3
PWR
DBRK DBRK +
2
BR-
1
BR+
Motor Feedback
(MF) Connector
(IAM/AM)
Motor Brake
Thermostat
Resistive Brake
Connections
A
B
BLACK
WHT/BLACK
C
D
E
F
K
L
N
R
RED
WHT/RED
SIN+
SINCOS+
COS-
GREEN
WHT/GREEN
DATA+
DATA-
GRAY
WHT/GRAY
+5VDC
ECOM
+9VDC
TS+
S
ORANGE
WHT/ORANGE
3
4
5
10
14
6
7
11
Refer to Low Profile Connector
illustration (lower left)
for proper grounding technique.
P
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15, 17
MPL-B (460V) SERVO MOTORS
WITH RESOLVER FEEDBACK
Motor Feedback
(MF) Connector
(IAM/AM)
D
Grounding Technique for
Feedback Cable Shield
1
2
Low Profile Connector
(2090-K6CK-D15M shown)
C
B
W
A
U
V
GND
Three-Phase
Motor Power
A
B
BLACK
WHT/BLACK
S2
S4
1
2
C
D
RED
WHT/RED
S1
S3
3
4
YELLOW
WHT/YELLOW
R1
R2
5
10
R
BLUE
TS+
11
S
WHT/BLUE
TS-
6
Motor Feedback G
H
Clamp
Exposed shield secured
under clamp.
Thermostat
Clamp screws (2)
Turn clamp over to hold
small cables secure.
C
BR-
A
BR+
Motor Brake
Refer to Low Profile Connector
illustration (lower left)
for proper grounding technique.
2090-CDNFDMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams
A-17
In the figure below, the Kinetix 6000 axis module (230V) is shown
connected to MP-Series Low Inertia (MPL) and Integrated Gear (MPG)
230V servo motors.
Figure A.14
Axis Module to MP-Series (230V) Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
MPL-A and MPG-A (230V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
D
1/Blue
2/Black
C
B
3/Brown
A
W
Three-Phase
U Motor Power
2090-XXNPMP-xxSxx
Motor Power Cable
Note 14
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
2090-UXNBMP-18Sxx Brake Cable
Note 14
Black
C
BR-
5
White
A
BR+
User Supplied
24V dc (1.2A max.)
3
PWR
2
DBRK DBRK +
Motor Feedback
6
4
COM
1
BRBR+
Motor Feedback
(MF) Connector
(IAM/AM)
GND
V
Motor Brake
Thermostat
Resistive Brake
Connections
A
B
BLACK
WHT/BLACK
C
D
E
F
K
L
N
R
RED
WHT/RED
S
P
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
1
2
SIN+
SINCOS+
COS-
3
4
DATA+
DATA+5VDC
ECOM
–
TS+
5
10
14
6
7
11
Refer to Low Profile Connector
illustration (lower left)
for proper grounding technique.
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Motor Feedback
(MF) Connector
(IAM/AM)
MPL-A (230V) SERVO MOTORS
WITH INCREMENTAL FEEDBACK
D
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
C
B
W
A
U
V
Clamp
Exposed shield secured
under clamp.
GND
C
D
E
F
Motor Feedback K
L
N
R
Three-Phase
Motor Power
Thermostat
Clamp screws (2)
Turn clamp over to hold
small cables secure.
C
A
BRBR+
A
B
Motor Brake
S
T
U
V
P
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
1
2
AM+
AMBM+
BM-
3
4
IM+
IM+5VDC
ECOM
–
TS+
5
10
14
6
7
11
–
S1
S2
S3
12
13
8
Refer to Low Profile Connector
illustration (lower left)
for proper grounding technique.
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Publication 2094-IN002E-EN-P — September 2005
A-18
Interconnect Diagrams
In the figure below, the Kinetix 6000 axis module is shown connected
to MP-Series Food Grade (MPF) and MP-Series Stainless Steel (MPS)
servo motors.
Figure A.15
Axis Module to MP-Series Food Grade and Stainless Steel Motors
Kinetix 6000
IAM (inverter) or AM
MPF-A or MPS-A (230V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Motor Feedback
(MF) Connector
(IAM/AM)
Shield
Note 9
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
Blue
D/
Black
C/W
B/V
Brown
A/U
W
GND
V Three-Phase
U Motor Power
2090-XXNPMF-xxSxx
Motor Power Cable
Note 14
Motor Feedback
(MF) Connector
Motor
Feedback
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
Thermostat
6
Black
G/-
BR-
5
White
F/+
BR+
4
COM
DBRK DBRK +
2
BR-
1
BR+
BLACK
WHT/BLACK
3
4
RED
WHT/RED
5
6
9
10
11
13
GREEN
WHT/GREEN
ORANGE
WHT/ORANGE
DATA+
DATA+5VDC
ECOM
–
TS+
14
BLUE
TS-
12
COM
GRAY
WHT/GRAY
Motor Brake
User Supplied
24V dc (1.2A max.)
3
PWR
1
2
D/
C/W
B/V
A/U
W
GND
V
Three-Phase
U Motor Power
Motor
Feedback
Clamp
Exposed shield secured
under clamp.
Thermostat
Clamp screws (2)
Turn clamp over to hold
small cables secure.
5
10
14
6
11
2090-XXNFMF-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Resistive Brake
Connections
Low Profile Connector
(2090-K6CK-D15M shown)
3
4
Refer to Low Profile Connector
illustration (lower left)
for proper grounding technique.
Note 18
MPF-B or MPS-B (460V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Grounding Technique for
Feedback Cable Shield
1
2
SIN+
SINCOS+
COS-
G/-
BR-
F/+
BR+
Motor Brake
Note 18
Motor Feedback
(MF) Connector
(IAM/AM)
RED
WHT/RED
3
4
5
6
GREEN
WHT/GREEN
DATA+
DATA-
5
10
9
10
11
13
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
–
ECOM
+9VDC
TS+
6
7
11
14
BLUE
TS-
12
COM
BLACK
WHT/BLACK
Refer to Low Profile Connector
illustration (lower left)
for proper grounding technique.
2090-XXNFMF-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Publication 2094-IN002E-EN-P — September 2005
1
2
SIN+
SINCOS+
COS-
1
2
3
4
Interconnect Diagrams
A-19
In the figure below, the Kinetix 6000 axis module (230V) is shown
connected to TL-Series (230V) servo motors.
Figure A.16
Axis Module to TL-Series (230V) Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
TL-Series (230V) MOTORS
WITH INCREMENTAL FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Motor Feedback
(MF) Connector
(IAM/AM)
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
4
Blue
Black
3
2
Brown
1
W
GND
V
Three-Phase
U Motor Power
2090-XXNPT-16Sxx
Motor Power Cable
Note 14
Motor Feedback
(MF) Connector
Motor Feedback
2090-DANBT-18Sxx
Motor Brake Cable
Note 14
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
COM
PWR
DBRK DBRK +
6
Black
5
White
4
2
BR-
1
BR+
Motor Brake
1
2
BLACK
WHT/BLACK
3
4
RED
WHT/RED
5
10
7
8
GREEN
WHT/GREEN
6
11
15
9
GRAY
WHT/GRAY
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
1
2
AM+
AMBM+
BM-
3
4
IM+
IM+5VDC
ECOM
5
10
14
6
S1
S2
S3
12
13
8
User Supplied
24V dc (1.2A max.)
3
2
BR-
1
BR+
Resistive Brake
Connections
2090-XXNFT-Sxx Feedback Cable
with pre-molded connector
Note 14
Publication 2094-IN002E-EN-P — September 2005
A-20
Interconnect Diagrams
In the figure below, the Kinetix 6000 axis module (460V) is shown
connected to 1326AB-Bxxxx (460V) servo motors.
Figure A.17
Axis Module to 1326AB Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
1326AB (M2L/S2L)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
D
1/Blue
C
B
W
2/Black
3/Brown
A
U
V
Motor Feedback
(MF) Connector
(IAM/AM)
GND
Three-Phase
Motor Power
2090-XXNPMP-xxSxx
Motor Power Cable
Note 14
Motor Feedback
(MF) Connector
Motor Feedback
Motor/Resistive
Brake (BC) Connector
2090-UXNBMP-18Sxx Brake Cable
Note 14
MBRK MBRK +
6
Black
C
BR-
5
White
A
BR+
4
COM
User Supplied
24V dc (1.2A max.)
3
PWR
2
DBRK -
1
DBRK +
BR-
Motor Brake
A
B
BLACK
WHT/BLACK
C
D
E
F
K
L
N
R
RED
WHT/RED
Thermostat
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
3
4
DATA+
DATA–
ECOM
+9VDC–
TS+
5
10
14
6
7
11
S
Resistive Brake
Connections
BR+
GREEN
WHT/GREEN
1
2
SIN+
SINCOS+
COS-
Refer to the
Kinetix 6000 Installation Manual
(publication 2094-IN001) for proper
P
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Note 14, 15
1326AB SERVO MOTORS
WITH RESOLVER FEEDBACK
Kinetix 6000
IAM (inverter) or AM
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1326-CPx1-xxx Motor Power Cable
Note 14
Cable Shield
Clamp
Green/Yellow
Note 9
Motor Power
(MP) Connector
W
V
U
Motor Feedback
(MF) Connector
MBRK MBRK +
COM
PWR
DBRK DBRK +
4
3
2
1
Braided Shield
6
5
8
7
Black
3
T3
Black
2
1
T2
Black
6
B1
Black
4
B2
Black
GND
Three-Phase
T1 Motor Power
Motor Brake
4
3
2
1
User Supplied
24V dc (1.2A max.)
BRResistive Brake
BR+
Connections
Motor/Resistive
Brake (BC) Connector
Motor Feedback
5
9
Motor Feedback
(MF) Connector
(IAM/AM)
G
H
GREEN
BLACK
D
E
A
B
K1
K2
Thermostat
1
1
2
BLACK
RED
S2
S4
S1
S3
3
4
BLACK
WHITE
R1
R2
5
10
1326-CCU-xxx
(flying-lead) Feedback Cable
Note 14
TS+
TS-
16
17
S
Shielded Cable
1
Publication 2094-IN002E-EN-P — September 2005
Wiring the thermal switch on 1326AB (resolver-based) motors requires the use of the Low Profile connector kit
(2090-K6CK-D15MF) and wire extension to the power connector. Pins 16, 17, and S are filtered to prevent noise
transmission back to the drive. Refer to the Kinetix 6000 Installation Manual (publication 2094-IN001) for wiring
instructions and a diagram.
Interconnect Diagrams
A-21
In the figure below, the Kinetix 6000 axis module (230V) is shown
connected to H- and F-Series (230V) servo motors.
Figure A.18
Axis Module to H/F-Series Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
H/F-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
D
1/Blue
2/Black
C
B
3/Brown
A
W
Motor Feedback
(MF) Connector
(IAM/AM)
GND
V
Three-Phase
U Motor Power
2090-XXNPH/HF-xxSxx
Motor Power Cable
Note 14
Motor Feedback
(MF) Connector
9101-0330 Brake Cable Connector Kit
Note 14
MBRK MBRK +
COM
PWR
DBRK DBRK +
Motor/Resistive
Brake (BC) Connector
Motor Feedback
6
Black
B
5
White
A
4
BRBR+
Motor Brake
User Supplied
24V dc (1.2A max.)
3
2
BR-
1
BR+
Resistive Brake
Connections
Thermostat
3
4
IM+
IMTS+
S3
5
10
11
8
GRAY
+5VDC
14
WHT/GRAY
ECOM
6
13
12
VIOLET
S2
S1
–
WHT/VIOLET
TS-
6
BLACK
WHT/BLACK
C
D
E
F
R
P
K
J
L
M
N
T
H
RED
WHT/RED
S
1
2
AM+
AMBM+
BM-
A
B
GREEN
WHT/GREEN
WHT/BROWN
BROWN
BLUE
WHT/BLUE
Refer to Low Profile Connector
illustration (below)
for proper grounding technique.
2090-XXNFHF-Sxx
(flying-lead) Feedback Cable
Note 14, 15
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
Clamp
Exposed shield secured
under clamp.
Clamp screws (2)
Turn clamp over to hold
small cables secure.
Publication 2094-IN002E-EN-P — September 2005
A-22
Interconnect Diagrams
In the figure below, the Kinetix 6000 axis module (230V) is shown
connected to N-Series (230V) servo motors.
Figure A.19
Axis Module to N-Series Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
N-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
1/Blue
E
D
2/Black
C
B
3/Brown
A
N/C
W
Motor Feedback
(MF) Connector
(IAM/AM)
GND
V
Three-Phase
U Motor Power
2090-XXNPN-xxSxx
Motor Power Cable
Note 14
Motor Feedback
(MF) Connector
9101-1698 Brake Cable Connector Kit
Note 14
MBRK MBRK +
COM
PWR
DBRK DBRK +
Motor Feedback
6
Black
B
BR-
5
White
A
BR+
4
C
User Supplied
24V dc (1.2A max.)
3
2
BR-
1
BR+
Motor/Resistive
Brake (BC) Connector
Motor Brake
N/C
Resistive Brake
Connections
Thermostat
3
4
IM+
IMTS+
S3
5
10
11
8
GRAY
+5VDC
14
WHT/GRAY
ECOM
6
13
12
6
BLACK
WHT/BLACK
C
D
E
F
R
V
K
J
L
M
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BROWN
BROWN
U
T
H
BLUE
WHT/BLUE
VIOLET
S2
S1
–
S
WHT/VIOLET
TS-
Refer to Low Profile Connector
illustration (below)
for proper grounding technique.
2090-XXNFN-Sxx
(flying-lead) Feedback Cable
Note 14, 15
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
Clamp
Exposed shield secured
under clamp.
Clamp screws (2)
Turn clamp over to hold
small cables secure.
Publication 2094-IN002E-EN-P — September 2005
1
2
AM+
AMBM+
BM-
A
B
Interconnect Diagrams
A-23
In the figure below, the Kinetix 6000 axis module (230V) is shown
connected to Y-Series (230V) servo motors.
Figure A.20
Axis Module to Y-Series Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Y-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
Note 13
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
W
V
U
Motor Feedback
(MF) Connector
4
3
2
1
Green/Yellow
4
3/Black
2/Black
3
2
1/Black
1
MBRK MBRK +
COM
PWR
DBRK DBRK +
Motor
Feedback
9
BR-
Black
7
BR+
6
5
4
User Supplied
24V dc (1.2A max.)
3
2
BR-
1
BR+
V
Three-Phase
U Motor Power
Black
Motor Feedback
(MF) Connector
(IAM/AM)
GND
Pigtail
2090-XXNPY-xxSxx
Motor Power and Brake Cable
Note 14
Motor/Resistive
Brake (BC) Connector
W
Motor
Brake
9
10
11
12
BLACK
WHT/BLACK
AM+
AM-
1
2
RED
WHT/RED
BM+
BM-
3
4
13
14
Pigtail
15
17
19
–
22
23
24
GREEN
WHT/GREEN
IM+
IMS1
S2
5
10
12
13
S3
–
+5VDC
ECOM
DRAIN
8
WHT/BLUE
BLUE
BROWN
WHT/BROWN
GRAY
WHT/GRAY
14
6
Refer to Low Profile Connector
illustration (below)
for proper grounding technique.
Resistive Brake
Connections
2090-XXNFY-Sxx
(flying-lead) Feedback Cable
Notes 14, 15, 16
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
Clamp
Exposed shield and drain wire
secured under clamp.
Clamp screws (2)
Turn clamp over to hold
small cables secure.
Publication 2094-IN002E-EN-P — September 2005
A-24
Interconnect Diagrams
Controlling a Brake
Example
The relay output of the Kinetix 6000 (MBRK± BC-5 and -6) is suitable
for directly controlling a motor brake, subject to the relay voltage limit
of 30V dc, and the relay current limit as shown in the table below.
Kinetix 6000 IAM/AM
Maximum Brake Current Rating
2094-AC05-Mxx, -AC09-Mxx,
2094-AMP5, -AM01, -AM02
1.0A
2094-BC01-Mxx, -BC02-Mxx,
2094-BMP5, -BM01, -BM02
2094-AC16-Mxx, -AC32-Mxx,
2094-AM03, -AM05
1.3A
2094-BC04-Mxx, -BC07-Mxx,
2094-BM03, -BM05
3.0A
IMPORTANT
For brake requirements outside of these limits, an
external relay must be used (refer to Figure A.21 for
an example).
The following tables list Allen-Bradley motors and brake coil current
ratings.
Coil Currents Rated at < 1.0A
Compatible Brake Motors
F-4030, -4050, and -4075
Coil Currents Rated at < 1.0A
Coil Current
Compatible Brake Motors
0.69A
MPL/MPF/MPS-x310, -x320, -x330 1
Coil Current
0.50A
1
H-3007 and -3016
0.60A
MPL-x420, -x430, -x4520, -x4530, -x4540
H-4030, -4050, and -4075
0.69A
MPF-x430, -x4530, -x4540 1
N-2302, and -2304
0.28A
MPG-x004 1
N-3406, -3412, -4214, and -4220
0.36A
MPG-x010 1
N-5630, -5637, and -5647
0.71A
MPG-x025 1
Y-1002 and -1003
0.26A
MPG-x050 1
0.50A
Y-2006 and -2012
0.31A
MPG-x110 1
1.0A
Y-3023
0.37A
TL-A110P-H, -A120P-H, and -A130P-H
0.208A
TL-A220P-H and -A230P-H
0.375A
1326AB-B4xxx
0.88A
TL-A2530P-H and -A2540P-H
0.396A
TL-A410P-H
0.746A
1
Publication 2094-IN002E-EN-P — September 2005
Applies to 230V and 460V motors.
0.64A
0.33A
0.45A
Interconnect Diagrams
Coil Currents Rated > 1.0A and ≤1.3A
Compatible Brake Motors
F-6100, -6200, and -6300
H-6100, -6200, and -6300
A-25
Coil Currents Rated > 1.0A and ≤1.3A
Coil Current
Compatible Brake Motors
1.30A
MPL-x520, -x540, -x560, -x580 1
Coil Current
1.05 to 1.28A
MPF-B540
1.13A
1326AB-B5xxx, and -B7xxx
1.20A
1Applies to 230V and 460V motors.
Coil Currents Rated > 1.3A and ≤3.0A
Coil Currents Rated > 1.3A and ≤3.0A
Compatible Brake Motors
Coil Current
Compatible Brake Motors
Coil Current
H-8350 and -8500
2.20A
MPL-B640, -B660, -B680, -B860, -B880,
-B960, -B980
1.91 to 2.19A
Figure A.21 shows an example configuration using MBRK± and an
external relay to control a motor brake which exceeds the drive (IAM/
AM) internal relay rating.
Figure A.21
Example Configuration Controlling a Motor Brake
Kinetix 6000
IAM (inverter) or AM
Note 13
MBRK MBRK +
CR1
5
4
COM
User Supplied
24V dc (3.0A max.)
3
PWR
DBRK DBRK +
Motor/Resistive 1
Brake (BC) Connector
6
2
1
BRCR1
BR+
Brake
Feedback
SERVO
MOTOR
Power
1
For Motor/Resistive Brake (BC) connector specifications, refer to the Kinetix 6000 Installation Manual (publication
2094-IN001).
ATTENTION
To avoid damage to the brake contactor, surge
suppression (flyback diode or MOV, rated at
appropriate voltage), must be used when controlling
a brake coil.
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
CAN (2)
GSHUNT (2)
CTRL 2
CTRL 1
DC-
SMPS
+/-12V (Control)
+24V (Customer I/O)
+9V, +5V (Motor Feedback)
Common Mode
Choke
(460V only)
FUSE_OK
PWR
MBRK
U
Inverter Section
V
Three-Phase Motor Output
W
Shunt Circuit
(460V only)
Motor Shield
System Block Diagrams
CONV_ID (5)
SYSOK
POWER
RAIL
DC+
DBRK
Motor/Resistive Brake Connections
A-26
Interconnect Diagrams
This section provides block diagrams of the Kinetix 6000 modules.
IAM/AM Inverter Block Diagram
Figure A.22
Inverter Block Diagram
DROK/
CONT_EN
Control Power
AC Input
L3
L2
L1
Three-Phase
AC Input
CONT_EN2
CONT_EN1
CTRL2
CTRL1
EMC Filter1
Vcc
95C
Rectifier Circuit 2
CONV_OT
L2
DCL2
DC-
DC+
DC Link
Inductor 3
L1
DCL1
4
3
2
1
Control Power
Loss Detector
120K
Shunt Circuit 2
Ground jumper shown in factory default position (grounded
facility power).
Internal DC link inductor present on 460V converters.
Connectors for external DC link inductor present on 230V
converters.
Rectifier and shunt circuits present only on 230V converters.
EMC filter present only on 460V converters.
Chassis
Ground Jumper 4
Gnd Flt CT
Common Bus
Power Connections
DC-
DC+
Vsns
GSHUNT
SYS_OK
CTRL+
CTRL-
DC-
CHASSIS
DC+
POWER
RAIL
Interconnect Diagrams
A-27
IAM Converter Block Diagram
Figure A.23
Converter Block Diagram
Publication 2094-IN002E-EN-P — September 2005
A-28
Interconnect Diagrams
Safe-Off Feature Block Diagram
The Kinetix 6000 Safe-Off drives ship with the wiring header and
motion allowed jumper installed, as shown in the figure below. With
the motion allowed jumper installed, the safe-off feature is not used.
Figure A.24
Safe-Off Feature Block Diagram
Safe-Off Option
Safe-Off (SO)
9-pin Connector
8
9
+24V
+24V_COM
3
4
FDBK1+
FDBK1-
7
ENABLE1+
6
ENABLE-
Gate Control
Power Supply
K1-C
K1-A
K1
5
ENABLE2+
1
2
FDBK2+
FDBK2-
Safety Monitor
uC
K2
Gate Control
Circuit (CCP)
K2-A
K2-C
Motion Allowed Jumper
(2090-XNSS-MA)
Wiring Header
(2090-XNSS-WP)
Gate Control
Enable Signal
+24V
DRIVE ENABLE
+24V_COM
M
SM Block Diagram
Figure A.25
Shunt Module Block Diagram
DC+
POWER
RAIL
Internal
or External
Shunt
Resistor
DC-
SYSOK
Shunt Circuit
CTRL 1
SMPS
CTRL 2
+5V (Control)
+/-15V (IGBT)
24V (Control)
GSHUNT (2)
Chassis
Publication 2094-IN002E-EN-P — September 2005
IPL
OPL
4
3
2
1
4
3
2
1
L1
L1
L2
L2
1
CB1
CR1
2
4
6
N/C
12 22 32 42
54
A2
L3
4
Pin 1
Pin 2
Pin 3
Pin 4
PE
L3
L2
L1
ALRM_COM
L2
IPL: VAC LINE
L1
3
PE
L3'
L2'
L1'
2
1
IPL
Pin 1
Pin 2
Pin 3
Pin 4
AL
1c
140U
B
2
4
1
3
FB1
4
3
ALRM_M
2
CB 3
3
ALRM_B
1
M
4
6
5
2
3
1
5
L1
L2
L3
N
1
2
3
4
6
7
8
9
10
L1'
L2'
L3'
N'
PE
Three Phase, 1-Stage
Line Filter (460VAC)
4
3
12
1
LF 2
CB 2
14
2
11
53
ALRM_M
ALRM_COM
ALRM_B
N/C
11 21 31 41
COIL_A2
A1
CONSTAT_54
L1'
4
OPL: VAC LOAD
CONSTAT_32
L2'
3
LF 1
COIL_E2
COIL_E1
PE
L1
L2
1
2
3
4
5
L1'
L2'
PE
20A Power Supply
PS1
AUX1_L1 and AUX2_L1
AUX1_L2 and AUX2_L2
L1
L2
Single Phase, 1-Stage
Line Filter (230VAC)
CONSTAT_53
CONSTAT_31
CONSTAT_21
CONSTAT_11
A1
100-JE
E2
E1
COIL_A2
CONSTAT_22
CONSTAT_12
L3'
2
1
OPL
Interface PCB
24+
2424+
24-
IO_PWR1
IO_COM1
IO_PWR2
IO_COM2
CTRL1
CTRL2
ALRM_M
COIL_E2
CONSTAT_54
CONSTAT_32
CONSTAT_22
CONSTAT_12
ALRM_COM
ALRM_B
COIL_E1
CONSTAT_53
CONSTAT_31
CONSTAT_21
CONSTAT_11
6
5
4
3
2
1
P1L
CPL
2
1
4
3
2
1
P2L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
IOL
24V Status LED
Interface PCB
1
2
3
4
5
6
P1L
1
2
CPL
1
2
3
4
P2L
21
1
IOL
20
2
IO_PWR1
IO_COM1
IO_PWR1
IO_COM1
IO_PWR1
IO_COM1
COIL_E1
COIL_E2
ALRM_M
SHIELD
ALRM_B
ALRM_COM
CONSTAT_11
CONSTAT_12
CONSTAT_21
CONSTAT_22
CONSTAT_31
CONSTAT_32
CONSTAT_53
CONSTAT_54
SHIELD
AUX1_L2
AUX1_L1
AUX2_L2
AUX2_L1
CTRL 2
CTRL 1
Pin 6
Pin 5
Pin 4
Pin 3
Pin 2
Pin 1
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
P1L: BRAKE AND I/O OUTPUT
Pin 2
Pin 1
CPL: CONTROL PWR OUTPUT
Pin 4
Pin 3
Pin 2
Pin 1
P2L: AUXILIARY PWR OUTPUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
Pin 16
Pin 17
Pin 18
Pin 19
Pin 20
Pin 21
IOL: STATUS I/O
Interconnect Diagrams
A-29
LIM Block Diagrams
Figure A.26
LIM Block Diagram (2094-AL75S)
Publication 2094-IN002E-EN-P — September 2005
IPL
OPL
Publication 2094-IN002E-EN-P — September 2005
4
3
2
1
4
3
2
1
PE
L3'
L2'
L1'
L3
L1
L1
L2
L2
1
CB1
CR1
2
4
6
N/C
12 22 32 42
54
A2
Pin 1
Pin 2
Pin 3
Pin 4
IPL: VAC LINE
4
3
2
1
IPL
Pin 1
Pin 2
Pin 3
Pin 4
PE
L3
L2
L1
ALRM_COM
L3
L2
L1
2
4
1
3
FB1
AL
1c
5
3
140U
B
ALRM_M
TX1
2
4
6
1
3
5
CB 3
3
ALRM_B
460V :: 230V
750VA
M
6
4
2
1
5
L1
L2
L3
N
1
2
3
4
6
7
8
9
10
L1'
L2'
L3'
N'
PE
Three Phase, 1-Stage
Line Filter (460VAC)
4
3
12
1
LF 2
CB 2
14
2
11
53
ALRM_M
ALRM_COM
ALRM_B
N/C
11 21 31 41
COIL_A2
A1
CONSTAT_54
L1'
4
OPL: VAC LOAD
CONSTAT_32
L2'
3
LF 1
COIL_E2
COIL_E1
1
2
3
4
5
L1'
L2'
PE
L1
L2
L3
PE
20A Power Supply
PS1
AUX1_L1 and AUX2_L1
AUX1_L2 and AUX2_L2
L1
L2
Single Phase, 1-Stage
Line Filter (230VAC)
CONSTAT_53
CONSTAT_31
CONSTAT_21
CONSTAT_11
A1
100-JE
E2
E1
COIL_A2
CONSTAT_22
CONSTAT_12
L3'
2
1
OPL
Interface PCB
24+
2424+
24-
IO_PWR1
IO_COM1
IO_PWR2
IO_COM2
CTRL1
CTRL2
ALRM_M
COIL_E2
CONSTAT_54
CONSTAT_32
CONSTAT_22
CONSTAT_12
ALRM_COM
ALRM_B
COIL_E1
CONSTAT_53
CONSTAT_31
CONSTAT_21
CONSTAT_11
6
5
4
3
2
1
P1L
CPL
2
1
4
3
2
1
P2L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
IOL
24V Status LED
Interface PCB
1
2
3
4
5
6
P1L
1
2
CPL
1
2
3
4
P2L
21
1
IOL
20
2
IO_PWR1
IO_COM1
IO_PWR1
IO_COM1
IO_PWR1
IO_COM1
COIL_E1
COIL_E2
ALRM_M
SHIELD
ALRM_B
ALRM_COM
CONSTAT_11
CONSTAT_12
CONSTAT_21
CONSTAT_22
CONSTAT_31
CONSTAT_32
CONSTAT_53
CONSTAT_54
SHIELD
AUX1_L2
AUX1_L1
AUX2_L2
AUX2_L1
CTRL 2
CTRL 1
Pin 6
Pin 5
Pin 4
Pin 3
Pin 2
Pin 1
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
P1L: BRAKE AND I/O OUTPUT
Pin 2
Pin 1
CPL: CONTROL PWR OUTPUT
Pin 4
Pin 3
Pin 2
Pin 1
P2L: AUXILIARY PWR OUTPUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
Pin 16
Pin 17
Pin 18
Pin 19
Pin 20
Pin 21
IOL: STATUS I/O
A-30
Interconnect Diagrams
Figure A.27
LIM Block Diagram (2094-BL75S)
APL
IPL
OPL
1
2
4
3
2
1
4
3
2
1
PE
L3'
L2'
L1'
1
1
CB1
CR1
2
4
6
N/C
12 22 32 42
54
A2
PE
L3
L2
L1
APL: AUXILIARY PWR INPUT
Pin 2
L2/N
Pin 1
L1
1
2
APL
Pin 1
Pin 2
Pin 3
Pin 4
L1
L1
L2/N
L2/N
ALRM_COM
L3
4
IPL: VAC LINE
L2
L1
3
2
1
IPL
Pin 1
Pin 2
Pin 3
Pin 4
AL
1c
5
3
3
FB1
4
2
140U
B
4
6
3
5
ALRM_M
2
CB 3
3
ALRM_B
1
M
6
4
2
1
5
53
L1
L2
L3
N
1
2
3
4
6
7
8
9
10
L1'
L2'
L3'
N'
PE
Three Phase, 1-Stage
Line Filter (460VAC)
4
3
12
1
LF 2
CB 2
14
2
11
ALRM_M
ALRM_COM
ALRM_B
N/C
11 21 31 41
COIL_A2
A1
LF 1
1
2
3
4
5
L1'
L2'
PE
PE
L1
L2
20A Power Supply
PS1
AUX1_L1 and AUX2_L1
AUX1_L2 and AUX2_L2
L1
L2
Single Phase, 1-Stage
Line Filter (230VAC)
CONSTAT_53
CONSTAT_31
CONSTAT_21
CONSTAT_11
A1
100-JE
E2
E1
COIL_E2
COIL_E1
CONSTAT_54
L1'
4
OPL: VAC LOAD
CONSTAT_32
L2'
3
COIL_A2
CONSTAT_22
CONSTAT_12
L3'
2
1
OPL
Interface PCB
24+
2424+
24-
IO_PWR1
IO_COM1
IO_PWR2
IO_COM2
CTRL1
CTRL2
ALRM_M
COIL_E2
CONSTAT_54
CONSTAT_32
CONSTAT_22
CONSTAT_12
ALRM_COM
ALRM_B
COIL_E1
CONSTAT_53
CONSTAT_31
CONSTAT_21
CONSTAT_11
6
5
4
3
2
1
P1L
CPL
2
1
4
3
2
1
P2L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
IOL
24V Status LED
Interface PCB
1
2
3
4
5
6
P1L
1
2
CPL
1
2
3
4
P2L
21
1
IOL
20
2
IO_PWR1
IO_COM1
IO_PWR1
IO_COM1
IO_PWR1
IO_COM1
COIL_E1
COIL_E2
ALRM_M
SHIELD
ALRM_B
ALRM_COM
CONSTAT_11
CONSTAT_12
CONSTAT_21
CONSTAT_22
CONSTAT_31
CONSTAT_32
CONSTAT_53
CONSTAT_54
SHIELD
AUX1_L2
AUX1_L1
AUX2_L2
AUX2_L1
CTRL 2
CTRL 1
Pin 6
Pin 5
Pin 4
Pin 3
Pin 2
Pin 1
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
P1L: BRAKE AND I/O OUTPUT
Pin 2
Pin 1
CPL: CONTROL PWR OUTPUT
Pin 4
Pin 3
Pin 2
Pin 1
P2L: AUXILIARY PWR OUTPUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
Pin 16
Pin 17
Pin 18
Pin 19
Pin 20
Pin 21
IOL: STATUS I/O
Interconnect Diagrams
A-31
Figure A.28
LIM Block Diagram (2094-XL75S-Cx)
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
IPL
OPL
1
2
3
4
1
2
3
4
PE
L3'
L2'
L1'
Pin 1
Pin 2
Pin 3
Pin 4
PE
L3
L2
L1
IPL: VAC LINE INPUT
Pin 4
Pin 3
Pin 2
Pin 1
OPL: VAC LOAD OUTPUT
L3_IN
L2_IN
L1_IN
6
5
L3
L2
L1
LF2
L2'
L2
PE
1
3
1
3
4
CB3
5
6
4
3
2
31
32
2
CB2
CB2_AUX
21
22
1
4
2
1
11
12
41
42
PE
L2
L1
PE
L2
L1
CONSTAT_11
CONSTAT_21
CONSTAT_31
PS1
2A Power Supply
PS2
6A Power Supply
D1
COIL_A1
CONSTAT_41
A1
A2
24-
24+
24-
24+
IO_PWR
MBRK_COM
MBRK_PWR
IO_COM
L1
L2/N
COIL_A2
COIL_A1
IO_PWR
IO_COM
CONSTAT_42
CONSTAT_41
CONSTAT_32
CONSTAT_31
CONSTAT_22
CONSTAT_21
CONSTAT_12
CONSTAT_11
2
1
CPL
4
3
2
1
PSL
19
PE
L1'
L1
LF1
L3'
L2'
L1'
Three Phase, 1-Stage
Line Filter (460VAC)
CR1
2
COIL_A2
IOL
MBRK_PWR
MBRK_COM
MBRK_PWR
MBRK_COM
Pin 1
Pin 2
L2/N
L1
CPL: CONTROL POWER
Pin 1
Pin 2
Pin 3
Pin 4
PSL: I/O 24V DC OUTPUT
IOL: STATUS I/O
Pin 1
N/C
Pin 2
N/C
Pin 3
N/C
Pin 4
COIL_A2
Pin 5
N/C
Pin 6
CONSTAT_12
Pin 7
CONSTAT_22
Pin 8
CONSTAT_32
Pin 9
CONSTAT_42
Pin 10
N/C
Pin 11
N/C
Pin 12
N/C
Pin 13
COIL_A1
Pin 14
N/C
Pin 15 CONSTAT_11
Pin 16 CONSTAT_21
Pin 17 CONSTAT_31
Pin 18 CONSTAT_41
Pin 19
N/C
Pin 20
IO_COM
Pin 21
IO_COM
Pin 22
IO_COM
Pin 23
N/C
Pin 24
IO_PWR
Pin 25
IO_PWR
Pin 26
IO_PWR
24V Status LEDs
9
18
26
Single-Phase, 1-Stage
Line Filter (230VAC)
4
3
CB1
2
1
L1_OUT
L2_OUT
L3_OUT
CONSTAT_42
CONSTAT_32
CONSTAT_22
CONSTAT_12
A-32
Interconnect Diagrams
Figure A.29
LIM Block Diagram (2094-AL09)
1
10
IPL
OPL
4
3
2
1
4
3
2
1
PE
L3'
L2'
L1'
Pin 4
Pin 3
Pin 2
Pin 1
L3_IN
L2_IN
L1_IN
6
5
L2
L1
LF2
CR1
100S-C85
L3
L2
L1
PE
1
2
3
1
3
4
CB3
5
6
4
3
2
31
32
2
CB2
CB2_AUX
21
22
1
4
2
1
11
12
41
42
PE
L2
L1
PE
L2
L1
CONSTAT_11
CONSTAT_21
CONSTAT_31
PS1
2A Power Supply
PS2
6A Power Supply
D1
COIL_A1
CONSTAT_41
A1
A2
COIL_A2
24-
24+
24-
24+
IO_PWR
MBRK_COM
MBRK_PWR
IO_COM
L1
L2/N
COIL_A2
COIL_A1
IO_PWR
IO_COM
CONSTAT_42
CONSTAT_41
CONSTAT_32
CONSTAT_31
CONSTAT_22
CONSTAT_21
CONSTAT_12
CONSTAT_11
PSL
2
1
CPL
4
3
2
1
IOL
MBRK_PWR
MBRK_COM
MBRK_PWR
MBRK_COM
Pin 1
Pin 2
L2/N
L1
CPL: CONTROL POWER
Pin 1
Pin 2
Pin 3
Pin 4
PSL: I/O 24V DC OUTPUT
IOL: STATUS I/O
Pin 1
N/C
Pin 2
N/C
Pin 3
N/C
Pin 4
COIL_A2
Pin 5
N/C
Pin 6
CONSTAT_12
Pin 7
CONSTAT_22
Pin 8
CONSTAT_32
Pin 9
CONSTAT_42
Pin 10
N/C
Pin 11
N/C
Pin 12
N/C
Pin 13
COIL_A1
Pin 14
N/C
Pin 15 CONSTAT_11
Pin 16 CONSTAT_21
Pin 17 CONSTAT_31
Pin 18 CONSTAT_41
Pin 19
N/C
Pin 20
IO_COM
Pin 21
IO_COM
Pin 22
IO_COM
Pin 23
N/C
Pin 24
IO_PWR
Pin 25
IO_PWR
Pin 26
IO_PWR
24V Status LEDs
19
PE
L2'
L1'
LF1
L3'
L2'
L1'
Three Phase, 1-Stage
Line Filter (460VAC)
Single-Phase, 1-Stage
Line Filter (230VAC)
4
3
CB1
2
1
L1_OUT
L2_OUT
L3_OUT
CONSTAT_42
CONSTAT_32
CONSTAT_22
CONSTAT_12
9
18
26
TX1
460V to 230V
750VA XFMR
PE
L3
L2
L1
IPL: VAC LINE INPUT
Pin 1
Pin 2
Pin 3
Pin 4
OPL: VAC LOAD OUTPUT
Interconnect Diagrams
A-33
Figure A.30
LIM Block Diagram (2094-BL02)
1
10
Publication 2094-IN002E-EN-P — September 2005
GROUND
W DRIVE
V DRIVE
U DRIVE
Drive Connections
(TB1) Connector
4
3
2
1
R1
R2
R3
W BRAKE
V BRAKE
U BRAKE
Publication 2094-IN002E-EN-P — September 2005
T1 (fault)
A2
12
22
32
42
11
21
31
41
A1
2
4
6
CR1
1
3
5
D1
T2 (warning)
RBM Enclosure
Interface PCB
5
6
7
8
1
2
3
4
4
3
2
1
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
SHIELD
I/O Connections
(TB3) Connector
24V Status LED
GROUND
W MTR
V MTR
U MTR
Motor Connections
(TB2) Connector
A-34
Interconnect Diagrams
RBM Block Diagrams
Figure A.31
RBM Block Diagram (2090-XB33-xx)
GROUND
W DRIVE
V DRIVE
U DRIVE
Drive Connections
(TB1) Connector
4
3
2
1
R1
R2
R3
W BRAKE
V BRAKE
U BRAKE
T1 (fault)
DC Interface Module
E1
A1
E2
2
4
6
12
22
32
42
54
A2
11
21
31
41
N/C 53
A1
CR1
1
3
5
N/C
T2 (warning)
RBM Enclosure
Interface PCB
5
6
7
8
1
2
3
4
4
3
2
1
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
SHIELD
I/O Connections
(TB3) Connector
24V Status LED
230V Status LED
GROUND
W MTR
V MTR
U MTR
Motor Connections
(TB2) Connector
Interconnect Diagrams
A-35
Figure A.32
RBM Block Diagram (2090-XB120-xx)
Publication 2094-IN002E-EN-P — September 2005
A-36
Interconnect Diagrams
Publication 2094-IN002E-EN-P — September 2005
Appendix
B
Upgrade Your Kinetix 6000 Firmware
Chapter Objectives
This appendix provides a procedure for upgrading the Kinetix 6000
firmware using DriveExplorer.
Upgrade Drive Firmware
Using DriveExplorer
Upgrading axis module firmware using DriveExplorer (via the DPI
port) involves setting the Axes to Flash parameter, configuring a
HyperTerminal session, and flashing the firmware.
Before You Begin
Before you begin this procedure, make sure you have the following:
Description
Catalog Numbers
Minimum Firmware
Revision
DriveExplorer Software 1
9306-4EXP02ENE
2.01
Smart Self-Powered (DPI) Serial Converter 1203-SSS (Series B)
3.004
Firmware upgrade file for Kinetix 6000
N/A 2
N/A 2
Personal computer with HyperTerminal
N/A
N/A
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Contact Rockwell Automation Technical Support at (440) 646-5800 for firmware upgrade file.
Select Axis Modules to Upgrade
In this procedure you will use DriveExplorer software to set the Axes
to Flash parameter (x708) and allow selective axis module upgrading.
Note: You will save time by selecting only the axis module(s) that
require a firmware upgrade.
1
Publication 2094-IN002E-EN-P — September 2005
B-2
Upgrade Your Kinetix 6000 Firmware
To set the Axes to Flash parameter:
1. Apply 95-264V AC to the IAM control power (CPD) connector.
ATTENTION
To avoid injury or damage to equipment due to
unpredictable motor activity, do not apply AC
input (three-phase) power or establish
communications with the 1756-MxxSE SERCOS
interface module.
2. Connect the 1203-SSS serial cable to the appropriate COM port on
your personal computer.
3. Connect the 1203-SSS DPI cable to the DPI connector on your
IAM.
4. Verify that the 1203-SSS has power by observing the LED indicated
in Figure B.1.
Figure B.1
1203-SSS DPI Adapter
DPI communication
5. Start the DriveExplorer software. Click on Explore\Connect.
DriveExplorer proceeds to read your system.
Publication 2094-IN002E-EN-P — September 2005
Upgrade Your Kinetix 6000 Firmware
B-3
6. Double-click on 2094D SERVO Config 0000. The linear list of
parameters appears, as shown in the window below.
Linear List Legend
N: P. x xxx
Parameter Number
30 = Version Data
Axis Number
0 = IAM (axis 1)
1 = AM (axis 2)
2 = AM (axis 3)
3 = AM (axis 4)
DPI Port Number
Network Node Number
7. Scroll down to parameter x:x.30 (Version Data) and record the
version (VERS: xx.xxx) of each axis module.
8. Double-click on Configuration. The following window opens.
9. Double-click on Axes to Flash. The Axis to Flash window opens.
10. Check each axis to flash (example above shows two axes to flash).
11. Select OK. The Axes to Flash parameter is set.
12. Close DriveExplorer.
Publication 2094-IN002E-EN-P — September 2005
B-4
Upgrade Your Kinetix 6000 Firmware
HyperTerminal Configuration
To open and begin a new HyperTerminal session:
1. From the Windows Start menu, select Programs\Accessories\
HyperTerminal\HyperTerminal. The New Connection window
opens.
•
Name the new HyperTerminal file
•
Choose an icon for the connection
2. Select OK. The following window opens.
Select the appropriate COM port
3. Select OK. The following window opens. Select the following
properties as shown or as appropriate for your 1203-SSS DPI
adapter.
IMPORTANT
Publication 2094-IN002E-EN-P — September 2005
Bits per second of HyperTerminal must match
the 1203-SSS DPI adapter setting for connection
to occur.
Upgrade Your Kinetix 6000 Firmware
B-5
4. Select OK. HyperTerminal configuration is complete.
Flash Your Firmware
This procedure assumes you have identified which axis module(s)
require flashing, have set the Axes to Flash parameter, and have
configured a HyperTerminal session.
IMPORTANT
You must also know where to find your firmware
upgrade file.
1. Press ENTER. The HyperTerminal main menu opens.
Publication 2094-IN002E-EN-P — September 2005
B-6
Upgrade Your Kinetix 6000 Firmware
2. Enter 3. The following window opens.
3. Enter 0. The following window opens.
4. Enter Y. As indicated in the text, the program begins displaying
the character C.
Note: Program times-out after 60 seconds. If program times-out
before you complete steps 5 - 7, return to step 1.
5. Go to the Transfer menu and select Send File. The Send File
window opens. Browse for your firmware upgrade file.
Firmware upgrade file, as provided by Rockwell
Automation Technical Support at (440) 646-5800.
Publication 2094-IN002E-EN-P — September 2005
Upgrade Your Kinetix 6000 Firmware
B-7
6. Select Xmodem protocol.
7. Select Send. The flash upgrade operation begins and the
following window opens.
ATTENTION
To avoid unrecoverable fault to modules, do not
interrupt control power to IAM, power to the
1203-SSS DPI adapter, or power to your PC while
the flash upgrade operation is in progress.
8. The flash operation completes and the following window opens.
9. Close the HyperTerminal session.
10. Verify that parameter 30 for each axis module is now upgraded to
the new firmware revision. Return to DriveExplorer (refer to Select
Axis Modules to Upgrade, step 6) to see the linear list of
parameters.
Publication 2094-IN002E-EN-P — September 2005
B-8
Upgrade Your Kinetix 6000 Firmware
Publication 2094-IN002E-EN-P — September 2005
Appendix
C
Integrate Resistive Brake Modules
with Kinetix 6000 Drives
Chapter Objectives
This appendix provides Bulletin 2090 Resistive Brake Module (RBM)
integration procedures specific to the Allen-Bradley Kinetix 6000
multi-axis servo drive systems using drive firmware v1.071 (or above).
The procedure involves setting the time delay parameter using
RSLogix 5000.
Before You Begin
These procedures assume you have mounted and wired your RBM
with your Kinetix 6000 drive system. The following publications are
available to assist you with RBM installation:
1
Title
Publication Number
Kinetix 6000 Installation Manual
2094-IN001
Resistive Brake Module Installation Instructions
2090-IN009
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C-2
Integrate Resistive Brake Modules with Kinetix 6000 Drives
Understand Safety
Precautions
The following precautions apply to resistive brake module installation
as shown in the interconnect diagrams. Be sure to read and
thoroughly understand them before proceeding.
ATTENTION
The interconnection diagrams should be used as a
general recommendation on how the safety control
circuit may be implemented. Actual applications may
vary due to requirements based on the machine
builders risk assessment. The machine builder must
perform a risk assessment and determine a category
level of safety that must be applied to the machine.
Safety Standards for Reference
Publication 2094-IN002E-EN-P — September 2005
•
EN 1050 Safety of Machinery - Principles for Risk Assessment
•
EN 60204-1 Safety of Machinery - Electrical Equipment of
Machines
•
EN 292-1/2 Safety of Machinery - Basic Concepts, General
Principles for Design
•
EN 954-1 Safety of Machinery - Safety Related Parts of Control
Systems
•
NFPA 79 Electrical Standard for Industrial Machinery
•
ANSI B11.TR3 Risk Assessment and Risk Reduction. A guide to
estimate, evaluate, and reduce risks associated with machine tools.
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-3
Background on Safety Design
There are numerous safety standards regarding machine design
including OSHA, NFPA, AMT, CENELEC and ISO. In Europe, CENELEC
and ISO coordinate the development of standards to which products
can satisfy the laws of the Machinery Directive. In the United States,
Standard Development Organizations (SDO) like the NFPA and AMT
sponsor the development of standards to help companies meet OSHA
requirements.
Stop Categories
One of the most basic safety functions is stopping the machine. The
stopping function of a machine must fall into one of three categories
(EN60204-1 and NFPA79). The categories are as follows:
•
Stop Category 0: Stopping by immediate removal of power to the
machine actuators.
•
Stop Category 1: A controlled stop with power to the machine
actuators to achieve the stop and then removal of power when the
stop is achieved.
•
Stop Category 2: A controlled stop with power left available to
the machine actuators.
E-Stops are a special case of stops, and have additional requirements
to those stated above. This appendix is intended to show how a light
curtain or gate interlock might interface with one axis of motion
control to achieve a machine stop and this stop may not be the same
as the E-stop function of a machine.
Publication 2094-IN002E-EN-P — September 2005
C-4
Integrate Resistive Brake Modules with Kinetix 6000 Drives
Risk Assessment
The European safety standard (EN 1050) and U.S. technical report
(ANSI B11.TR3) explain the process of risk assessment, which must be
conducted by the machine builder. This is done by analyzing the tasks
that people perform on and around the machine. This includes
functions such as operation, set up, and maintenance. For the purpose
of this appendix, the light curtain or gate interlock is intended to focus
on the operation and perhaps loading/unloading of a machine.
Additional protective measures must be identified by the risk
assessment.
Machinery Directive EN 954-1 Safety Related Parts of Control Systems
defines how to determine the safety requirements by categorizing the
risk. This standard outlines the design of fail-safe control circuits by
categorizing five levels of risk. It is deemed the machine designers
responsibility to objectively identify a risk level for a particular
machine and design all safety related systems to that level. The five
categories are as follows:
Category B: Safety devices and control systems, as a minimum, must
be designed, selected, and assembled to meet the operational
requirements of design limits and influence of the processed materials
and other external influences listed as: effects of vibration, loss of
power supply, and external fields.
Category 1: All conditions of Category B apply, but the safety related
part of the control system must use well tried principles and
components (refer to 7.2.2: prEN951-1). The use of single electronic
components, electronic logic or software is not considered adequate,
even at this level.
Category 2: All conditions of Category B apply, but in addition, the
machine shall be prevented from starting if a fault is detected upon
power up. This suggests the use of an interface relay with redundancy
and self-checking on energization. Single channel operation is
permitted providing that the input devices (E-Stop buttons, gate
switches, etc.) are tested for operation on a regular basis. If regular
testing cannot be guaranteed, then the designer has little choice but to
opt for two channel control.
Category 3: All conditions of Category B apply, but the complete
safety control system shall be designed so that any single fault shall
not lead to the loss of the safety function and, where practical, the
single fault shall be detected. This now calls for not only redundancy
in the interface relay but also in the input devices pointing to dual
channel systems.
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Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-5
Category 4: All the conditions of Category B apply and, in addition,
any single fault must be detected at or before the next call on the
safety system, or an accumulation of three faults shall not lead to the
loss of the safety function.
Control Reliability
In the United States the AMT has promoted a concept called Control
Reliability as part of the ANSI B11.TR3 standard. This standard has
similar requirements to those in the Machinery Directive EN954-1
Category 3 risk standard.
Control Reliability is defined as the ability of a safety system to go into
a safe state in the event of a failure. In other words, the safety system
must bring the machine to a safe state in the event of a single fault.
Resistive Brake Module
Interconnect Diagram
Notes
This section provides interconnect diagrams to assist you in wiring a
Kinetix 6000 system which includes an RBM. The notes in the table
below apply to the following example RBM interconnect diagrams.
ATTENTION
The National Electrical Code and local electrical
codes take precedence over the values and
methods provided. Implementation of these
codes is the responsibility of the machine
builder.
Note
Information
1
Cable shield clamp must be used in order to meet CE requirements. No external connection to ground required.
2
For motor cable specifications, refer to the Kinetix Motion Control Selection Guide (publication GMC-SG001).
3
The BRKTMP0 signal can be wired to a ControlLogix input as overtemp warning in user program.
4
Firmware version 1.071 (or higher) is required to use the DBRK outputs on the Kinetix 6000 IAM or AM.
5
The safety relay time delay should be set beyond the time required to stop and disable the axis when running at full speed.
6
Drive Enable Input Checking must be selected in Axis Properties.
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
230V ac Auxiliary
Input Power
(APL) Connector
2
1
4
3
2
1
L2/N
L1
L1
L2
L3
K
I/O (IOL)
Connector
230V ac Output
(P2L) Connector
24V dc Output
(P1L) Connector
1
L1'
L2'
L3'
6
5
4
3
2
COIL_E1
IO_PWR1
COIL_E2
IO_COM1
D
2
8
7
1, 3, 5
1
2, 4, 6
C
B
6
4
A
5
3
1
AUX1_L1
2
AUX1_L2
3
AUX2_L1
AUX2_L2 4
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
4
2
1
3
2
1
2
1
1
CTRL 2
2
CTRL 1
IO_PWR2
Three-Phase Output
(OPL) Connector
Single-Phase Output
(CPL) Connector
Kinetix 6000
LINE INTERFACE MODULE
2094-AL75S, -BL75S, or
-XL75S-C2
Control Power
(CPD) Connector
IO_PWR1
Note 1
Motor Power
(MP) Connector
Cable Shield
Clamp
Contactor Enable
(CED) Connector
Motor/Resistive
Brake (BC) Connector
DC Bus
and
3-Phase
Input (IPD)
Connector
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
U
V
W
1
1
1
2
3
4
5
6
Note 3
IO_PWR1
BRKTMP0
BRKSTAT0
Note 4
B
1
2
3
4
5
6
7
8
1
2
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
2
3
3
2
4
4
AUX3
AUX2
AUX1
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
1
2
3
4
A
B
C
D
U
V
W
M
GND
Motor Power
Connections
Refer to the Kinetix 6000
Installation Manual (publication
2094-IN001) for motor power
cable catalog numbers.
Note 2
* INDICATES USER SUPPLIED COMPONENT
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
RESISTIVE BRAKE MODULE
2090-XBxx-xx
(RBM_0)
Resistive Brake Module
Interconnect Diagrams
Three-Phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
C-6
Integrate Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM, AM, and LIM
(2094-AL75S, -BL75S, and -XL75S) wired with the Bulletin 2090 RBM.
Figure C.1
Example RBM Interconnection Diagram (Category 2 Configuration per EN954-1)
GND-15
NOT USED
36
IO_COM
GND-14
GND-15
GND-11
GND-12
GND-13
GND-8
GND-9
GND-10
GND-5
GND-6
GND-7
GND-2
GND-3
GND-4
GND-0
GND-1
30
32
34
24
26
28
18
20
22
14
16
8
10
12
2
4
6
35
29
31
33
23
25
27
17
19
21
11
13
15
5
7
9
1
3
BRKSTAT1
BRKSTAT0
BRKTMP1
Note 3
BRKTMP0
* INDICATES USER SUPPLIED COMPONENT
IN-15
NOT USED
NOT USED
IN-12
IN-13
IN-14
IN-9
IN-10
IN-11
IN-6
IN-7
IN-8
IN-3
IN-4
IN-5
IN-0
IN-1
IN-2
ControlLogix Input Device
1756-IB16
D
Latching
Pushbutton *
Note 1
Motor/Resistive
Brake (BC) Connector
Motor Power
(MP) Connector
Cable Shield
Clamp
Kinetix 6000
AXIS MODULE
2094-AMxx or -BMxx
(Axis_1)
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
U
V
W
2
1
2
1
1
2
3
4
5
6
Note 3
Note 4
2
1
IO_PWR1
3
4
5
6
7
8
1
2
BRKTMP1
BRKSTAT1
A
C
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
4
3
4
AUX3
AUX2
AUX1
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
K
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
Bulletin 2090
RESISTIVE BRAKE MODULE
2090-XBxx-xx
(RBM_1)
A
B
C
D
U
V
W
M
GND
Refer to the Kinetix 6000
Installation Manual (publication
2094-IN001) for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-7
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
Three-Phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
K
L1'
L1
COIL_A2
COIL_A1
IO_COM
IO_PWR
MBRK_COM
MBRK_PWR
MBRK_COM
I/O (IOL)
Connector
24V dc Output
(PSL) Connector
L2'
MBRK_PWR
L3'
L2
L1
L2
L3
Three-Phase Output
(OPL) Connector
Single-Phase Output
(CPL) Connector
Kinetix 6000
LINE INTERFACE MODULE
2094-AL09 and -BL02
4
3
2
1
B
2
1
2
20-22
4
13
1
24-26
A
6
5
4
3
2
1
1
2
Control Power
(CPD) Connector
Note 1
Motor Power
(MP) Connector
Cable Shield
Clamp
Contactor Enable
(CED) Connector
Motor/Resistive
Brake (BC) Connector
DC Bus
and
Three-Phase
Input (IPD)
Connector
IO_PWR
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
U
V
W
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
1
1
1
2
3
4
5
6
Note 3
IO_PWR
BRKTMP0
BRKSTAT0
Note 4
1
2
3
4
5
6
7
8
1
2
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
2
3
3
2
4
4
AUX3
AUX2
AUX1
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
1
2
3
4
A
B
C
D
U
V
W
M
GND
Motor Power
Connections
Refer to the Kinetix 6000
Installation Manual (publication
2094-IN001) for motor power
cable catalog numbers.
Note 2
* INDICATES USER SUPPLIED COMPONENT
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
RESISTIVE BRAKE MODULE
2090-XBxx-xx
(RBM_0)
C-8
Integrate Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM, AM, and LIM
(2094-AL09 and -BL02) wired with the Bulletin 2090 RBM.
Figure C.2
Example RBM Interconnection Diagram (Category 2 Configuration per EN954-1)
GND-15
NOT USED
36
IO_COM
GND-14
GND-15
GND-11
GND-12
GND-13
GND-8
GND-9
GND-10
GND-5
GND-6
GND-7
GND-2
GND-3
GND-4
GND-0
GND-1
30
32
34
24
26
28
18
20
22
14
16
8
10
12
2
4
6
35
29
31
33
23
25
27
17
19
21
11
13
15
5
7
9
1
3
BRKSTAT1
BRKSTAT0
BRKTMP1
Note 3
BRKTMP0
* INDICATES USER SUPPLIED COMPONENT
IN-15
NOT USED
NOT USED
IN-12
IN-13
IN-14
IN-9
IN-10
IN-11
IN-6
IN-7
IN-8
IN-3
IN-4
IN-5
IN-0
IN-1
IN-2
ControlLogix Input Device
1756-IB16
B
Latching
Pushbutton *
Note 1
Motor/Resistive
Brake (BC) Connector
Motor Power
(MP) Connector
Cable Shield
Clamp
Kinetix 6000
AXIS MODULE
2094-AMxx or -BMxx
(Axis_1)
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
U
V
W
2
1
2
1
1
2
3
4
5
6
Note 3
Note 4
2
1
IO_PWR
3
4
5
6
7
8
BRKTMP1
BRKSTAT1
A
1
2
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
4
3
4
AUX3
AUX2
AUX1
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
K
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
Bulletin 2090
RESISTIVE BRAKE MODULE
2090-XBxx-xx
(RBM_1)
A
B
C
D
U
V
W
M
GND
Refer to the Kinetix 6000
Installation Manual (publication
2094-IN001) for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-9
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
4
3
2
1
230V ac Auxiliary 1
Input Power 2
(APL) Connector
Three-Phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
K
L2/N
L1
L1'
L1
I/O (IOL)
Connector
230V ac Output
(P2L) Connector
24V dc Output
(P1L) Connector
L2'
6
5
4
3
2
1
4
3
2
COIL_E2
COIL_E1
IO_COM1
IO_PWR1
8
B
2, 4, 6
7
A
6
5
4
3
2
1
2
1
L1
L2
L3
DC+
DC-
CTRL 1
CTRL 2
I/O (IOD)
Connector
Note 6
Motor/Resistive
Brake (BC) Connector
Contactor Enable
(CED) Connector
Note 1
U
V
W
+24V_COM
ENABLE
+24V_PWR
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
DC Bus
and
Three-Phase
Input (IPD)
Connector
CONT EN2
CONT EN+
1
IO_PWR1
1, 3, 5
1
AUX1_L1
2
AUX1_L2
3
AUX2_L1
AUX2_L2 4
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
L3'
L2
1
Three-Phase Output
(OPL) Connector
L3
CTRL 2
2
CTRL 1
1
Single-Phase Output
(CPL) Connector
Kinetix 6000
LINE INTERFACE MODULE
2094-AL75S, -BL75S, or
-XL75S-C2
Power Rail
Ground Stud
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
2
1
1
2
3
4
5
C
D
Note 4
BRKTMP0
2
3
4
5
6
7
8
1
2
Note 3 IO_PWR1 1
E
BRKSTAT0
A
1
1
6
2
3
3
2
4
4
Cable Shield
Clamp
R3
R2
R1
AUX3
AUX2
AUX1
L3
L2
L1
AUX4
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
1
2
3
4
A
B
C
D
U
V
W
M
GND
Motor Power
Connections
Refer to the Kinetix 6000
Installation Manual (publication
2094-IN001) for motor power
cable catalog numbers.
Note 2
* INDICATES USER SUPPLIED COMPONENT
TS_21
TS_22
CONSTANT_41
CONSTANT_42
SHIELD
COIL_A1
COIL_A2
SHIELD
I/O Connections
(TB3) Connector
L1
L2
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
RESISTIVE BRAKE MODULE
2090-XBxx-xx
(RBM_0)
C-10
Integrate Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM and LIM
(2094-AL75S, -BL75S, and -XL75S) wired with the Bulletin 2090 RBM.
Figure C.3
Example RBM Interconnection Diagram (Category 3 Configuration per EN954-1)
COM
IN-0
IN-1
IN-2
IN-3
IN-4
IN-5
IN-6
IN-7
IN-8
IN-9
IN-10
IN-11
IN-12
IN-13
IN-14
IN-15
NOT USED
NOT USED
GND-0
GND-0
GND-0
GND-0
GND-1
GND-1
GND-1
GND-1
GND-2
GND-2
GND-2
GND-2
GND-3
GND-3
GND-3
GND-3
NOT USED
NOT USED
31
33
35
25
27
29
21
23
15
17
19
1
3 STOPSTAT
5
7
9
BRKTMP0
11
13
* INDICATES USER SUPPLIED COMPONENT
32
34
36
24
26
28
30
20
22
14
16
18
2
4
6
8
10
12
ControlLogix Input Device
1756-IB16
COM
A2
A1
IO_PWR1
X1
S52
Out2
S21
S22
COM
X2
X4
STOPSTAT
X3
Y39
Y40
Y2
Y1
S34
Reset *
S33
IO_PWR1
Safety Relay *
Allen-Bradley/Guardmaster MSR138DP
Note 5
S12
COM
PWR
E-STOP *
Out1
Light Curtain *
S11
B
14
13
C
24
23
38
37
48
47
E
58
57
COIL0
ENABLE0
BRKSTAT0
IO_PWR1
D
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-11
Publication 2094-IN002E-EN-P — September 2005
Publication 2094-IN002E-EN-P — September 2005
Three-Phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
L1'
L1
K
L2'
1
I/O (IOL)
Connector
IO_PWR
COIL_A2
COIL_A1
IO_COM
IO_PWR
2
1
4
13
A
20-22
24-26
I/O (IOD)
Connector
Note 6
Motor/Resistive
Brake (BC) Connector
DC Bus
and
Three-Phase
Input (IPD)
Connector
Note 1
U
V
W
+24V_COM
ENABLE
+24V_PWR
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
Contactor Enable
(CED) Connector
L1
L2
L3
DC+
DC-
CTRL 1
CTRL 2
CONT EN2
CONT EN+
1
6
5
4
3
2
1
1
2
2
24V dc Output MBRK_COM
3
(PSL) Connector MBRK_PWR
4
MBRK_COM
MBRK_PWR
L3'
L2
L1
L2
L3
Three-Phase Output
(OPL) Connector
Single-Phase Output
(CPL) Connector
Kinetix 6000
LINE INTERFACE MODULE
2094-AL09 and -BL02
Power Rail
Ground Stud
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
2
1
1
2
3
4
5
B
C
Note 4
BRKTMP0
2
3
4
5
Note 3 IO_PWR 1
D
BRKSTAT0
6
7
8
1
2
1
1
6
2
3
3
2
4
4
Cable Shield
Clamp
R3
R2
R1
AUX3
AUX2
AUX1
L3
L2
AUX4
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
1
2
3
4
A
B
C
D
U
V
W
M
GND
Motor Power
Connections
Refer to the Kinetix 6000
Installation Manual (publication
2094-IN001) for motor power
cable catalog numbers.
Note 2
* INDICATES USER SUPPLIED COMPONENT
TS_21
TS_22
CONSTANT_41
CONSTANT_42
SHIELD
COIL_A1
COIL_A2
SHIELD
I/O Connections
(TB3) Connector
L1
L2
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L1
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
RESISTIVE BRAKE MODULE
2090-XBxx-xx
(RBM_0)
C-12
Integrate Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM and LIM
(2094-AL09 and -BL02) wired with the Bulletin 2090 RBM.
Figure C.4
Example RBM Interconnection Diagram (Category 3 Configuration per EN954-1)
COM
IN-0
IN-1
IN-2
IN-3
IN-4
IN-5
IN-6
IN-7
IN-8
IN-9
IN-10
IN-11
IN-12
IN-13
IN-14
IN-15
NOT USED
NOT USED
GND-0
GND-0
GND-0
GND-0
GND-1
GND-1
GND-1
GND-1
GND-2
GND-2
GND-2
GND-2
GND-3
GND-3
GND-3
GND-3
NOT USED
NOT USED
31
33
35
25
27
29
21
23
15
17
19
1
3 STOPSTAT
5
7
9
BRKTMP0
11
13
* INDICATES USER SUPPLIED COMPONENT
32
34
36
24
26
28
30
20
22
14
16
18
2
4
6
8
10
12
ControlLogix Input Device
1756-IB16
COM
A2
A1
IO_PWR
X1
S52
Out2
S21
S22
COM
X2
X4
STOPSTAT
X3
Y39
Y40
Y2
Y1
S34
Reset *
S33
IO_PWR
Safety Relay *
Allen-Bradley/Guardmaster MSR138DP
Note 5
S12
COM
PWR
E-STOP *
Out1
Light Curtain *
S11
A
14
13
B
24
23
38
37
48
47
D
58
57
COIL0
ENABLE0
BRKSTAT0
IO_PWR
C
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-13
Publication 2094-IN002E-EN-P — September 2005
C-14
Integrate Resistive Brake Modules with Kinetix 6000 Drives
Set the RBM Delay Time
Using DriveExplorer
In this procedure you will break SERCOS ring communications, set the
delay time parameter using DriveExplorer software, and re-establish
SERCOS communication.
If you are using this version
of RSLogix 5000 software
Then
v11 or v12
Proceed with these instructions using DriveExplorer to
set the RBM delay time parameter.
v13 or above
Go to Configure Axis Properties on page 1-24 and use
RSLogix 5000 to set the RBM delay time parameter.
The following hardware and software tools are required to provide
the necessary communication link between your PC and the Kinetix
6000 drive system running RSLogix 5000.
Description
Catalog Numbers
Version
DriveExplorer Software 1, 3
9306-4EXP02ENE
2.01 or above
Serial to SCANport Adapter 2, 3
1203-SSS (Series B)
3.004 or above
RSLogix 5000 Software
9324-RLD300NE
11.0 or 12.0
Personal computer with HyperTerminal
N/A
N/A
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Refer to 1203-SSS (Series B) FRN 3.xxx User Manual (publication 20COMM-UM001) for instructions.
3
Additional information regarding these communication and software tools is available at www.ab.com/
support/abdrives.
ATTENTION
To avoid personal injury or equipment damage,
at least one end of a SERCOS fiber-optic cable
must be disconnected from the drive. This
ensures that motion will not occur while
changes are made to the time delay parameter.
Remove SERCOS Communication
To remove (break) SERCOS communications:
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Remove one of the SERCOS fiber-optic cables. Fiber-optic cable
connections (Tx and Rx) are located on the top of each IAM/AM.
3. Re-apply three-phase and control power.
Publication 2094-IN002E-EN-P — September 2005
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-15
Set the RBM Delay Time Parameter
To set the RBM delay time parameter:
1. Start the DriveExplorer software.
2. Click on Explore\Connect\Local in the menu bar or enter
Ctrl-L from the keyboard. DriveExplorer will read your system.
3. Observe the Linear List of parameters as grouped by Node, Port,
and Axis hierarchy as shown below.
Linear List Legend
N: P. x xxx
Parameter Number
30 = Version Data
Axis Number
0 = IAM (axis 1)
1 = AM (axis 2)
2 = AM (axis 3)
3 = AM (axis 4)
DPI Port Number
Network Node Number
4. Click on Devices\Node\Product\Axis x Group\Config and
navigate to the Config parameters as shown below.
Publication 2094-IN002E-EN-P — September 2005
C-16
Integrate Resistive Brake Modules with Kinetix 6000 Drives
5. Double-click on the x:x:x641 RBM Delay parameter. The
command window for parameter x641 - RBM Delay opens.
6. Click on the Value Edit tab and enter the delay time Value (ms).
The recommended RBM delay time is 71 ms.
7. Select OK. The RBM delay time is changed, but not saved in
non-volatile memory.
Save the Delay Time Parameter to Non-Volatile Memory
To save the delay time parameter to non-volatile memory:
1. Click on Actions\Non-Volatile Memory in the menu bar. The
following message window opens.
2. Click on Save. The changes are saved to non-volatile memory and
the following cautionary message window opens.
Publication 2094-IN002E-EN-P — September 2005
Integrate Resistive Brake Modules with Kinetix 6000 Drives
C-17
3. Click on Yes to complete saving changes to non-volatile memory.
The following confirmation message window opens.
4. Click OK.
5.
If you
Then
Have another RBM in the
Kinetix 6000 system
Go to Set the RBM Delay Time
Parameter (step 4).
1. Close DriveExplorer.
Do not have another RBM
in the Kinetix 6000 system 2. Go to Reconnect SERCOS
Communication.
Reconnect SERCOS Communication
To reconnect SERCOS communication:
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Replace the SERCOS fiber-optic cable(s) removed earlier.
Fiber-optic cable connections (Tx and Rx) are located on the top
of each IAM/AM.
3. Re-apply three-phase and control power.
Publication 2094-IN002E-EN-P — September 2005
C-18
Integrate Resistive Brake Modules with Kinetix 6000 Drives
Publication 2094-IN002E-EN-P — September 2005
Appendix
D
DC Common Bus Applications
Chapter Objectives
This appendix provides integration procedures specific to the Kinetix
6000 multi-axis servo drive systems configured for DC common bus
and using drive firmware v1.85 (or above). The procedure involves
calculating capacitance values and setting the Add Bus Cap parameter
using DriveExplorer software.
Before You Begin
These procedures assume you have mounted and wired your Kinetix
6000 DC common bus system. Refer to the Kinetix 6000 Installation
Manual (publication 2094-IN001) for mounting and wiring
information.
Before you set the Additional Bus Capacitance (Add Bus Cap)
parameter in DriveExplorer, you need to calculate the following
values using the tables provided:
• Total Bus Capacitance
• Additional Bus Capacitance
1
Publication 2094-IN002E-EN-P — September 2005
D-2
DC Common Bus Applications
Calculate Total Bus Capacitance
Total bus capacitance is the sum of all capacitance values for your
Kinetix 6000 common bus modules. Specifically, this includes the
capacitance values for the following modules:
• Leader IAM (converter and inverter)
• Each AM and SM (if present) on the Leader IAM power rail
• Each Follower IAM (converter and inverter)
• Each AM on the Follower IAM power rails
Refer to Kinetix 6000 Capacitance Values on page D-3 for IAM/AM/
SM capacitance values.
IMPORTANT
Leader IAM (230V)
2094AC05-MP5
AC05-M01
Maximum Bus
Capacitance
µF
7145
Leader IAM (460V)
2094BC01-MP5
BC01-M01
Maximum Bus
Capacitance
µF
4585
AC09-M02
15295
BC02-M02
8955
AC16-M03
34400
BC04-M03
8955
AC32-M05
62825
BC07-M05
17915
IMPORTANT
Publication 2094-IN002E-EN-P — September 2005
When total bus capacitance exceeds the Leader IAM
maximum value given in the table below, the IAM
seven-segment LED displays error code E90
(pre-charge timeout fault) and the drive is disabled.
If your total bus capacitance value exceeds the value
in the table above, you must increase the size of the
Leader IAM or decrease the total bus capacitance by
removing axis modules.
DC Common Bus Applications
D-3
Calculate Additional Bus Capacitance
Additional bus capacitance is the sum of all Follower IAM and AM
capacitance values for your Kinetix 6000 common bus modules.
Specifically, this includes the capacitance values for the following
modules:
• Each Follower IAM (converter and inverter)
• Each AM on the Follower IAM power rails
Enter the additional bus capacitance value in step 6 of Set the
Additional Bus Capacitance Parameter.
Kinetix 6000 Capacitance Values
Use the tables below when calculating total bus capacitance and
additional bus capacitance for your Kinetix 6000 common bus
application.
IAM/AM (230V) Modules
IAM Converter (230V)
2094AC05-MP5
AC05-M01
Capacitance
µF
270
AM Inverter (230V)
2094-
Capacitance
µF
AMP5
390
AM01
660
AC09-M02
540
AM02
780
AC16-M03
1320
AM03
1320
AC32-M05
1980
AM05
2640
AM Inverter (460V)
2094-
Capacitance
µF
BMP5
75
BM01
150
IAM/AM (460V) Modules
IAM Converter (460V)
2094BC01-MP5
BC01-M01
Capacitance
µF
110
BC02-M02
220
BM02
270
BC04-M03
940
BM03
840
BC07-M05
1410
BM05
1175
SM (230/460V) Module
SM (230-460V)
2094-
Capacitance
µF
BSP2
470
Publication 2094-IN002E-EN-P — September 2005
D-4
DC Common Bus Applications
Common Bus Capacitance Example
In the figure below, the sum of the Leader IAM power rail modules
capacitance (6530 µF) and the Follower IAM power rail modules
capacitance (5280 µF) equals 11810 µF Total Bus Capacitance.
The sum of the Follower IAM power rail modules equal 5280 µF
Additional Bus Capacitance.
Figure D.1
Calculating Common Bus Capacitance
AC Line
Filter
Three-Phase
Input Power
MAIN VAC
Kinetix 6000 (230V)
Leader IAM
11810 µF Total Bus Capacitance
Line Interface
Module
(optional
component)
PRF (2094-PRF) N/A
SM (2094-BSP2) 470 µF
AM (2094-AM02) 780 µF
AM (2094-AM03) 1320 µF
AM (2094-AM03) 1320 µF
IAM (2094-AC16-M03) Converter 1320 µF
IAM (2094-AC16-M03) Inverter 1320 µF
DC Common Bus
Kinetix 6000 (230V)
Follower IAM
5280 µF Additional Bus Capacitance
PRF (2094-PRF) N/A
AM (2094-AM03) 1320 µF
AM (2094-AM03) 1320 µF
IAM (2094-AC16-M03) Converter 1320 µF
IAM (2094-AC16-M03) Inverter 1320 µF
Publication 2094-IN002E-EN-P — September 2005
DC Common Bus Applications
Set the Additional Bus
Capacitance Parameter
D-5
In this procedure you will set the Add Bus Cap parameter using
DriveExplorer software.
The following hardware and software tools are required to provide
the necessary communication link between your PC and the Kinetix
6000 drive system running DriveExplorer.
Description
Catalog Numbers
Version
DriveExplorer Software 1, 3
9306-4EXP02ENE
2.01 or above
Serial to SCANport Adapter 2, 3
1203-SSS (Series B)
3.004 or above
RSLogix 5000 Software
9324-RLD300NE
15.0 or above
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Refer to 1203-SSS (Series B) FRN 3.xxx User Manual (publication 20COMM-UM001) for instructions.
3
Additional information regarding these communication and software tools is available at www.ab.com/
support/abdrives.
ATTENTION
To avoid personal injury or equipment damage, at
least one end of a SERCOS fiber-optic cable must be
disconnected from the drive. This ensures that
motion will not occur while changes are made to the
Add Bus Cap parameter.
Remove SERCOS Communication
To remove (break) SERCOS communications:
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Remove one of the SERCOS fiber-optic cables. Fiber-optic cable
connections (Tx and Rx) are located on the top of each IAM/AM.
3. Re-apply three-phase and control power.
Publication 2094-IN002E-EN-P — September 2005
D-6
DC Common Bus Applications
Set the Additional Bus Capacitance Parameter
To set the Additional Bus Capacitance parameter:
1. Start the DriveExplorer software.
2. Click on Explore\Connect\Local in the menu bar or enter
Ctrl-L from the keyboard. DriveExplorer will read your system.
3. Observe the Linear List of parameters as grouped by Node, Port,
and Axis hierarchy as shown below.
Linear List Legend
N: P. x xxx
Parameter Number
30 = Version Data
Axis Number
0 = IAM (axis 1)
1 = AM (axis 2)
2 = AM (axis 3)
3 = AM (axis 4)
DPI Port Number
Network Node Number
4. Click on Devices\Node\Product\ and navigate to the parameter
x:x:x599 as shown below.
Publication 2094-IN002E-EN-P — September 2005
DC Common Bus Applications
D-7
5. Double-click on the x:x:x599 Add Bus Cap parameter. The
command window for parameter x599 - Add Bus Cap opens.
6. Click on the Value Edit tab and enter the Add Bus Cap Value (µF).
7. Select OK. The Add Bus Cap parameter is changed, but not saved
in non-volatile memory.
8. Go to Save the Add Bus Cap Parameter to Non-Volatile Memory.
Save the Add Bus Cap Parameter to Non-Volatile Memory
To save the Add Bus Cap parameter to non-volatile memory:
1. Click on Actions\Non-Volatile Memory in the menu bar. The
following message window opens.
Publication 2094-IN002E-EN-P — September 2005
D-8
DC Common Bus Applications
2. Click on Save. The changes are saved to non-volatile memory and
the following cautionary message window opens.
3. Click on Yes to complete saving changes to non-volatile memory.
The following confirmation message window opens.
4. Click OK. Close DriveExplorer.
5. Go to Reconnect SERCOS Communication.
Reconnect SERCOS Communication
To reconnect SERCOS communication:
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Replace the SERCOS fiber-optic cable(s) removed earlier.
Fiber-optic cable connections (Tx and Rx) are located on the top
of each IAM/AM.
3. Re-apply three-phase and control power.
Publication 2094-IN002E-EN-P — September 2005
Index
Numerics
1203-SSS serial cable B-2, B-4
16 axis SERCOS interface PCI
card installation instructions
P-3
1756 module properties 1-18
1756-MxxSE interface module
1-9, 1-16
1784-PM16SE PCI card 1-9
24V power LED 2-12
26-pin I/O connector 2-20
A
acronyms P-4
additional bus capacitance
calculating D-3
example D-4
analog test points
DAC0 2-20
DAC1 2-20
applying power 1-26
with LIM 1-26
without LIM 1-30
atune fault 2-6
aux fdbk noise fault 2-6
aux feedback AQB 2-6
aux feedback loss 2-6
auxiliary encoder error,
see troubleshooting
axis module
connector designators 1-2
connector locations 1-4
axis properties 1-24
axis unstable 2-14
B
backplane comm 2-7
bandwidth 1-37
base node address 1-10
example with two
ControlLogix chassis 1-12,
1-13
example with two power rails
1-11
baud rate 1-14, 1-15
block diagrams
converter A-27
inverter A-26
LIM A-29, A-30, A-31, A-32,
1
A-33
RBM A-34, A-35
safe-off feature A-28
shunt module A-28
blown fuse 2-3
brake A-24
brake power LED 1-27, 2-12
bus
overvoltage 2-4
undervoltage 2-4
bus overcurrent 2-7
bus regulator 1-22
bus status LED 1-29, 1-32, 2-9,
2-11
C
cables
fiber optic cable length 1-9
CAD files P-3
can init 2-7
CB1, CB2, CB3 1-26
certifications
Rockwell Automation Product
Certification P-3
changing parameters
DriveExplorer 2-19
HIM 2-20
circuit breakers 1-26
comm status LED 1-29, 1-31, 2-8
commissioning your Kinetix 6000
1-1
common bus (see DC common
bus)
Common Bus FLT 2-7
component removal and
replacement 2-22
configuring
AM 1-15
base node address 1-10
baud rate, AM 1-15
baud rate, IAM 1-14
feedback only axis 1-21
IAM 1-10
Kinetix 6000 1-9
optical power level 1-14, 1-15
SERCOS module 1-16
connector designators
axis module 1-2
integrated axis module 1-2
line interface module 1-6
Publication 2094-IN002E-EN-P — September 2005
I-2
Index
shunt module 1-5
connector locations
axis module 1-4
integrated axis module 1-3
line interface module 1-6, 1-8
shunt module 1-5
contents of manual P-2
control reliability C-5
controller properties 1-16
controlling a brake A-24
Controllogix Motion Module
Programming Manual P-3
conventions used in this manual
P-4
conversion tab 1-24
converter A-27
coordinated system time master
1-17
CPLD FLT 2-7
cycle time 1-19
D
DAC0 2-20
DAC1 2-20
data rate 1-19
data type 1-20
date and time tab 1-17
DC common bus
configuring 1-22
interconnect diagram A-8, A-9,
A-10, A-12
setting the add bus cap
parameter D-5
digital I/O not working correctly
2-3
dip switches 1-19
disable drive 2-16
documentation files P-3
download program 1-25
drive enable fault 2-5
drive overcurrent 2-3
drive overtemp 2-5, 2-7
drive status LED 1-29, 1-31, 2-8
drive tab 1-24
drive undervoltage 2-5
DriveExplorer 2-19, B-1, C-14,
D-5
E
encoder communication fault 2-5
Publication 2094-IN002E-EN-P — September 2005
erratic operation 2-15
error codes 2-3
establishing communications 2-8
F
fault action 2-16
fault action, programmable 2-16
fault actions tab 1-25
feedback only axis 1-21
feedback tab 1-24
fiber optic cables
receive and transmit
connectors 1-9
Fiber-Optic Cable Installation
Instructions P-3
firmware
upgrade file B-6
flyback diodes A-25
follow error 2-4
G
ground fault 2-5
H
hardware overtravel 2-4
HIM 2-19
hookup fault 2-6
hookup tab 1-34
human interface module (HIM)
2-19
hyperterminal B-4
I
I/O connector 2-20
I/O power LED 1-27, 2-12
Ifbk HW Fault 2-6
illegal hall state 2-4
integrated axis module
configuring 1-10
connector designators 1-2
connector locations 1-3
interconnect diagram A-3, A-4,
A-6, A-7, A-8, A-9, A-10,
A-12
interconnect diagrams
2094 with H-Series motor A-21
2094 with MPG-A motor A-17,
A-18, A-19
Index
2094 with MPG-B motor A-16
2094 with MPL-A motor A-17,
A-18, A-19
2094 with MPL-B motor A-16
2094 with N-Series motor A-22
2094 with Y-Series motor A-23
2094 with1326AB motor A-20
controlling a brake example
A-25
notes A-1, C-5
power, DC common bus A-8,
A-9, A-10, A-12
power, IAM with LIM A-3, A-4
power, IAM without LIM A-6,
A-7
RBM C-6
shunt module A-13, A-14, A-15
introduction P-1
inverter A-26
IPM fault, see troubleshooting
K
Kinetix 6000
axis properties 1-24
configuring 1-9
Installation Manual P-3
Line Interface Module
Installation Instructions P-3
module properties 1-20
troubleshooting 2-1
user documentation and CAD
files CD P-3
Kinetix Motion Control Selection
Guide P-3
Kinetix Safe-Off Feature
Reference Manual P-3
L
LED
24V power, LIM 2-12
brake power, LIM 1-27, 2-12
bus status 1-29, 1-32, 2-9, 2-11
comm status 1-29, 1-31, 2-8
drive status 1-29, 1-31, 2-8
I/O power, LIM 1-27, 2-12
logic power 1-28, 1-30, 2-2
RBM 230V status 2-13
RBM 24V status 2-12
SERCOS 1756 module 1-32
SERCOS interface module 1-29
I-3
seven segment 1-28
shunt fault 2-11
status 1-28, 1-31, 1-33, 2-2
temperature fault 2-11
LIM 1-26
line interface module
brake power LED 1-27
connector designators 1-6
connector locations 1-6, 1-8
I/O power LED 1-27
interconnect diagram A-3, A-4,
A-6, A-7
removing 2-27
replacing 2-28
system block diagram A-29,
A-30, A-31, A-32, A-33
Literature Library P-3
logic power 1-30, 2-2
logic power LED 1-28
Logix5000 Controllers Motion
Instructions Reference Manual
P-3
Logix5000 Motion Modules User
Manual P-3, 1-16, 1-33
loop configuration 1-24
M
maintenance 2-2
memory init 2-6
module mismatch 2-7
module properties
1756 SERCOS interface 1-18
IAM 1-20
Motion Analyzer CD P-3
Motion Control Selection Guide
P-3
motion group properties 1-23
motor accel/decel problems 2-14
motor and feedback tab 1-24
motor encoder error 2-4
motor feedback loss 2-4
motor jumps when first enabled
2-3
motor overheating 2-15
motor overtemp 2-3
motor velocity 2-14
motors
interconnect diagram
1326AB A-20
H-Series A-21
Publication 2094-IN002E-EN-P — September 2005
I-4
Index
MPG-A A-17, A-18, A-19
MPG-B A-16
MPL-A A-17, A-18, A-19
MPL-B A-16
N-Series A-22
Y-Series A-23
testing 1-33
tuning 1-33
MOV A-25
mtr fdbk noise fault 2-6
N
National Electrical Code P-3
no communication 2-8
no rotation 2-15
node address 1-20
noise
abnormal 2-15
feedback 2-15
NV mem init 2-6
O
objects init 2-6
optical power level 1-14, 1-15,
1-19
overspeed fault 2-4
P
parameters, changing 2-19
power indicator not on 2-3
power phase loss 2-5
power rail
removing 2-25
removing modules 2-23
replacing 2-26
power up 1-26
precautions
general startup 1-1
precharge fault 2-5
purpose of this manual P-1
R
related documentation P-3
relay output A-24
removing
components 2-22
LIM 2-27
modules 2-23
Publication 2094-IN002E-EN-P — September 2005
replacing
components 2-22
LIM 2-28
power rail modules 2-24
resistive brake module
interconnect diagrams C-6
setting the RBM delay time
C-14
system block diagram A-34,
A-35
Resistive Brake Module
Installation Instructions P-3
risk assessment C-4
Rockwell Automation Product
Certification P-3
RSLogix 5000 software 1-16, 2-19,
C-14, D-5
S
safe-off
block diagram A-28
safe-off HW fault 2-6
safety
control reliability C-5
risk assessment C-4
standards C-2
stop categories C-3
safety reference manual P-3
SCANport comm 2-6
SCANport/DPI adapter C-14, D-5
self sense fault 2-5
SERCOS init 2-7
SERCOS interface module
installation instructions P-3
SERCOS ring fault 2-5
SERCOS same addr 2-6
setting the add bus cap parameter
D-5
seven segment status LED 1-28,
1-30
shunt fault LED 2-11
shunt module A-28
connector designators 1-5
connector locations 1-5
interconnect diagram A-13,
A-14, A-15
shunt module troubleshooting
2-10
shunt time fault 2-7
shunt time out 2-7
Index
shutdown 2-16
SoftLogix Motion Card Setup and
Configuration Manual P-3,
1-16, 1-33
software
RSLogix 5000 1-16, 2-19
software overtravel 2-4
start-up procedure 1-1
status LEDs 1-28, 1-31, 1-33, 2-2
status only 2-16
stop categories C-3
stop motion 2-16
storage P-2
supplemental troubleshooting
information 2-19
surge suppression A-25
switches
base node address 1-10
baud rate 1-14, 1-15
optical power level 1-14, 1-15
system block diagrams
converter A-27
inverter A-26
LIM A-29, A-30, A-31, A-32,
A-33
RBM A-34, A-35
safe-off feature A-28
shunt module A-28
System Design for Control of
Electrical Noise P-3
T
task init 2-6
temperature fault LED 2-11
testing axes
hookup tab 1-34
total bus capacitance
calculating D-2
example D-4
troubleshooting 2-2
24V power LED 2-12
brake power LED 2-12
bus status LED 2-9, 2-11
comm status 2-8
disable drive 2-16
drive status LED 2-8
error codes 2-3
fault action 2-16
general
atune fault 2-6
I-5
aux fdbk noise fault 2-6
aux feedback AQB 2-6
aux feedback loss 2-6
auxiliary encoder error
2-4
backplane comm 2-7
blown fuse 2-3
bus overcurrent 2-7
bus undervoltage 2-4
can init 2-7
Common Bus FLT 2-7
CPLD FLT 2-7
digital I/O not working
correctly 2-3
drive enable fault 2-5
drive overcurrent 2-3
drive overtemp 2-5, 2-7
drive undervoltage 2-5
encoder communication
fault 2-5
follow error 2-4
ground fault 2-5
hardware overtravel 2-4
hookup fault 2-6
Ifbk HW Fault 2-6
illegal hall state 2-4
IPM fault 2-3
memory init 2-6
module mismatch 2-7
motor encoder error 2-4
motor feedback loss 2-4
motor jumps when first
enabled 2-3
motor overtemp 2-3
mtr fdbk noise fault 2-6
NV mem init 2-6
objects init 2-6
overspeed fault 2-4
power indicator not on
2-3
power phase loss 2-5
precharge fault 2-5
safe-off HW fault 2-6
SCANport comm 2-6
self sense fault 2-5
SERCOS init 2-7
SERCOS ring fault 2-5
SERCOS same addr 2-6
shunt module fault 2-7
shunt time out 2-7
software overtravel 2-4
Publication 2094-IN002E-EN-P — September 2005
I-6
Index
task init 2-6
unknown axis 2-6
general system problems 2-14
abnormal noise 2-15
axis unstable 2-14
erratic operation 2-15
feedback noise 2-15
motor accel/decel
problems 2-14
motor overheating 2-15
motor velocity 2-14
no rotation 2-15
I/O power LED 2-12
Logix/drive fault behavior 2-16
programmable fault action
2-16
RBM 230V status LED 2-13
RBM 24V status LED 2-12
shunt fault LED 2-11
shunt module 2-10
shutdown 2-16
status only 2-16
stop motion 2-16
supplemental troubleshooting
Publication 2094-IN002E-EN-P — September 2005
information 2-19
changing parameters
2-19
using analog test points
2-20
temperature fault LED 2-11
troubleshooting your Kinetix
6000 2-1
tuning axes
bandwidth 1-37
tune tab 1-36
U
units tab 1-24
unknown axis 2-6
user manuals P-3
W
who should use this manual P-1
X
Xmodem B-7
Rockwell Automation
Support
Rockwell Automation provides technical information on the web to assist you
in using its products. At http://support.rockwellautomation.com, you can find
technical manuals, a knowledge base of FAQs, technical and application
notes, sample code and links to software service packs, and a MySupport
feature that you can customize to make the best use of these tools.
For an additional level of technical phone support for installation,
configuration and troubleshooting, we offer TechConnect Support programs.
For more information, contact your local distributor or Rockwell Automation
representative, or visit http://support.rockwellautomation.com.
Installation Assistance
If you experience a problem with a hardware module within the first 24
hours of installation, please review the information that's contained in this
manual. You can also contact a special Customer Support number for initial
help in getting your module up and running:
United States
1.440.646.3223
Monday – Friday, 8am – 5pm EST
Outside United
States
Please contact your local Rockwell Automation representative for any
technical support issues.
New Product Satisfaction Return
Rockwell tests all of its products to ensure that they are fully operational
when shipped from the manufacturing facility. However, if your product is
not functioning and needs to be returned:
United States
Contact your distributor. You must provide a Customer Support case
number (see phone number above to obtain one) to your distributor in
order to complete the return process.
Outside United
States
Please contact your local Rockwell Automation representative for
return procedure.
Publication 2094-IN002E-EN-P — September 2005
Supersedes Publication 2094-IN002D-EN-P — July 2005
Copyright © 2005 Rockwell Automation. All rights reserved. Printed in USA.