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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 Scroll down to view your document! 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. Publication 2094-IN002E-EN-P — September 2005 1-20 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). Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 1-22 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). Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 1-24 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. Publication 2094-IN002E-EN-P — September 2005 Commission Your Kinetix 6000 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. Publication 2094-IN002E-EN-P — September 2005 1-26 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. Publication 2094-IN002E-EN-P — September 2005 Commission Your Kinetix 6000 1-27 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. Publication 2094-IN002E-EN-P — September 2005 1-28 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 Publication 2094-IN002E-EN-P — September 2005 1-30 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. Publication 2094-IN002E-EN-P — September 2005 Commission Your Kinetix 6000 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. Publication 2094-IN002E-EN-P — September 2005 1-32 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 Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 1-34 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 Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 1-36 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 Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 1-38 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 Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 2-16 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 2-18 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 Publication 2094-IN002E-EN-P — September 2005 2-20 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 2-22 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 Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 2-26 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. Publication 2094-IN002E-EN-P — September 2005 2-28 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 Publication 2094-IN002E-EN-P — September 2005 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. Publication 2094-IN002E-EN-P — September 2005 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.