Navigating the Future of Motion Control with Allen-Bradley Kinetix 6200

The Allen-Bradley Kinetix 6200 (Bulletin 2094) are multi-axis servo drives that offer a Kinetix Integrated Motion platform for drive/actuator or drive/motor applications through SERCOS (Serial Real-time Communications System) interface. These drives are available with Safe Torque Off (STO) and Safe Speed Monitoring (SSM) safety options to enhance workplace safety and ensure increased machine productivity. They are also compatible with Kinetix 6000 drive systems, meaning you can upgrade any number of existing Kinetix 6000 drive axes to advanced safety with Kinetix 6200 drives, where needed.

In addition, the Kinetix 6200 servo drives feature an innovative modular design that allows for greater machine flexibility and adaptability for future drive improvements, such as increasing the drive’s power or control range by adding a new power or control module. The modular design also allows Kinetix 6200 drive axes to easily transition from SERCOS interface connectivity to EtherNet/IPnetworking and from Safe-Torque-Off to Safe-Speed functionality. This makes the drives ideal for motion control applications requiring single, flexible network support and advanced safety.

Components of a Kinetix 6200 Drive System

To configure a Kinetix 6200 drive system to provideKinetix Integrated Motion capability, you will require the following components:

Power Modules

Each Kinetix 6200 servo drive system requires one 400V-class Integrated Axis (power) Module (IAM and a maximum of seven 400V-class Axis (power) Modules (AM) to power up to eight rotary/linear servo motors or linear actuators. The Integrated Axis power module delivers power to a common power rail for the seven AM power modules; it essentially includes all the power connections and configurations for the incoming supply voltage.  

Note: If your system requires two IAM power modules, the Leader IAM should be connected to the Follower IAM through a common DC bus.

Kinetix 6200 drive systems include 2094-BCxx-Mxx-M Integrated Axis Modules that are rated for 400V-class AC input and which come with Safe Speed Monitoring functionality. These IAM modules also incorporate a power converter and inverter section.

Here are the Bulletin 2094 IAM power modules that can be used in a Kinetix 6200 drive system.

• 2094-BC01-MP5-M
• 2094-BC01-M01-M
• 2094-BC02-M02-M
• 2094-BC04-M03-M
• 2094-BC07-M05-M

Similarly, Kinetix 6200 servo drive systems require 2094-BMxx-M Axis (power) Modules. These are inverters that use a shared DC bus to connect to a 2094 IAM power module. They are rated for 400V-class AC input.

Listed below are the Bulletin 2094 AM power modules that can be used in a Kinetix 6200 drive system.

• 2094-BMP5-M
• 2094-BM02-M
• 2094-BM01-M
• 2094-BM03-M
• 2094-BM05-M

Control Modules

Each of the above-mentioned Bulletin 2094 Integrated Axis (power) Modules and Axis (power) Modules requires a Kinetix 6200 control module. The Kinetix 6200 control units use EtherNet/IP connectivity to gain access to safety configuration tools and the SERCOS interface to exchange data with Logix 5000controllers. Each control unit provides motor feedback, safety functions, user I/O feedback, and auxiliary feedback.

The following control modules can be used in a Kinetix 6200 drive system.

Kinetix 6200 SERCOS Control Modules:

• 2094-SE02F-M00-S1, with Safe Speed Monitor
• 2094-SE02F-M00-S0, with Safe Torque Off

Kinetix 6200 EtherNet/IP Control Modules:

• 2094-EN02D-M01-S1, with Safe Speed Monitor
• 2094-EN02D-M01-S0, with Safe Torque Off

In essence, Kinetix 6200 control units coupled with Bulletin 2094 AM and Integrated Axis power modules provide various status indicators, including DC-bus, network, drive, comm, and safety lock status indicators. They also serve as an interface to EtherNet/IP or SERCOS communications, auxiliary feedback, I/O feedback, motor feedback, and functional safety. A standard Kinetix 6200 drive system requires up to 8 control modules: 2094-EN02D-M01-Sx EtherNet/IP control modules or 2094-SE02F-M00-Sx SERCOS control modules.

Compatible Servo Motors/Actuators

A Kinetix 6200 servo drive system can include one to eight compatible Allen-Bradley rotary/linear servo motors or linear actuators.

Compatible Rotary Servo Motors include:

• 400V-class KinetixMPM: These are MP-SeriesMedium-inertia servo motors that deliver precise control in a power-dense, full-featured package for heavy-weight loads or motion profiles generating greater inertia. They include high-resolution resolvers or absolute multi-turn/single-turn encoders.
• 400V-class KinetixMPL: These are MP-SeriesLow-inertia brushless servo motors designed to deliver a high-power output in a smaller package. They are available in the form of either multi-turn or single-turn high-performance encoders.
• 400V-class KinetixMPF: The MP-Series Food-Grade (Bulletin MPF) servo motors combine high-torque and high-efficiency capabilities with specially designed features for food and beverage applications. For example, they incorporate stainless-steel fasteners and non-corrosive food-grade coatings and sealing techniques. They also feature a high-resolution absolute encoder feedback option.
• 400V-class KinetixMPS: The MP-Series Stainless-steel (Bulletin MPS) servo motors are uniquely designed to provide high-performance motion in highly caustic or high-pressure wash-down systems. They also provide high-resolution feedback with an absolute encoder option.
• 400V-class KinetixRDB: These are Direct-drive Allen-Bradley servo motors that connect directly to a given load, allowing for fast, precise, and flexible motion control in modern manufacturing facilities. They are available with multi-turn or single-turn high-resolution absolute encoders.
• 400V-class 1326AB (M2L/S2L): These are medium-inertia rotary AC servo motors. They offer a choice of either single-turn or multi-turn high-performance absolute encoders.

Compatible Linear Servo Motors:

• 400V-class Kinetix LDC: These are iron-core linear servo motors that connect directly to the payload to be moved, allowing faster settling times, better servo responsiveness, and improved overall control of the connected payload.

Compatible Linear Actuators include:

• 400V-class Kinetix MPAS: These are single-axis, stage-type linear actuators from Rockwell Automation that can handle large moment loads and heavy-weight loads. They are well-suited for high-precision motion applications in clean industrial environments. Typical applications include electronic assembly, Cartesian robots, pick and place, and quality inspection.
• Kinetix MPMA: These are integrated, multi-axis, electric linear stages that provide a solution for high-accuracy velocity control and two-dimensional positioning.
• Kinetix MPAR Electric Cylinders: They deliver a highly integrated solution with a flexible, precise response for an extensive range of linear motion industrial applications.
• 400V-class Kinetix MPAI: These are compact, ready-to-install, high-force electric actuators that serve as an economical alternative to hydraulic solutions in high-precision, multi-point positioning applications.

SERCOS Interface and EtherNet/IP Network Modules

SERCOS interface modules provide a communication link between a Kinetix 6200 drive system and SoftLogix /CompactLogix/ ControlLogix controller platforms. This link uses the EN/IEC 61491 SERCOS protocol over a fiber-optic communication cable.

Available SERCOS interface modules for use in Kinetix 6200 drive systems include:

• 1784-PM16SE SoftLogix PCI card
• 1768-M04SE CompactLogix SERCOS interface module
• 1756-MxxSE ControlLogix SERCOS modules

The EtherNet/IP network modules serve as a communication link between a Kinetix 6200 drive system and compatible ControlLogix 5000controllers. These modules do support star, Device Level Ring (DLR), and linear network topologies. Kinetix 6200 servo drives are compatible with 1756-ENxTx EtherNet/IP modules.

Required Accessories

• Bulletin 2094 Power Rail: This power rail is made up of a backplane with electrical connectors and mounting fixture for each Bulletin 2094 Integrated Axis and AM power module, 2094 slot-filler module, and 2094 shunt module. The rail transmits control and power signals from the IAM converter section to adjoining inverters. A range of 2094-PRSx and 2094-PRx power rails are available for use in 1-, 2-, 3-, 4-, 5-, 7-, and 8-axis Kinetix 6200 drive systems.
• 2094-BSP2 Shunt Module: This module is installed on the Bulletin 2094 power rail. It provides secondary shunting in regenerative motion control applications.
• 2094-PRF Slot-filler Module: This module is utilized when a slot(s) on the Bulletin 2094 power rail are left unused after all the required Kinetix 6200 modules are installed. 
• Kinetix 6000M IDM (Integrated Drive-Motor) System: This system uses the IDM Power Interface Module (IPIM)—Catalog No. 2094-SEPM-B24-S—to connect up to sixteen (Bulletin MDF) Integrated Drive-Motor units to 400V-class Kinetix 6200 multi-axis servo drive systems. A SERCOS II real-time network controls the IDM units and IPIM module.
• Motor Feedback and Power Cables: A wide range of Bulletin 2090 feedback and power cables with SpeedTEC DIN, threaded, and bayonet connectors are available for connecting the Allen-Bradley rotary and linear servo motors discussed earlier with Kinetix 6200 servo drive axes.
• Bulletin 2090 SERCOS Communication Cables, available as PVC (Polyvinyl Chloride), glass, CPE (Chlorinated Polyethylene), and nylon fiber-optic communication cables with connectors at both ends.
• 2090-K6CK-D44M Low-profile Connector Kit: This kit supports safety, auxiliary, and I/O feedback in Bulletin 2090 feedback cables with flying leads.
• 2090-K6CK-D44S0 Low-profile Connector Kit: The kit supports cascading Safe Torque Off and I/O connections in Kinetix 6200 drive systems.
• Ethernet Cables: Shielded Ethernet network cables in standard lengths are provided for Kinetix 6200 control modules and Kinetix 6000M Power Interface Modules.
• Kinetix 6000 Integrated Drive-Motor (IDM) Cables: These are Bulletin 2090 IDM network and hybrid cables that are used to connect the Kinetix 6000M IDM units and Bulletin 2094 IPIM modules.

Benefits of Using Kinetix6200 Drives in Motion Control Applications

• Reduced downtime, less energy consumption and production waste, and enhanced machine operating efficiencies with the Kinetix 6200 Safe-Speed functionality, which helps provide safer access to protected areas while a process or machine is in operation.
• Improved workplace safety with inbuilt advanced safety features.
• Greater flexibility with the innovative Kinetix 6200 modular design. For example, a Kinetix 6200 drive system can readily transition from SERCOS interface connectivity to EtherNet/IP networking by just changing the drive’s communication and control modules accordingly.
• Excellent machine performance: Kinetix 6200 drive axes feature advanced control capabilities that help deliver greater precision and higher throughput levels, allowing increased machine productivity.
• Reduced wiring costs: Generally, Kinetix 6200 servo drive systems require fewer wiring connections. For instance, the Bulletin 2094 power rail replaces the Logix control wiring, power wiring, and other complex cables, significantly reducing the total number of required connections.
• Exceptional machine adaptability, such as Kinetix 6200 drive systems, has an expansive potential for control scalability.
• Enhanced diagnostics due to increased availability of drive data and fault messages.
• Less wear on the connected Allen-Bradley servo motors and linear actuators because of the Safe Speed Monitoring feature that helps reduce/eliminate unnecessary drive stops and starts. This feature allows operators to monitor and reduce the speed of a Kinetix 6200 drive system to a point where they can safely inspect and carry out maintenance tasks without completely stopping the machine.
• Simplified maintenance is due to the simple modular design of Kinetix 6200 drive systems, so you don’t need to replace the entire drive system if a technical issue arises, just the faulty module.