From Zero to Precision: How Kinetix 6200 Enhances Efficiency in Modern Industries

Allen-Bradely Kinetix 6200 drives are high-performance, multi-axis, safe-speed servo drives intended to provide a Kinetix Integrated-Motion solution through SERCOS (Serial Real-time Communications System) interface modules for machines with high power demands and large axis counts. A typical Kinetix 6200 drive system can support one to eight axis drive configurations on a Bulletin 2094 (2094-PRSx) power rail.  

Kinetix 6200 servo drives feature cutting-edge motor control technologies and an innovative, flexible modular design with embedded safety features, including Safe Speed Monitoring (SSM) and Safe Torque Off (STO), that help safeguard machines/personnel and increase system efficiency and productivity. The modular design also provides ease of maintenance and greater machine flexibility and functionality. For instance, changing the connected control modules allows you to readily transition a standard Kinetix 6200 drive system from Safe Torque-Off functionality to Safe speed monitoring.

Key Drive Features

• Multi-axis modular design for integrated motion, communication, and networked safety options with the following:
  • 2094-BCxx-Mxx-M, 400V-class Integrated Axis (power) Modules (IAM)
  • 2094-BMxx-M, 400V-class Axis (power) Modules (AM)
  • 2094-SE02F-M00-Sx SERCOS interface control modules
  • Integrated Motion capability on the SERCOS interface
• Three-phase, 324 to 528V rms (360 to 480V nominal) AC input to the Bulletin 2094 AM/IAM power modules
  • 1.8 to 22.0 kW (kilowatts) continuous output power (inverter ratings)
  • 2.8 to 34.6 A (rms) or 4.0 to 49.0 A (0-pk) continuous output current (inverter ratings)
  • 6.0 to 45.0 kW (kilowatts) continuous output power to bus (converter ratings)
  • 9.0 to 68.0 A (A_DC) continuous current output to bus (converter ratings)
•  Control power:
  • Single-phase, 95 to 264V rms (110 to 240V rms nominal) AC input control voltage
  • 6.0 or 98.0 A control input current: 6.0 A – Nominal at 115/11V AC rms; 6.0 A – Nominal at 230/220V AC rms; 98.0 A – Maximum inrush (0-pk)
• TÜV Rheinland approved safety functions:
  • PLe, Category 4, and SIL CL3 Safe Torque-Off (STO) control
  • PLe, Category 4, and SIL CL3 Safe Speed-Monitoring (SSM) control
• Kinetix Integrated Motion with compatible CompactLogix, SoftLogix, or ControlLogix Allen-Bradley controllers
• High-resolution, single-turn, and multi-turn absolute encoder feedback or feedback-only auxiliary axis

How Kinetix6200 Drives Enhance Efficiency in Modern Industries

With the following features, Kinetix 6200 drives greatly enhance the efficiency of a vast array of motion control applications across different modern-day industries.

SERCOS Connectivity

SERCOS (Serial Real-time Communications System) protocol is an IEC 61491-approved communication network for motion control. It is designed for real-time, high-speed serial communications involving standardized transfer of closed-loop data over fiber-optic cables with high noise immunity.  

Kinetix 6200 servo drives support SERCOS connectivity using Allen-Bradley Logix 5000 SERCOS interface motion modules. They include:

• 1756-MxxSE Modules: The modules provide a SERCOS communication link between Logix 5000 ControlLogix controllers and a Kinetix 6200 servo drive system.
• 1768-M04SE Module: This 4-axis motion interface module connects Logix 5000 CompactLogix controllers to a Kinetix 6200 drive system using SERCOS fiber-optic cables.
• 1784-PM16SE PCI card: A 16-axis SERCOS interface PCI (Peripheral Component Interconnect) card that functions as a SERCOS communication link between the Allen-Bradely SoftLogix controller platform and a Kinetix 6200 servo drive system.

In addition, Kinetix 6200 drives feature Integrated Motion on the SERCOS interface, a robust drive/controller communication system that utilizes noise-immune fiber-optic cables. A single fiber-optic cable ring acts as the sole communication link between an Allen-Bradley Logix 5000 controller and a Kinetix 6200 drive system. This design eliminates the need for complex feedback and control wiring, significantly reducing both installation time and wiring costs. Additionally, the SERCOS interface allows for advanced drive diagnostics and process reporting.

The integration of Logix 5000 controllers, Kinetix 6200 drives, and a wide range of high-performance Allen-Bradley linear actuators and linear/rotary servo motors ensures seamless operation and improved motion control. This combination enhances machine efficiency and simplifies the design, configuration, and maintenance of motion systems.

Multi-axis Modular Design

The multi-axis Kinetix 6200 features a modular design that allows for interchangeable SERCOS-controlled drive axes to switch between various safety functions, such as transitioning from Safe Torque-Off to Safe Speed Monitoring. It also enables the use of different network protocols, allowing a shift from SERCOS interface to EtherNet/IP connectivity. This flexibility provides machine builders with the ability to design, control, and scale their Kinetix 6200 drive systems to effectively and efficiently meet a wide range of application needs.

In essence, the modular design allows for increased adaptability for future system enhancements and is suitable for applications requiring a single, flexible network. It includes the following Kinetix 6200-Series control and power modules:

Kinetix 6200 Control Modules

The Allen-Bradley Kinetix 6200 control modules rely on the SERCOS interface for drive connectivity and diagnostics. These modules work seamlessly with motor feedback, auxiliary feedback, and functional safety I/O. Available control module options include:

• Safe Torque Off, SERCOS interface, Control Module: Catalog No. 2094-SE02F-M00-S0
• Safe Speed Monitoring, SERCOS interface, Control Module: Catalog No. 2094-SE02F-M00-S1

Note: Ethernet cable (RJ45) connections are only used when configuring the 2094-SE02F-M00-S1 Safe Speed Monitoring safety function.

In addition, Kinetix 6200 SERCOS control modules coupled with the 2094-BCxx-Mxx-M Integrated Axis (power) Modules and 2094-BMxx-M Axis (power) Modules provide various drive status indicators and a SERCOS interface to functional safety user I/O, motor feedback, drive communications, and auxiliary feedback. A classic Kinetix 6200 drive system can include up to eight SERCOS interface control modules and one to nine Bulletin 2090 SERCOS fiber-optic cables for connecting the control modules.

Kinetix 6200 control modules are compatible with the following SERCOS network cables include:

• 2090-SCEPx-x plastic, Chlorinated Polyethylene (CPE), fiber-optic cables for in-cabinet applications
• 2090-SCVPx–x plastic, Polyvinyl Chloride (PVC), fiber-optic cables for conduit and outdoor applications
• 2090-SCNPx–x plastic,Nylon,fiber-optic cables for on-machine applications in harsh environments
• 2090-SCVGx–x glass,Polyvinyl Chloride (PVC), fiber-optic cables for conduit and outdoor applications

Kinetix 6200 Power Modules

• 400V-class 2094-BCxx-Mxx-M: Kinetix 6200Integrated Axis (power) Modules (IAM) that include a converter and an inverter section. They are as follows:

400-class IAM Power Module Catalog No.	Continuous Output Ratings
	Inverter (A, 0-pk)	Converter (ADC)
2094-BC07-M05-M	22.0 kW, 49.0 A	45.0 kW, 68.0 A
2094-BC04-M03-M	13.5 kW, 30.0 A	28.0 kW, 42.0 A
2094-BC02-M02-M	6.6 kW, 14.6 A	15.0 kW, 23.0 A
2094-BC01-M01-M	3.9 kW, 8.6 A	6.0 kW, 9.0 A
2094-BC01-MP5-M	1.8 kW, 4.0 A	6.0 kW, 9.0 A

Note: Each of the Bulletin 2094 IAM power modules listed above requires one Kinetix 6200 SERCOS control module. You can only mount one 2094-BCxx-Mxx-M Integrated Axis (power) Module on the 2094-PRSx power rail. The power rail is available for 1 to 8-axis Kinetix 6200 drive systems.

• 400V-class 2094-BMxx-M: Kinetix 6200 Axis (power) Modules made of a common DC-bus inverter that requires 400V-class AC input power. They include:

400-class AM Power Module Catalog No.	Continuous Output Ratings
	Inverter (A, 0-pk)	Converter (ADC)
2094-BM05-M	22.0 kW, 49.0 A	N/A
2094-BM03-M	13.5 kW, 30.0 A
2094-BM02-M	6.6 kW, 14.6 A
2094-BM01-M	3.9 kW, 8.6 A
2094-BMP5-M	1.8 kW, 4.0 A

Note: Each of the Bulletin 2094 AM power modules listed above requires one Kinetix 6200 SERCOS control module and ought to be used with one 2094-BCxx-Mxx-M IAM power module. You can mount a maximum of seven single-width 2094-BMxx-M Axis (power) Modules on an 8-axis 2094-PRSx power rail.

Advanced Safety Functions

Kinetix 6200 servo drives are certified by the TÜV Rheinland group for use in safety-related motion control applications up to and including Safety Integrity Level (SIL) CL3 in conformity with IEC EN 61062, IEC 61508, and EN 61800-5-2, and Performance Level e (PLe), CAT 4 (Category 4) industrial safety per ISO 13849-1. This is because Kinetix 6200 SERCOS control modules are offered with either PLe CAT 4 and SIL CL3 certified Safe Speed-Monitoring or Safe Torque-Off functionality.

Safe Speed Monitoring (SSM) Function

The Kinetix 6200 Safe Speed-Monitoring function provides a drive output signal that indicates if the speed of the connected motor is below a specific limit value. In practice, safe speed monitoring capability makes it possible to only permit personnel access to a danger zone if the motor speed drops below a defined minimum value. This not only helps enhance workplace and machine safety but also enables improved system efficiency and increased machine productivity.

In Kinetix 6200 servo drives, the Safe Speed Monitoring feature incorporates five dual-channel inputs, one bipolar safety output, and two sets of DC sourcing safety outputs that support the following safety functions:

• Safe Limited Speed Monitoring (SLS)
• Safe Stop (SS)
• Door Control (DC)
• Door Monitoring (DM)
• Lock Monitoring (LM)
• Enabling Switch Monitoring (ESM)

Note: Each Kinetix 6200 SSM input/output supports only one specific safety function.

Safe Torque-Off (STO) Function

The Kinetix 6200 Safe Torque-Off feature allows machine builders to implement motion control systems that increase maximum machine availability, process efficiency, and machine/personnel safety. With this feature enabled, tasks such as drive setup, removal of jams, cleaning, and other routine maintenance practices that previously required the entire drive system to be powered down are performed without disconnecting the power supply.

The Safe Torque-Off function safely disables the Kinetix 6200 drive output to eliminate motor torque, safely bringing the drive to a no-torque state. This ensures that the connected motor and drive system environment is safe for carrying out maintenance tasks or personnel entry. Enabling the STO feature also allows users to benefit from shorter system downtime, faster machine restarts, and reduced risk of unexpected motor restarts. In addition, protection devices like safety contactors and safety relays can be done away with, simplifying the Kinetix 6200 drive system design and reducing both the overall system costs and panel space requirements.

Unlock the full potential of your Kinetix 6200 servo drive system with help from DO Supply. Whether you’re seeking expert advice, new components, or support for maintenance and repairs, our knowledgeable technicians and sales team are here to guide you. Visit DO Supply today to explore our extensive range of automation solutions and ensure your operations run at peak efficiency. If you enjoyed this article and would like to read another like it, this article on the Kinetix 2000 Series Drives might be for you.