Applying 2094 LIM Modules to Multiple Loads Kinetix Application Note PURPOSE This document addresses application cases where it is desired to utilize a single 2094 LIM module to supply three phase power to multiple load equipment. WHAT THIS NOTE CONTAINS This document contains information and application guidelines to properly size, select, and apply the 2094 LIM module for a variety of application needs. Also included are recommendations for circuit protection, proper selection of AB contactors and recommended wire type and sizes for specific load voltage and current ratings. INTENDED AUDIENCE Only personnel familiar with electrical panel layout and NEC codes should use this application note. Personnel who design electrical panels should be familiar with and conform to national and regional electrical codes. SUPPLIMENTAL INFORMATION Pub 2094-IN001x-EN-P Pub 2094-IN005x-EN-P Pub 2094-IN009x-EN-P Pub GMC-SG001x-EN-P GMC-RM001x-EN-P National Electrical Code SCOPE Kinetix 6000 Installation Manual Line Interface Module Installation Instructions Removing and Replacing the Line Interface Module Internal Components Kinetix Motion Control Selection Guide System Design for Control of Electrical Noise Published by the National Fire Protection Association of Boston, MA. The 2094 Line Interface Module is designed to reduce electrical panel space for servo drive applications while reducing wire terminations, installation time, and overall cost. The unit s compact design and form factor allows for ease of mounting and termination of associated connections. This product was originally intended for use with single-rack Kinetix 6000 Multi-Axis servo drive systems; however, application requirements have expanded this limitation to allow for use with multiple parallel AC/DC power loads. Any load equipment, including multiple combinations of Kinetix IAM modules, Ultra 3000, 1394, AB brand drives and third party load equipment within the voltage and current ratings of the 2094 LIM product specification may be used. Page 1
This application note assumes the following LIM product catalog numbers; Line Interface Modules 2094-AL75S 2094-BL75S 2094-XL75S-C2 2094-XL75S-C1 AC Input frequency - 50/60 Hertz - AC Input V 230 460 230/460 AC Input I Main AC output I 75 A rms Aux AC Input V 230 VAC 110 VAC Aux AC Input I 11 A rms 20 A rms Aux AC output V 230 VAC 1ph 110 VAC 1ph Aux AC output I 3 A rms 5 A rms 12 A rms Internal line filter No 24 Vdc I/O pwr 20 A 24 Vdc Brake pwr Table 1. APPLICATION GUIDELINES As with any panel design, a common sense approach is always recommended. Branch circuits become complex as distributed loads increase in number and vary in current. Avoid extended cable lengths keeping load equipment within the same panel as the LIM. Extended cable lengths will increase chances of cross coupling noise in clean areas of the panel. Practice proper cable routing to segregate Dirty areas from the Clean areas. Read and observe additional wiring guidelines in GMC-RM001x-EN-P System Design for Control of Electrical Noise. AC motor branch conductors and short circuit protection for Drive/motor systems must be sized for 125% of the RMS rated load current in accordance with NEC article 430 section III. For panel wiring, refer to NEC Article 310 and associated tables for correct wire selection and number of conductors allowed in a given raceway. LIMITATIONS Do not use 2094-AL09 or 2094-BL02 to drive multiple loads in parallel. This equipment is not designed with built-in short circuit protection. Also, the built-in AC filter does not satisfy CE compliance for parallel loads. Do not exceed rated output capacities of LIM module with summed capacities of load/s. Refer to CALCULATING AUXILIARY AC LOAD CURRENT in this publication. Note; As a general rule, LIM models 2094-AL75S and -BL75S can supply Control power for a maximum of eight (2094) axes. LIM models 2094-XL75S-Cx can supply control power for a maximum of sixteen (2094) axes. For systems with more than sixteen axes, auxiliary transformers may be used where the sum of Control Power and IO ratings exceed load limits per LIM Specifications. See Control Power Input in Publication 2094-IN001G for control power input requirements. Page 2
LIM SIZING Any combination of load equipment configured in parallel branches with properly sized conductors and short circuit protection is allowable. Several examples include; - Multiple Kinetix IAM modules of various ratings connected in parallel with a single LIM module. - One Kinetix, one Ultra 3000, and one Kinetix 7000 module connected in Parallel with a single LIM module (460Vac). Note; In case 24Vdc PLC IO Power and/or single-phase AC power requirements of miscellaneous load equipment exceed ratings of LIM specification; install appropriate auxiliary DC power supply and/or AC distribution transformer. LINE FILTERS Line Filters are needed in cases where CE compliance is required. To attain system CE compliance, each branch circuit with a Kinetix drive requires CE Filtering sized according to selection charts in corresponding AB drive installation manuals. Drive Catalog Number AC Line Filter Description AC Line Filter Catalog Number 2094-AC05-MP5 2094-AC05-M01 2094-AC09-M02 30 Amp, Three-phase, 500V 50/60 Hz 2090-XXLF-X330B 2094-AC16-M03 75 Amp, Three-phase, 500V 50/60 Hz 2090-XXLF-375 2094-AC32-M05 100 Amp, Three-phase, 500V 50/60 Hz 2090-XXLF-3100 2094-BC01-MP5 2094-BC01-M01 2094-BC02-M02 30 Amp, Three-phase, 500V 50/60 Hz 2090-XXLF-X330B 2094-BC04-M03 75 Amp, Three-phase, 500V 50/60 Hz 2090-XXLF-375B 2094-BC07-M05 100 Amp, Three-phase, 500V 50/60 Hz 2090-XXLF-3100 2099-BM06-S 50 Amp, Three-phase, 500V 50/60 Hz 2090- XXLF-TC350 2099-BM07-S 2099-BM08-S 65 Amp, Three-phase, 500V 50/60 Hz 2090- XXLF-TC365 2099-BM09-S 100 Amp, Three-phase, 500V 50/60 Hz 2090- XXLF-TC3100 2099-BM10-S 150 Amp, Three-phase, 500V 50/60 Hz 2090- XXLF-TC3150 2099-BM11-S 200 Amp, Three-phase, 500V 50/60 Hz 2090- XXLF-TC3200 Note; Refer to the Motion Control Accessories section of Publication GMC-SG001 for additional Line Filter compatibility charts. WIRE SIZE Select feeder branch circuit wire gage and temperature ratings based on 125% of the combined RMS rated load current. Select branch circuit wire gage and temperature ratings based on 125% of each RMS rated load. Refer to NEC Table 310.16 for capacities of insulated conductors rated 0 2000 volts, 60 through 90 degrees C. Be sure to use correction factor of.88 for ambient temperature of 40 degrees C. Also include correction factor in NEC table 310.15 when more than 3 current carrying conductors are used in a raceway or cable. Note: For load devices with a 125% rated current of less than 20 amps, use 90 degree C wire rated for 125% of the branch circuit rated load. Short circuit protection must be 125% of conductor capacity. Page 3
Note: No additional circuit protection is required where branch circuit wire size is equivalent to LIM input wire size. CIRCUIT BREAKER SIZING & SELECTION Short circuit protection for the feeder circuit is already provided by the LIM module; therefore, circuit protection is only necessary for multiple branch loads on the LIM output feed circuit. It is recommended to use circuit breakers with a 65K Amps (or greater than the rated plant supply) short circuit interrupt rating. AB Bulletin 140U-H circuit breakers provide this rating for circuits rated up to 125 amps. Select a breaker with branch circuit protection not to exceed 125% the maximum rms current rating of the conductor. Refer to Table 1. For the list of recommended 140U circuit breakers and specific current ratings. Note: Note: No circuit protection is required for LIM Control Power Output, Aux AC power output, or 24Vdc power output; short circuit protection is provided. No additional circuit protection is required where branch circuit wire size is equivalent to LIM input wire size. Page 4
CALCULATING RATED LOAD CURRENT The potential load current realized by the LIM is equal to the SUM of combined rms current ratings for all loads attached in parallel. Size the LIM according to RMS rated load specifications per NEC Article 430.24. Sizing according to motion profiles or anticipated usage is not defined in NEC motor branch circuit requirements and therefore must be approved by a licensed electrical engineer. CALCULATING AUXILIARY AC LOAD CURRENT The AC auxiliary load current realized at the LIM is calculated based on devices driven by individual load equipments on board power supplies. Logic power, Motor encoders, Auxiliary encoders, HIM modules and Drive signal I/O all contribute to the sum of required power. Full sized Ultra products specify a minimum rms current of 1amp@460Vac or.5 amps@230vac. Micro sized Ultra and 1394 drives do not have Aux AC power inputs. Kinetix 6000 products are somewhat different requiring a calculated current usage. To obtain Auxiliary AC current requirement, divide the summed power requirements of the axis modules by the Aux. AC power source voltage. See Tables 2 and 3 for referenced Auxiliary Power consumption per 2094 IAM module and associated auxiliary power devices. CALCULATING DC LOAD CURRENT Micro sized Ultra drives require a minimum 24Vdc 300ma current draw for digital IO. 1394 products require a minimum 24 Vdc power supply current of 3.5, 4.4, 5.2, and 6 amps for 1, 2, 3, and 4, axes consecutively. PLC IO, external relay cubes, motor brakes, and peripherals may also be included but not to exceed the rated DC output current specification of the LIM. Bulletin 140U 70/65 ka, Thermal-Magnetic, Fixed Thermal-Fixed Magnetic Rated Current I n [A] Thermal Trip [A] I r = I n (Fixed) Magneti c Trip [A] I m = 10 x I n Breaking Capacity (50 Hz) I cu /I cs [ka] TABLE 2. Page 5 Interrupting Rating (60 Hz) [ka] 220..240 380..415V 500V 690V 240V 480V 600/347V Cat. No. 15 A 15 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C15 20 A 20 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C20 25 A 25 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C25 30 A 30 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C30 35 A 35 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C35 40 A 40 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C40 45 A 45 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C45 50 A 50 500 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C50 60 A 60 600 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C60 70 A 70 700 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C70 80 A 80 800 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C80 90 A 90 900 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-C90 100 A 100 1000 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-D10 110 A 110 1100 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-D11 125 A 125 1250 100 50 70 35 35 18 6 3 100 65 25 140U-H6C3-D12
Summary of K6K Modules and logic power consumption K6K MODULE Power [W] Amps @ 115 Volts Amps @ 230 Volts 2094-AM /P5 /01 /02 15.74 0.137 0.068 2094-BM /P5 /01 /02 18.64 0.162 0.081 2094-AM /03 /05 22.44 0.195 0.098 2094-BM /03 /05 24.4 0.212 0.106 2094-AC /05 /09 18.74 0.163 0.081 2094-BC /01 /02 24.04 0.209 0.105 2094-AC /16 /32 25.32 0.220 0.110 2094-BC /04 /07 29.2 0.254 0.127 TABLE 3. Summary of Encoder Types Encoder Type Voltage [V] Current [ma] Power [W] Current @ 115 Volts Current @ 230 Volts Stegmann SRS 50/60 9 80 0.72 Absolute Single Turn 0.006 0.003 Stegmann SRM 50/60 9 80 0.72 Absolute Multi-Turn 0.006 0.003 Stegmann SNS 50/60 9 100 0.9 0.008 0.004 Renco RCM 21 5.25 135 0.70875 Rotary Optical w/hall, MP motor line 0.006 0.003 Renco RCH20 5.25 235 1.23375 Rotary Optical w/hall, N motor line 0.011 0.005 Sanyo??? 5.25 225 1.18125 Rotary Optical w/hall Y motor line 0.010 0.005 Tamagawa SI35 5.25 110 0.5775 Rotary Optical Absolute, Samsung Motors 0.005 0.003 Tamagawa??? 5.25?? Rotary Optical w/hall, Samsung Motors?? Renishaw RGB25X 5.25 120 0.63 Linear Optical, 1Vpp 20um Sine/Cosine Raptor 0.005 0.003 Heidenhain LS 5.25 150 0.7875 Linear Optical Encoders Inc. (Many versions) 0.007 0.003 Heidenhain ERN/ERM/ERO/ROD 5.25 150 0.7875 Rotary Optical Encoders Inc. (Many versions) 0.007 0.003 Heidenhain LC181 5.25 300 1.575 Linear Endat Absolute 0.014 0.007 Heidenhain ECI & EQI 5.25 130 0.6825 Rotary Endat Absolute 0.006 0.003 Lenord Bauer GEL 244 5.25 200 1.05 Magnetic for Frameless Applications 0.009 0.005 Admotec EK6210 5.25 200 1.05 Magnetic for Frameless Applications 0.009 0.005 Newall Spherosyn 5.25 180 0.945 Linear Optical Incremental 0.008 0.004 Newall Spherosyn 5.25 300 1.575 Linear Optical SSI Absolute 0.014 0.007 Sony SH12 5.25 150 0.7875 Linear Optical 0.007 0.003 DRC Encoders 5.25 170 0.8925 All types 0.008 0.004 Netzer Electric Encoder 5.25 10 0.0525 0.000 0.000 Rockwell 845X 5.25 150 0.7875 Many types 0.007 0.003 TABLE 4. Page 6
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