398 ULTRA Plus Series Positioning Drive Module (Catalog Nos.
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Preface Introduction 5HDG WKLV SUHIDFH WR IDPLOLDUL]H \RXUVHOI ZLWK WKH UHVW RI WKH PDQXDO 7KLV SUHIDFH FRYHUV WKH IROORZLQJ WRSLFV • • • • • • • Who Should Use this Manual :KR VKRXOG XVH WKLV PDQXDO 7KH SXUSRVH RI WKLV PDQXDO &RQWHQWV RI WKLV PDQXDO 5HODWHG GRFXPHQWDWLRQ &RQYHQWLRQV XVHG LQ WKLV PDQXDO 3URGXFW UHFHLYLQJ DQG VWRUDJH UHVSRQVLELOLW\ $OOHQ %UDGOH\ VXSSRUW 8VH WKLV PDQXDO LI \RX DUH UHVSRQVLEOH IRU GHVLJQLQJ LQVWDOOLQJ SURJUDPPLQJ RU WURXEOHVKRRWLQJ WKH 8/75$ 3OXV 3'0 ,I \RX GR QRW
Preface 2 Contents of this Manual 5HIHU WR WKH IROORZLQJ PDQXDO IRU WKH GHVFULSWLYH FRQWHQWV RI WKLV LQVWDOODWLRQ PDQXDO Chapter Publication 1398-5.1 - January 2000 Title Contents Preface Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended. 1 Overview Gives a functional description of the ULTRA Plus PDM product series. 2 Install ULTRA Plus PDM Components Provides mounting information for the ULTRA Plus PDM system.
Preface Related Documentation 7KH IROORZLQJ GRFXPHQWV FRQWDLQ DGGLWLRQDO LQIRUPDWLRQ FRQFHUQLQJ UHODWHG $OOHQ %UDGOH\ SURGXFWV 7R REWDLQ D FRS\ FRQWDFW \RXU ORFDO $OOHQ %UDGOH\ RIILFH RU GLVWULEXWRU For this information Read This Document Document Number An overview of the ULTRA Plus Positioning Drive ULTRA Plus Brochure 1398-2.0 A description and specifications for the ULTRA Series family. ULTRA Series Product Data 1398-2.
Preface 4 Product Receiving and Storage Responsibility
Chapter 1 Overview of the ULTRA Plus PDM System Functional Description 7KH 8/75$ 3OXV 3'0 PRWLRQ FRQWURO V\VWHP LV D SRVLWLRQLQJ GULYH V\VWHP ZKLFK LQWHJUDWHV D KLJK SHUIRUPDQFH VLQXVRLGDO EUXVKOHVV PRWRU YHORFLW\ FRQWUROOHU DQG D SURJUDPPDEOH SRVLWLRQ FRQWUROOHU LQWR D VLQJOH SDFNDJH 7UDGLWLRQDO PRWLRQ FRQWUROOHU DUFKLWHFWXUH XVHV VHSDUDWH GULYH DQG SRVLWLRQ FRQWURO PRGXOHV ZLWK DQ DQDORJ LQWHUIDFH EHWZHHQ LQGLYLGXDO FRPSRQHQWV 7KH 8/75$ 3OXV 3'0 PRWLRQ FRQWUROOHUV XVH DGYDQFHG PLFURSURFHVVRU
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Overview of the ULTRA Plus PDM System 1-3 Figure 1.
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Overview of the ULTRA Plus PDM System 1-5 Power Supply Module (PSM) 7KH SRZHU VXSSO\ PRGXOH LV RQO\ UHTXLUHG IRU 3'0 DQG V\VWHPV 7KH 3RZHU 6XSSO\ 0RGXOH 360 FDQ VXSSO\ '& SRZHU WR DV PDQ\ DV VL[ 8/75$ 3OXV 3'0 PRGXOHV 7KH RQO\ LQSXW WR WKH 360 LV ² 9$& VLQJOH RU WKUHH SKDVH SRZHU 7KH LQSXW SRZHU PD\ EH RSWLRQDOO\ LVRODWHG WKURXJK D WUDQVIRUPHU 7KH RXWSXW LV D WZR ZLUH '& EXV 7KH 360 UHTXLUHV QR DGMXVWPHQWV SURWHFWV LWVHOI SURYLGHV WURXEOHVKRRWLQJ GLDJQRVWLFV DQG
1-6 Overview of the ULTRA Plus PDM System Accessories Operator Terminal 7KH RSWLRQDO 2SHUDWRU 7HUPLQDO DOORZV WKH PDFKLQH RSHUDWRU FRQYHQLHQW DFFHVV WR VWDWXV LQIRUPDWLRQ SURJUDP YDULDEOHV FRQWURO IXQFWLRQV DQG PHVVDJH GLVSOD\ FDSDELOLWLHV 7KH 2SHUDWRU 7HUPLQDO KDV D EULJKW OLQH E\ FKDUDFWHU YDFXXP IOXRUHVFHQW GLVSOD\ DQG D VHDOHG PHPEUDQH NH\ERDUG ZLWK WDFWLOH IHHGEDFN 7KH WZR DYDLODEOH 2SHUDWRU 7HUPLQDOV GLVSOD\ PXOWLSOH VWDWXV VFUHHQV IRU PRQLWRULQJ DQG GLDJQRVWLFV )RXU SURJUDPPDE
Overview of the ULTRA Plus PDM System 1-7 Transformers 0XOWL WDS VLQJOH SKDVH DQG WKUHH SKDVH LVRODWLRQ WUDQVIRUPHUV DUH DYDLODEOH LQ D YDULHW\ RI SRZHU UDWLQJV IRU OLQH YROWDJH PDWFKLQJ 5HIHU WR 7UDQVIRUPHUV RQ SDJH % Auxiliary Power Supply Module (PSM) $Q DX[LOLDU\ SRZHU VXSSO\ PRGXOH 360 $8; LV DYDLODEOH WR VXSSO\ '& SRZHU WR WKH ORJLF VXSSOLHV RI XS WR IRXU 8/75$ 3OXV 3'0V LI WKH 360V DUH 2)) 7KH 360 $8; XVHV VLQJOH SKDVH 9$& SRZHU DV WKH LQSXW 7KLV RSWLRQ LV RQO\ QHFHVVDU\ IRU WKH
1-8 Overview of the ULTRA Plus PDM System Shunt Kits 7KH 3'0 DQG % KDV D EXLOW LQ VKXQW UHJXODWRU ,I WKH DSSOLFDWLRQ UHTXLUHV D KLJKHU FRQWLQXRXV SRZHU GLVVLSDWLRQ WKH 8/75$ 3OXV 3'0 SURYLGHV HDV\ DFFHVV IRU DQ H[WHUQDO VKXQW FRQQHFWLRQ )DFWRU\ DYDLODEOH ([WHUQDO 6KXQW .LW Ω : RU DQ ([WHUQDO 6KXQW .
Chapter 2 Install the ULTRA Plus PDM Components 7KLV FKDSWHU H[SODLQV WKH SK\VLFDO LQVWDOODWLRQ RI WKH LQGLYLGXDO FRPSRQHQWV DVVRFLDWHG ZLWK DQ 8/75$ 3OXV 3'0 V\VWHP 3ULRU WR LQVWDOODWLRQ RI WKH 8/75$ 3OXV 3'0 V\VWHP YHULI\ WKDW DOO WKH QHFHVVDU\ FRPSRQHQWV DUH DYDLODEOH (DFK D[LV RI PRWLRQ UHTXLUHV DQ 8/75$ 3OXV 3'0 DQG D PRWRU ,I 3'0 DQG LV XVHG WKHUH PXVW EH DW OHDVW RQH SRZHU VXSSO\ PRGXOH IRU WKH V\VWHP ATTENTION ! Mounting :LULQJ SUDFWLFHV JURXQGLQJ GLVFRQQHFWV
2-2 Install the ULTRA Plus PDM Components Environment 7KH 8/75$ 3OXV 3'0 DQG SRZHU VXSSO\ PRGXOHV DUH GHVLJQHG IRU VLPSOH LQVWDOODWLRQ RQ D IODW VXUIDFH VXFK DV WKH EDFN ZDOO RU SODWH RI DQ HQFORVXUH 7KH\ PXVW EH HQFORVHG LQ D JURXQGHG PHWDO HQFORVXUH RIIHULQJ SURWHFWLRQ DV GHILQHG LQ VWDQGDUG (1 ,(& WR DW OHDVW ,3 VXFK WKDW WKH\ DUH QRW DFFHVVLEOH WR DQ RSHUDWRU RU XQVNLOOHG SHUVRQ 1(0$ HQFORVXUH H[FHHGV WKHVH UHTXLUHPHQWV SURYLGLQJ SURWHFWLRQ WR ,3 7KH HQYLURQPHQW LQ WKH HQFO
Install the ULTRA Plus PDM Components 2-3 Ventilation 7KH PD[LPXP SRZHU ORVVHV DUH VKRZQ EHORZ WR KHOS LQ VL]LQJ DQ HQFORVXUH DQG DQ\ UHTXLUHG YHQWLODWLRQ 7\SLFDO KHDW ORVVHV FDQ UXQ DSSUR[LPDWHO\ RQH KDOI PD[LPXP SRZHU ORVVHV Maximum power losses for help in sizing enclosures Model Maximum Loss (Watts) 1398-PDM-10 50 + dissipative shunt 1398-PDM-20 100 + dissipative shunt 1398-PDM-25 200 1398-PDM-30 150 + dissipative shunt 1398-PDM-50 180 1398-PDM-75 300 + dissipative shunt 1398-PDM-100
2-4 Install the ULTRA Plus PDM Components Transformer Sizing 8/75$ 3OXV 3'0 V\VWHPV GR QRW UHTXLUH LVRODWLRQ WUDQVIRUPHUV $ WUDQVIRUPHU PD\ EH UHTXLUHG KRZHYHU WR PDWFK WKH YROWDJH UHTXLUHPHQWV RI WKH FRQWUROOHU WR WKH DYDLODEOH VHUYLFH 7R VL]H D WUDQVIRUPHU IRU D 8/75$ 3OXV 3'0 WKH SRZHU RXWSXW .
Install the ULTRA Plus PDM Components 2-5 6L]LQJ D WUDQVIRUPHU ZLWK DQ 3'0 DQG + PRWRU IMPORTANT 7KH VSHHG WRUTXH FXUYH LQIRUPDWLRQ LV EDVHG XSRQ D 3'0 PRGXOH LQSXW YROWDJH RI 9$& )RU D 9$& LQSXW YROWDJH WKH PD[LPXP VSHHG LV UHGXFHG E\ KDOI KVA 3000RPM × 75lb – in 746Watts KVA = ------------------------------------------------------ × ------------------------ × --------------------------- × 2.0 63, 025 HP 1000Watts Transformer Size = 5.3KVA Publication 1398-5.
2-6 Install the ULTRA Plus PDM Components Figure 2.
Install the ULTRA Plus PDM Components 2-7 Figure 2.
2-8 Install the ULTRA Plus PDM Components Figure 2.3 Single PhaseTransformer Outline Diagram NOTES: 1. DIMENSIONS ARE IN INCHES (mm) 1/4-20 GROUND STUD (6.35 DIA) (TRANSFORMER CHASSIS) 2 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING CONNECTIONS TO TRANSFORMER TERMINAL STRIPS. SECONDARY CONNECTIONS 8-32 THD BOLTS 2 (4.17 DIA) CONNECTION INSTRUCTIONS PRIMARY CONNECTIONS 8-32 THD BOLTS 2 (4.17 DIA) 9.10 MAX. (230) 8.00 MIN. (200) 8.20 MAX.
Install the ULTRA Plus PDM Components 2-9 Figure 2.4 Three Phase Transformer Outline Diagram PART NO. 9101-0131 CONNECTION INSTRUCTIONS 1 PRIMARY CONNECTIONS G REF 1 SECONDARY CONNECTIONS E ±0.06 B MAX 0.56 ±0.03 DIA THRU (4) 0.25-20 GROUND STUD (TRANSFORMER CHASSIS) 1 8.0 MIN CLEARANCE RECOMMENDED FOR ACCESS TO WIRING C MAX RELIANCE MOTION CONTROL TRANSFORMER PART NO.
2-10 Install the ULTRA Plus PDM Components Mounting Requirements 3RVLWLRQ WKH 8/75$ 3OXV 3'0 LQ D YHUWLFDO SRVLWLRQ RQ D IODW VROLG VXUIDFH WKDW PHHWV WKH PRXQWLQJ UHTXLUHPHQWV IRU ZHLJKW KXPLGLW\ DQG WHPSHUDWXUH OLVWHG LQ $SSHQGL[ $ 7KH IROORZLQJ GLDJUDPV OLVW GLPHQVLRQDO PRXQWLQJ UHTXLUHPHQWV Figure 2.5 1398-PDM-10, 20 and 30 Mounting 4.10 104.1 1.05 26.6 0.27 7.0 8.93 226.8 1.00 25.4 1.00 25.
Install the ULTRA Plus PDM Components 2-11 Figure 2.6 1398-PDM-75 Mounting 5.97 151.7 0.27 7.0 1.00 25.4 1.99 50.5 8.93 226.8 1.00 25.4 AIR EXHAUST Allen-Bradley Ultra Plus Series Internal P7 Serial 1 Auxiliary 2 U10 3 TB2 P6 Serial 2 Computer FINAL INSPECTION External Shunt Status 1 P5 Encoder 1 Motor WARNING: High Voltage May Exist Up To Five Minutes After Removing Power P4 Encoder 2 Auxiliary DC Bus 14.20 360.7 R 13.75 349.
2-12 Install the ULTRA Plus PDM Components Figure 2.7 1398-PDM-25, 50, 100, and 150 Mounting 4.50 114.3 9.93 252.1 1.38 0.25 34.9 6.4 9.70 246.4 1.38 0.45 34.9 AIR EXHAUST 11.4 Allen-Bradley Ultra Plus Series P7 Serial Port 1 P6 Serial Port 2 P5 Encoder Input 1 P4 Encoder Input 2 P3 Analog I/O And Status 16.15 410.2 16.87 17.50 428.6 444.5 P2 General Purpose Inputs And Outputs P1 General Purpose Inputs WARNING: Do Not Apply Power With Cover Removed.
Install the ULTRA Plus PDM Components 2-13 Figure 2.8 1398-PDM-150B Mounting 5.97 151.7 0.27 7.0 1.25 31.8 2.75 69.9 8.93 226.8 2.75 69.9 AIR EXHAUST Allen-Bradley Ultra Plus Series P10 P9 P8 Status 1 P7 Serial 1 Auxiliary 2 1 U10 U10 3 TB2 DC BUS WARNING: High Voltage May Exist Up To Fifteen Minutes After Removing Power. P6 Serial 2 Computer POT1 POT2 POT3 P5 Encoder 1 Motor R Motor 1 FINAL INSPECTION Internal External Shunt 1 S P4 Encoder 2 Auxiliary T U57 13.75 349.2 14.
2-14 Install the ULTRA Plus PDM Components 1398-PDM-25, 50, 100, and 150 Power Supply Module 7KH SRZHU VXSSO\ PRGXOH VKRXOG EH FHQWUDOO\ ORFDWHG WR PLQLPL]H WKH GLVWDQFH EHWZHHQ LW DQG WKH 3'0 PRGXOHV 7KH KLJKHU FXUUHQW UDWLQJ 3'0 PRGXOHV VKRXOG EH ORFDWHG FORVHVW WR WKH SRZHU VXSSO\ PRGXOH PSM Auxiliary Transformers )LJXUH VKRZV WKH PRXQWLQJ GLDJUDP DQG FRQQHFWLRQV IRU WKH 360 $X[LOLDU\ 7UDQVIRUPHU Figure 2.9 PSM Auxiliary Transformer mounting 5.50 MAX. SPECIFICATIONS: 4.
Install the ULTRA Plus PDM Components 2-15 Figure 2.10 PSM-AUX Outline and Connection Diagram 3.50 (89) 1.75 (44.5) 0.50 (13) 0.50 (13) 0.25 (6.5) 0.50 (13) 9.00 (229) 8.38 (213) 3.00 (77) 2.00 (50) DIAGRAM, OUTLINE & CONNECTION DRAWING AUXILIARY POWER SUPPLY MODULE DOCUMENT NO. 9101-0134 REV D1 Publication 1398-5.
2-16 Install the ULTRA Plus PDM Components Motors 7KH LQVWDOODWLRQ DQG RSHUDWLRQ RI PRWRUV VKRXOG DGKHUH WR WKH IROORZLQJ JXLGHOLQHV • 'R QRW UXQ PRWRUV WKDW DUH QRW SURSHUO\ PRXQWHG $WWDFK DOO PRWRU FDEOHV DIWHU PRWRU LV PRXQWHG • 0RXQW PRWRU ZLWK FRQQHFWRUV SRLQWLQJ GRZQZDUG DQG XVH D GULS ORRS WR NHHS OLTXLGV IORZLQJ DZD\ IURP FRQQHFWRUV • &RQVLGHU PRWRU FDVH WHPSHUDWXUH LI QHFHVVDU\ WR VDIHJXDUG RSHUDWRU DQG PDLQWHQDQFH VWDII 0D[LPXP FDVH WHPSHUDWXUH LV DSSUR[LPDWHO\ & ) IRU D PRWRU
Install the ULTRA Plus PDM Components 2-17 External Shunt 7KH IROORZLQJ SURFHGXUH RXWOLQHV WKH LQVWDOODWLRQ RI ([WHUQDO 6KXQW : DQG ([WHUQDO 6KXQW : XQLWV 5HPRYH MXPSHU EHWZHHQ WHUPLQDOV DQG DW WKH LQWHUQDO VKXQW FRQQHFWLRQ 7KH MXPSHU LV VXSSOLHG ZLWK WKH DPSOLILHU :LUH DQ H[WHUQDO VKXQW UHVLVWRU EHWZHHQ WHUPLQDOV DQG DW WKH H[WHUQDO VKXQW FRQQHFWLRQV 8VH ZLUH RI WKH UHFRPPHQGHG ZLUH VL]H Figure 2.
2-18 Install the ULTRA Plus PDM Components Figure 2.12 External Shunt (900W) mounting and connection diagram At terminal block, Cabinet There must be 155mm (6.1 in.) Of clearance on all sides of remove jumper shunt module installed at factor y for internal shunt INTERNAL 1 155mm (6.1 in.
Install the ULTRA Plus PDM Components 2-19 Operator Terminal )LJXUH DQG )LJXUH RQ SDJH LOOXVWUDWH WKH GLPHQVLRQV RI WKH WZR DYDLODEOH 2SHUDWRU 7HUPLQDOV $OO GLPHQVLRQV DUH LQ LQFKHV PP $OORZ ILIW\ PLOOLPHWHUV WZR LQFKHV FOHDUDQFH DERYH DQG EHORZ WKH 2SHUDWRU 7HUPLQDO IRU DLUIORZ DQG PLOOLPHWHUV IRXU LQFKHV FOHDUDQFH EHKLQG WR DOORZ IRU FDEOH FRQQHFWRUV 5HIHU WR ´6SHFLILFDWLRQVµ RQ SDJH $ IRU DGGLWLRQDO WHFKQLFDO LQIRUPDWLRQ Figure 2.
2-20 Install the ULTRA Plus PDM Components Figure 2.14 Operator Terminal (1398-HMI-003) Dimensions GASKET SUPPLIED WITH UNIT 8.11 [206.0] 3.86 [98.0] 3.86 [98.0] 0.20 [5.0] 3.28 [83.25] 6.89 [175.0] 6.13 MAX. [155.7] 3.28 [83.25] 0.17 [4.25] 2.22 [56.5] 7.40 [188.0] 1 2 3 4 5 6 7 8 9 10 Not used 24 VDC 3.28 [83.25] 3.13 [79.5] 7.27 MAX. [184.7] 6.26 [159.0] 3.86 [98.0] 3.70 [94.0] Ø 0.14 (8) Ø [3.5] RECOMMENDED PANEL CUTOUT DIMENSIONS Publication 1398-5.
Install the ULTRA Plus PDM Components 2-21 I/F Conversion Card, 24VDC Sourcing )LJXUH LOOXVWUDWHV WKH GLPHQVLRQV RI WKH , ) 9 &RQYHUVLRQ &DUG DQG WKH ',1 PRXQWLQJ SDQHO $OO GLPHQVLRQV DUH LQ PLOOLPHWHUV LQFKHV DUH DSSUR[LPDWH FRQYHUVLRQV 7KH FRQYHUVLRQ FDUG PXVW EH PRXQWHG LQ WKH VDPH HQFORVXUH DV WKH 8/75$ 3OXV 3'0 WR FRPSO\ ZLWK WKH (8 /9' GLUHFWLYH Figure 2.15 I/F 24 Volt Sourcing Conversion Card Mounting Dimensions P1 26 1 77.0 (1.9) P2 1 26 USER 47.0 (1.9) 169.0 (6.7) 77.0 (1.
2-22 Install the ULTRA Plus PDM Components PDM Fusing Requirements )XVLQJ IRU WKH 8/75$ 3OXV 3'0V GLIIHUV EHFDXVH RI WKH VHSDUDWH SRZHU VXSSO\ IRU VRPH PRGHOV Short Circuit Protection ,Q WKH 8QLWHG 6WDWHV WKH 1DWLRQDO (OHFWULFDO &RGH VSHFLILHV WKDW IXVH VHOHFWLRQ PXVW EH EDVHG RQ WKH PRWRU·V )XOO /RDG $PSHUDJH )/$ ZKLFK LV QRW WR EH FRQIXVHG ZLWK WKH 3'0 LQSXW FXUUHQW 7KH ODUJHVW IXVH DOORZHG XQGHU DQ\ FLUFXPVWDQFHV LV IRXU WLPHV WKH PRWRU·V )/$ 7KHUHIRUH WKH ODUJHVW IXVHV SHUPLVVLEOH IRU X
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2-32 Install the ULTRA Plus PDM Components Multiple Sub Panels %RQGLQJ PXOWLSOH VXE SDQHOV FUHDWHV D FRPPRQ ORZ LPSHGDQFH H[LW SDWK IRU WKH KLJK IUHTXHQF\ HQHUJ\ LQVLGH WKH FDELQHW 6XE SDQHOV WKDW DUH QRW ERQGHG WRJHWKHU PD\ QRW VKDUH D FRPPRQ ORZ LPSHGDQFH SDWK 7KLV GLIIHUHQFH LQ LPSHGDQFH PD\ DIIHFW QHWZRUNV DQG RWKHU GHYLFHV WKDW VSDQ PXOWLSOH SDQHOV 5HIHU WR WKH LOOXVWUDWLRQ EHORZ IRU UHFRPPHQGHG ERQGLQJ SUDFWLFHV Figure 2.21 Multiple sub-panels and cabinet Publication 1398-5.
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Install the ULTRA Plus PDM Components 2-35 Emergency Stop Contactor 6RPH PDFKLQHV UHTXLUH WKDW D FRQWDFWRU EH LQVHUWHG EHWZHHQ WKH PRWRU DQG 3'0 IRU HPHUJHQF\ VWRS SXUSRVHV $ KD]DUG DQDO\VLV RI WKH PDFKLQH ZLOO GHWHUPLQH LI WKLV LV QHHGHG ,I XVHG WKH FRQWDFWRU PXVW QRW VLPSO\ EUHDN WKH PRWRU FXUUHQW LW PXVW VZLWFK D SKDVH UHVLVWLYH ORDG LQ SDUDOOHO ZLWK WKH PRWRU ZLQGLQJV 7KH WKUHH UHVLVWRUV ZLOO SURYLGH G\QDPLF EUDNLQJ DQG D FDWHJRU\ ]HUR VWRS 7KH UHVLVWRUV DOVR FDQ SUHYHQW FRQWLQXRXV DUFLQ
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Install the ULTRA Plus PDM Components 2-37 Figure 2.
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2-40 Install the ULTRA Plus PDM Components AC Line Filter Selection 6HOHFWLRQ RI WKH SURSHU ILOWHU LV RQO\ WKH ILUVW VWHS LQ UHGXFLQJ FRQGXFWHG HPLVVLRQV &RUUHFW ILOWHU LQVWDOODWLRQ LV FUXFLDO WR DFKLHYLQJ ERWK (0, DWWHQXDWLRQ DQG WR HQVXUH VDIHW\ $OO RI WKH IROORZLQJ JXLGHOLQHV VKRXOG EH PHW IRU HIIHFWLYH ILOWHU XVH 7KH ILOWHU PXVW EH PRXQWHG FORVH WR WKH 3'0 LQSXW WHUPLQDOV 7KLV LV SDUWLFXODUO\ LPSRUWDQW IRU KLJKHU IUHTXHQF\ HPLVVLRQV 0+] ,I WKH GLVWDQFH H[FHHGV PP IW WKHQ D
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2-46 Install the ULTRA Plus PDM Components Figure 2.27 Motor power winding methods to minimize noise emissions PDM BRUSHLESS MOTOR TWISTED TOGETHER R R S T MOTOR CASE S T CHASSIS TO SINGLE POINT EARTH GROUND PDM BRUSHLESS MOTOR TWISTED TOGETHER R R S T S T CHASSIS MOTOR CASE SHIELD TO SINGLE POINT EARTH GROUND PDM BRUSHLESS MOTOR COMMON MODE CHOKE (10-20 TURNS ON COMMON FERRITE TORROID CORE) R R S T S T CHASSIS MOTOR CASE TWISTED TOGETHER TO SINGLE POINT EARTH GROUND Publication 1398-5.
Chapter 3 Wire the ULTRA Plus PDM Components 7KLV FKDSWHU H[SODLQV WKH ZLULQJ UHTXLUHPHQWV RI DQ 8/75$ 3OXV 3'0 V\VWHP System Power Connections ATTENTION ! 7KH XVHU LV UHVSRQVLEOH IRU FRQIRUPLQJ WR 1DWLRQDO (OHFWULFDO &RGHV DQG DOO RWKHU DSSOLFDEOH ORFDO FRGHV )DLOXUH WR FRQIRUP WR FRGHV FDQ UHVXOW LQ GDPDJH WR WKH HTXLSPHQW RU VHYHUH ERGLO\ LQMXU\ 1398-PDM-10, 20, 75, and 150B 7KH 3'0 DQG UHTXLUH VLQJOH SKDVH $& SRZHU WR 9$& 7KH 3'0 DQG % UHTXLUH WKUHH S
3-2 Wire the ULTRA Plus PDM Components Figure 3.1 Power Wiring Diagram for 1398-PDM-10, 20, and 30 MOTOR POWER WIRES R,S,T,GND MOTOR MOTOR POWER MATING CONNECTOR CONTACT SIZE (GAUGE/mmÉ) H-2005 H-3007 H-3016 H-4030 F-4030 H-4050 F-4050 H-4075 F-4075 INPUT POWER WIRES RECOMMENDED MOTOR POWER CONNECTOR MINIMUM RECOMMENDED POWER WIRE (GAUGE/mmÉ) (60˚C ˚ COPPER ONLY) PIN A B C D SIGNAL R S T MOTOR CASE 16 AWG/1.
Wire the ULTRA Plus PDM Components 3-3 Figure 3.2 Power Wiring for 1398-PDM-75 MOTOR POWER WIRES R,S,T,GND MOTOR H-4050 F-4050 H-4075 F-4075 H-6100 F-6100 H-6200 F-6200 MOTOR POWER MATING CONNECTOR CONTACT SIZE (GAUGE/mmÉ) PIN SIGNAL A B C D R S T MOTOR CASE (60˚C COPPER MIN) 12 AWG/3.0mmÉ 14 AWG/2.5mmÉ 8 AWG/10.0mmÉ 10 AWG/6.
3-4 Wire the ULTRA Plus PDM Components Figure 3.3 Power Wiring for 1398-PDM-150B MOTOR POWER WIRES R,S,T,GND MOTOR MOTOR POWER MATING CONNECTOR CONTACT SIZE 2 (GAUGE/mm ) H-6200 F-6200 H-6300 F-6300 H-8350 H-8500 2 8 AWG/10.0mm 2 8 AWG/10.0mm 2 4 AWG/25.0mm 2 4 AWG/25.0mm INPUT POWER WIRES MOTOR POWER CONNECTOR MINIMUM RECOMMENDED POWER WIRE 2 (GAUGE/mm ) PIN A B C D (75 C COPPER MIN) SIGNAL R S T MOTOR CASE DRIVE TERMINAL(S) L1 AUX, L2/N AUX ALL 2 10 AWG/6.0mm 2 16 AWG/1.
Wire the ULTRA Plus PDM Components 3-5 Auxiliary Logic Power 6LQJOH SKDVH $& SRZHU 9$& PD\ EH VXSSOLHG WR WKH LQWHUQDO ORJLF VXSSO\ WKURXJK / $8; DQG / 1 $8; $X[LOLDU\ VXSSO\ SRZHU WR WKH LQWHUQDO ORJLF VXSSO\ LV XVHIXO LI WKH 8/75$ 3OXV 3'0 ORJLF PXVW VWD\ 21 ZKHQ WKH PRWRU SRZHU PXVW EH WXUQHG 2)) $EVROXWH SRVLWLRQLQJ LV RQH H[DPSOH RI ZKHQ WKLV ZRXOG EH XVHIXO VLQFH SRVLWLRQ LQIRUPDWLRQ LV PDLQWDLQHG DV ORQJ DV ORJLF SRZHU LV RQ $QRWKHU H[DPSOH ZRXOG EH PDLQWDLQLQJ WKH 8/75$ 3OXV
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Wire the ULTRA Plus PDM Components 3-11 Figure 3.8 Power Supply Module jumper location DS1 DIAGNOSTIC INDICATOR LIGHTS POWER SUPPLY MODULE CIRCUIT BOARD TB1 (COMPONENT SIDE) W1 1 A B 4 INTERFACE CONNECTOR W1 JUMPER SETTING SELECTS: SHORTING JUMPER ACROSS TOP 2 PINS (POSITION A) EXTERNAL ENABLE INPUT IS SELECTED. EXTERNAL CONNECTION IS REQUIRED TO CONNECTOR TB1 SIGNALS ENABLE+ AND ENABLE-. REFER TO INSTRUCTION MANUAL FOR SIGNAL SPECIFICATION AND DETAILS OF OPERATION BEFORE USING POSITION A.
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Wire the ULTRA Plus PDM Components 3-13 7KH H[WHUQDO VKXQW LV HQDEOHG ZKHQ WKH '& %86 LQFUHDVHV WR D VSHFLILF YDOXH 9'& $Q LQFUHDVH LQ '& %86 YROWDJH PD\ RFFXU ZKHQ WKH DPSOLILHU GHFHOHUDWHV WKH PRWRU DQG LWV ORDG 7KLV LV GXH WR WKH HQHUJ\ IORZ IURP WKH PRWRU WR WKH '& %86 :KHQ WKH HQHUJ\ WUDQVIHUUHG IURP WKH URWDWLQJ LQHUWLD FDXVHV WKH '& %86 YROWDJH WR H[FHHG 9'& WKH VKXQW LV HQDEOHG DQG H[FHVV HQHUJ\ LV GLVVLSDWHG DV KHDW Internal Shunt Dissipation Ratings Shunt Rating 1398 PDM
3-14 Wire the ULTRA Plus PDM Components Figure 3.
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3-16 Wire the ULTRA Plus PDM Components Operator Terminals Power Connections (1398-HMI-002) )LJXUH LOOXVWUDWHV WKH SRZHU FRQQHFWLRQV WR WKH 2SHUDWRU 7HUPLQDO 9$& VLQJOH SKDVH ,W PXVW EH SURSHUO\ JURXQGHG WR SUHYHQW UDGLDWLQJ UDGLR IUHTXHQF\ QRLVH Figure 3.11 Operator Terminal power connections GROUND (EARTH) 115/230 VAC (NEUTRAL) 115/230 VAC (HOT) Publication 1398-5.
Wire the ULTRA Plus PDM Components 3-17 Power Connections (1398-HMI-003) 7KH 8/75$ 3OXV +0, 2SHUDWRU 7HUPLQDO UHTXLUHV D YROW SRZHU VXSSO\ UDWHG DW DPSV XQOHVV RWKHUZLVH VWDWHG RQ WKH ODEHO Figure 3.
3-18 Wire the ULTRA Plus PDM Components Motors Power Connections 3KDVLQJ RI WKH WKUHH SKDVH GULYH PRGXOH RXWSXWV 5 6 DQG 7 PXVW FRQIRUP WR WKH PRWRU 5 6 DQG 7 OHDGV IRU SURSHU RSHUDWLRQ &RQQHFW WKH HDUWK JURXQG WR HQVXUH D VDIH LQVWDOODWLRQ DQG SURSHU RSHUDWLRQ 6HH )LJXUH IRU FRQQHFWRU SLQ DQG VLJQDO LGHQWLILFDWLRQ RI + DQG ) 6HULHV PRWRUV Figure 3.13 Motor power connections for H, and F-Series motors 1. Do not interchange any connection in the cable 2.
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3-22 Wire the ULTRA Plus PDM Components Figure 3.
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3-24 Wire the ULTRA Plus PDM Components (Continued) PDM Connector PDM Pin Number Wire Color IF Card Pin Number Cable Pair P2 General purpose inputs and outputs 1 (Input) WHITE 1 Pair 8 2 (Input) BLACK 2 Pair 8 3 (Input) BLUE 3 Pair 9 4 (Output) BLACK 4 Pair 9 5 (Output) GREEN 5 Pair 10 6 (Output) BLACK 6 Pair 10 7 (Output) BROWN 7 Pair 11 8 (Output) BLACK 8 Pair 11 9 (Output) GREEN 9 Pair 12 10 (Output) BLUE 10 Pair 12 11 (Output) WHITE 11 Pair 13 12 (+24
Wire the ULTRA Plus PDM Components 3-25 Digital Inputs 7KH RSWLFDOO\ LVRODWHG LQSXWV DUH FRQQHFWHG ZLWK DQ LQWHUQDO SXOO XS UHVLVWRU WR 9'& 0DNLQJ D FRQQHFWLRQ WR WKH YROW FRPPRQ FORVLQJ D VZLWFK ZLOO DOORZ FXUUHQW WR IORZ WKURXJK WKH RSWR LVRODWRU WXUQLQJ LW RQ ,Q JHQHUDO LQSXWV DUH FRQVLGHUHG 21 LQ WKLV VWDWH DQG 2)) ZKHQ WKHUH LV QR FRQQHFWLRQ IURP WKH LQSXW WR YROW FRPPRQ 7KH )RUZDUG DQG 5HYHUVH /LPLW VZLWFKHV DUH H[FHSWLRQV ZLWK WKH VZLWFK RSHQ LQGLFDWLQJ WKDW D OLPLW KDV EHHQ
3-26 Wire the ULTRA Plus PDM Components (Continued) Connector Pin Signal Name Assignable Function (1) P1 General purpose inputs 14 Input 13 Program Select 13 Input 12 Int2 / Program Select 12 Input 11 Int1 / Program Select 11 Input 10 Emergency Return 10 Input 9 Pause 9 Input 8 Jog Forward 8 Input 7 Jog Reverse 7 Input 6 Home Command 6 Input 5 Home Switch 5 Input 4 Start Program 4 Input 3 Enable 3 Input 2 Reverse Limit 2 Input 1 Forward Limit 1 24 VDC Common (
Wire the ULTRA Plus PDM Components 3-27 Digital Outputs 7KH JHQHUDO SXUSRVH RXWSXWV DUH UHIHUUHG WR DV 2 WKURXJK 2 LQ SURJUDP VWDWHPHQWV 7KH RXWSXWV DUH RSWLFDOO\ LVRODWHG DQG RSHUDWH RQ WKH VDPH YROW VXSSO\ XVHG E\ WKH JHQHUDO SXUSRVH LQSXWV Digital outputs and assignable functions 7KHVH RXWSXWV DUH DOO FDSDEOH RI VLQNLQJ P$ FRQWLQXRXVO\ GULYHQ WR OHVV WKDQ YROW 2XWSXWV 2 2 DQG 2 DUH GHILQHG UHVSHFWLYHO\ DV +RPH 6HTXHQFH &RPSOHWH ,Q 3RVLWLRQ DQG (UURU 2XWSXWV KRZHYHU IXQFWL
3-28 Wire the ULTRA Plus PDM Components FRQQHFWLQJ WKH (UURU RXWSXWV IURP HDFK D[LV RI D V\VWHP WR D KRVW 3/& RU PDFKLQH FRQWUROOHU WR LQGLFDWH DQ HUURU LQ DQ\ RI WKH D[HV 0XOWLSOH GLJLWDO LQSXWV PD\ EH ZLUHG WRJHWKHU ,I WKH OLQH LV SXOOHG ORZ DOO FRQQHFWHG LQSXWV ZLOO WXUQ RQ 7KLV LV XVHIXO IRU FRQQHFWLQJ DQ LQSXW RQ HDFK D[LV RI D V\VWHP WR DQ RXWSXW IURP D KRVW 3/& RU PDFKLQH FRQWUROOHU WR V\QFKURQL]H HYHQWV Analog Input )LJXUH LOOXVWUDWHV WKH $QDORJ WR 'LJLWDO FRQYHUWHU $'& LQSXW $'&
Wire the ULTRA Plus PDM Components 3-29 Analog Output 7KH 'LJLWDO WR $QDORJ &RQYHUWHU '$& RXWSXW '$& RQ SLQ 3 RXWSXWV DQ DQDORJ VLJQDO ZLWK D UDQJH RI YROW Analog output and signal names 7KH DQDORJ VLJQDO JURXQG PXVW EH FRQQHFWHG WR WKH $QDORJ &RPPRQ RQ SLQ 3 7KH ELW '$& KDV D UHVROXWLRQ RI DSSUR[LPDWHO\ P9 5HIHU WR WKH *0/ 8OWUD 6RIWZDUH IRU LQIRUPDWLRQ DERXW WKH XVH RI WKLV RXWSXW Connector Pin Signal Name 3 $QDORJ , 2 DQG VWDWXV 4 $QDORJ &RPPRQ 6 $QDORJ 2XWSXW '$&
3-30 Wire the ULTRA Plus PDM Components Ready Relay Output 6HH )LJXUH RQ SDJH LOOXVWUDWLQJ WKH 5HDG\ RXWSXW 3 ZKLFK LV D QRUPDOO\ RSHQ UHOD\ FRQWDFW WKDW FORVHV ZKHQ WKH 3'0 LV SRZHUHG XS LI QR IDXOWV H[LVW ZLWKLQ WKH 3'0 Ready relay output and signal names 5HOD\ &RPPRQ 3 LV WKH FRPPRQ RI WKLV FRQWDFW 7KLV FRQWDFW LV UDWHG $ DW 9'& 7KH 5HDG\ RXWSXW ZLOO RSHQ LI D V\VWHP IDXOW RFFXUV Connector Pin Signal Name P3 Analog I/O and status 1 Ready (Relay output) 3 Re
Wire the ULTRA Plus PDM Components 3-31 Enabled Relay Output 7KH (QDEOHG RXWSXW 3 LV D QRUPDOO\ RSHQ UHOD\ FRQWDFW 7KH (QDEOHG RXWSXW FORVHV ZKHQ WKH 3'0 LV HQDEOHG DQG RSHQV ZKHQ WKH 3'0 LV GLVDEOHG Enabled relay output and signal names 5HOD\ &RPPRQ 3 LV WKH FRPPRQ RI WKLV FRQWDFW 7KLV FRQWDFW LV UDWHG $ DW 9'& ATTENTION ! 7KH 8/75$ 3OXV 3'0 ZLOO QRW DXWRPDWLFDOO\ WXUQ RXWSXWV 2)) ([WHUQDO FLUFXLWU\ PXVW EH XVHG WR HQVXUH WKH VWDWH RI GLJLWDO RXWSXWV LQ DQ HPHUJHQF\ VW
3-32 Wire the ULTRA Plus PDM Components Figure 3.20 Encoder input circuitry example Publication 1398-5.
Wire the ULTRA Plus PDM Components 3-33 Encoder 1 )LJXUH LOOXVWUDWHV WKH FRQQHFWLRQV RI (QFRGHU ZKLFK PXVW FRQQHFW WR WKH HQFRGHU PRXQWHG WR WKH PRWRU 7KLV LV WKH RQO\ PRWRU PRXQWHG IHHGEDFN QHFHVVDU\ IRU FRQWURO RI WKH PRWRU YHORFLW\ 7KLV HQFRGHU LV DOVR QRUPDOO\ XVHG IRU SRVLWLRQ IHHGEDFN Encoder 1 and signal names 7KH (QFRGHU LQWHUIDFH DOVR LQFOXGHV FRQQHFWLRQV IRU WKH QRUPDOO\ FORVHG WKHUPRVWDW LQ WKH PRWRU ZLQGLQJV DQG IRU DQ DQDORJ VWDUW XS VLJQDO UHTXLUHG IRU SURSHU RSHUDWLRQ
3-34 Wire the ULTRA Plus PDM Components Figure 3.21 Encoder 1 connections R S P5-15 T G P5-13 P5-12 P5-11 P5-14 P5-10 P5-9 P5-8 P5-7 BRUSHLESS MOTOR Publication 1398-5.
Wire the ULTRA Plus PDM Components 3-35 Encoder 2 6HH )LJXUH RQ SDJH VKRZLQJ WKH FRQQHFWLRQV RI (QFRGHU ZKLFK SURYLGHV DQ RSWLRQDO VHFRQG HQFRGHU ,W FDQ EH XVHG DV SRVLWLRQ IHHGEDFN GLUHFWO\ IURP WKH ORDG RU DV D PDVWHU LQSXW IRU UHODWLYH SRVLWLRQLQJ PDVWHU IROORZHU V\VWHPV RU IRU HOHFWURQLF JHDULQJ $V DQ DOWHUQDWLYH WKH (QFRGHU SRUW PD\ DOVR EH XVHG WR RXWSXW HQFRGHU VLJQDOV ZKHQ RQO\ WKH PRWRU PRXQWHG HQFRGHU LV XVHG 7KH IXQFWLRQ RI WKH (QFRGHU SRUW LV VHOHFWHG DV LQSXW RU
3-36 Wire the ULTRA Plus PDM Components Figure 3.
Wire the ULTRA Plus PDM Components 3-37 Step and Direction Inputs )LJXUH LOOXVWUDWHV FRQQHFWLRQV RI WKH 3'0 ZKLFK FDQ DFFHSW VWHS DQG GLUHFWLRQ LQSXWV RQ 3 7KHVH LQSXWV SURYLGH D VWDQGDUG LQWHUIDFH WR DQ LQGH[HU ,I WKH VWHS DQG GLUHFWLRQ LQSXWV RQ 3 DUH XVHG WKH (QFRGHU SRUW PD\ VWLOO EH XVHG DV (QFRGHU RXW EXW QRW IRU FRQQHFWLRQV WR DQ DX[LOLDU\ HQFRGHU LQSXW Step and direction inputs and signal names 7KH VWHS DQG GLUHFWLRQ LQSXWV UHTXLUH D VRXUFH WR GULYH D P$ ORDG DW 9'& 77
3-38 Wire the ULTRA Plus PDM Components 7KH LQSXW UHVLVWDQFH SURYLGHV WKH SURSHU FXUUHQW OLPLW IRU D 9'& VLJQDO ([WHUQDO UHVLVWDQFH LQ VHULHV ZLWK WKH VWHS DQG GLUHFWLRQ OLQHV WR OLPLW FXUUHQW WR P$ DOORZV RSHUDWLRQ ZLWK YROWDJHV JUHDWHU WKDQ 9'& Vcc – 1.8 RE = ----------------------- – 0.
Wire the ULTRA Plus PDM Components Serial Port Connections 3-39 7KHUH DUH WZR VHULDO SRUWV RQ D 3'0 6HULDO $X[LOLDU\ 3 DQG 6HULDO &RPSXWHU 3 7KH 2SHUDWRU 7HUPLQDO LV FRQQHFWHG WR WKH 3'0 WKURXJK 6HULDO SRUW 3 6HULDO SRUW 3 LV XVHG DV WKH SURJUDPPLQJ SRUW IRU D 3& WKDW LV UXQQLQJ *0/ 8OWUD 6RIWZDUH 63 LV DOVR WKH VHULDO SRUW XVHG IRU +RVW FRPPXQLFDWLRQV 'DWD PD\ EH VHQW WR RU UHFHLYHG IURP HLWKHU VHULDO SRUW E\ DQ DSSOLFDWLRQ SURJUDP 7KH DSSOLFDWLRQ PD\ XVH D 35,17 VWDWHPHQW WR VH
3-40 Wire the ULTRA Plus PDM Components 3'0 LV LQ WKH QHWZRUN HDFK PXVW KDYH D XQLTXH DGGUHVV VHOHFWHG RQ WKH 6: GLS VZLWFK 5HIHU WR ´1HWZRUNLQJµ RQ SDJH IRU PRUH LQIRUPDWLRQ Connector P6 Serial Port 2 Pin Signal Name RS-232 RS-422 1 No connection RXD+ 2 RXD RXD- 3 TXD TXD- 4 No connection TXD+ 5 Common Common 6 Shield Shield )LJXUH VKRZV W\SLFDO 56 FRQQHFWLRQV EHWZHHQ D SHUVRQDO FRPSXWHU 3& DQG WKH 6HULDO SRUW 3 RQ WKH 3'0 7KHVH GLDJUDPV LOOXVWUDWHV WKH FRQQH
Wire the ULTRA Plus PDM Components 3-41 Operator Terminal 1398-HMI-002 7KH RSWLRQDO 2SHUDWRU 7HUPLQDO FRQQHFWV WR WKH 3'0 WKURXJK 6HULDO SRUW 3 7KH FDEOH FRQQHFWV WR WKH &20 FRQQHFWRU RQ WKH EDFN RI WKH 2SHUDWRU WHUPLQDO P7 at Serial Port 1 on PDM ,Q WKH GHIDXOW FRQILJXUDWLRQ WKH 3'0 H[SHFWV DQ +0, ; 2SHUDWRU 7HUPLQDO WR EH FRQQHFWHG VR LI D DQRWKHU WHUPLQDO LV XVHG WKH 3'0 PXVW EH FRQILJXUHG SURSHUO\ 5HIHU WR WKH *0/ 8OWUD 6RIWZDUH PDQXDOV PDM Connector P7, Serial Port 1 Pin
3-42 Wire the ULTRA Plus PDM Components Figure 3.25 Operator Terminal RS-232 connections ULTRA Plus PDM P7 Connector Operator Terminal COM1 Connector RXD- P7-2 TXD- P7-3 COM P7-5 Shield P7-6 2 TXD 3 RXD 7 GND Figure 3.
Wire the ULTRA Plus PDM Components 3-43 Operator Terminal (screw terminal on back) . Pin and Signal names Pin RS-232 Pin RS-422 1 Tx 6 TxA 2 RxD 7 TxB 3 RTS 8 RxA 4 CTS 9 RxB 5 Common 10 Common Figure 3.
3-44 Wire the ULTRA Plus PDM Components Networking ULTRA Plus PDM Controls 2QH RU PRUH 3'0V PD\ EH LQVWDOOHG RQ DQ 56 PXOWL GURS QHWZRUN RU DQ 56 GDLV\ FKDLQ QHWZRUN ,I PRUH WKDQ RQH 3'0 LV RQ WKH QHWZRUN HDFK 3'0 PXVW KDYH D XQLTXH DGGUHVV VHOHFWHG RQ WKH 6: ',3 VZLWFK SDQHO ZKLFK LV LOOXVWUDWHG LQ )LJXUH Figure 3.
Wire the ULTRA Plus PDM Components 3-45 SRUW ,I 6: LV 21 VHULDO SRUW DQG VHULDO SRUW DUH OLQNHG WRJHWKHU GDLV\ FKDLQHG $Q\ GDWD WKDW LV UHFHLYHG RQ RQH VHULDO SRUW LV DXWRPDWLFDOO\ WUDQVPLWWHG RXW WKH RWKHU VHULDO SRUW Figure 3.
3-46 Wire the ULTRA Plus PDM Components RS-422 Multi-Drop 6HH )LJXUH RQ SDJH LOOXVWUDWLQJ WKH FRQQHFWLRQV QHHGHG IRU PXOWLSOH 3'0V ZKLFK FDQ EH OLQNHG ZLWK DQ 56 PXOWL GURS FRQILJXUDWLRQ 5HPHPEHU WR VHW D GLIIHUHQW DGGUHVV RQ ',3 VZLWFK 6: IRU HDFK 3'0 RQ WKH 56 QHWZRUN 7KH FDEOH XVHG IRU WKHVH FRQQHFWLRQV VKRXOG EH $:* WZLVWHG SDLU ZLWK DQ RYHUDOO VKLHOG JURXQGHG DW RQH SRLQW Figure 3.
Wire the ULTRA Plus PDM Components 3-47 Operator Terminal (1398-HMI-002) )LJXUH LOOXVWUDWHV DQ DGGLWLRQDO RSWLRQ ZKLFK LV WR FRQQHFW RQH 2SHUDWRU 7HUPLQDO WR PXOWLSOH 3'0V 7KLV PHWKRG UHTXLUHV 56 FRQQHFWLRQV DV VKRZQ LQ WKH IROORZLQJ GUDZLQJ $ 3'0 PD\ EH VHOHFWHG IURP WKH WHUPLQDO E\ XVLQJ WKH 12 NH\ IROORZHG E\ WKH QXPHULF NH\ FRUUHVSRQGLQJ WR WKH 3'0 2SHUDWRU 7HUPLQDO DGGUHVV ZKLFK PXVW EH VHW XS LQ *0/ 8OWUD 6RIWZDUH Figure 3.
3-48 Wire the ULTRA Plus PDM Components Operator Terminal (1398-HMI-003) 2QH 2SHUDWRU FDQ FRQQHFW WR PXOWLSOH 8/75$ 6HULHV 'ULYHV 7KLV PHWKRG UHTXLUHV FXVWRPHU VXSSOLHG 56 FDEOH FRQQHFWLRQV $ SDUWLFXODU 8/75$ 3OXV 3'0 PD\ EH VHOHFWHG IURP WKH WHUPLQDO E\ XVLQJ WKH ´12µ NH\ IROORZHG E\ WKH QXPHULF NH\ FRUUHVSRQGLQJ WR WKH 8/75$ 3OXV 3'0 DGGUHVV 5HIHU WR WKH *0/ 8OWUD 6RIWZDUH PDQXDO IRU IXUWKHU GHWDLOV Figure 3.
Wire the ULTRA Plus PDM Components 3-49 5HIHU WR 0RWRU &RQQHFWRUV RQ SDJH % IRU RUGHULQJ LQIRUPDWLRQ DERXW WKHVH DQG RWKHU FDEOHV Cables Figure 3.35 ULTRA Plus PDM P7 to Operator Terminal (P/N 9101-2205) OPERATOR TERMINAL SERIAL PORT CONNECTOR POSITIONING MODULE CONNECTOR P7 25 PIN FEMALE 9 PIN MALE POSITIONING MODULE CONNECTOR P7 OPERATOR TERMINAL SERIAL PORT CONNECTOR Figure 3.
3-50 Wire the ULTRA Plus PDM Components Figure 3.37 ULTRA Plus PDM P4 or P5 to Auxiliary Encoder (Unterminated) (P/N 9101-2031) POSITIONING MODULE CONNECTOR P4 INDEXER/ ENCODER CONNECTIONS 15 PIN MALE HIGH-DENSITY POSITIONING MODULE CONNECTOR P4 STEP+ STEPDIR+ P4-11 P4-12 P4-8 DIR- P4-13 +5V P4-14 COM P4-7 A+ P4-1 A- P4-2 B+ P4-3 B- P4-4 I+ P4-5 I+5V COM SHIELD Publication 1398-5.
Wire the ULTRA Plus PDM Components 3-51 Figure 3.38 ULTRA Plus PDM P4 to P4, 2 foot (P/N 9101-2127) MASTER AXIS CONNECTOR P4 SLAVE AXIS CONNECTOR P4 15 PIN MALE HIGH-DENSITY 15 PIN MALE HIGH-DENSITY MASTER AXIS CONNECTOR P4 SLAVE AXIS CONNECTOR P4 A+ A+ A- A- B+ B+ B- B- I+ I+ I- I- SHIELD Figure 3.39 ULTRA Plus PDM P5 to H, or F-Series Motor Encoder (P/N 9101-2027) 15 PIN MALE HIGH DENSITY Publication 1398-5.
3-52 Wire the ULTRA Plus PDM Components Figure 3.40 ULTRA Plus PDM P5 to N-Series Motor Encoder (9101-1474) ™0.395 ™1.16 1.96 E (E=feet) 2 3.31 12.0±0.5 2.50 START OF BEND RADIUS 45˚ 0.65 B C D A P R E V S F M N L U T G K J H 0.12 THREAD PROTRUSION MOLDING ADAPTER, ALUMINUM, BLACK COBALT PLATED MARKED WITH ELECTRO-CRAFT P/N & REV, MANUFACTURERS P/N & REV, AND DATE CODE 1.34 CONNECTOR, ITT CANNON #KPSE05E14-19S-A71 4-40 RETRACTABLE MACHINED THUMBSCREW 1.
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Check for Problems in the System 5-5 7KH IROORZLQJ WDEOH OLVWV WKH IDXOWV WKDW DFWLYDWH WKH (UURU RXWSXW 7KH QXPEHU SUHFHGLQJ WKH IDXOW LV WKH HUURU QXPEHU No. Error Messages Description 3 2ms Reentrancy Fault The system did not finish the required calculations in the previous 2ms position loop update in time for the next position loop update. 4 Math Overflow A math overflow occurred (a calculation exceeded the internal system limit). Check the values of the variables used in the program.
5-6 Check for Problems in the System (Continued) Publication 1398-5.1 — January 2000 No. Error Messages Description 33 Iavg Fault The average current output of the GML exceeded safe levels for the motor or GML. Check for correct connection of the motor encoder to the GML or of the motor leads to the GML. Other possible causes are motor stall or end of travel condition, excessive duty cycle, or no DC bus voltage.
Check for Problems in the System 5-7 (Continued) No. Error Messages Description 43 Peak Overcurrent The GML current sensors detected a short circuit in the motor leads. Check motor power cables for shorts. 44 Bus Overvoltage The DC bus voltage exceeded safe levels. This error usually indicates that the power supply shunt is not operating properly. Check the shunt fuse on the Power Supply Module (1398 PDM-25, 50, 100, and 100). See Figure 3.10 on page 3-15.
5-8 Check for Problems in the System Publication 1398-5.
Appendix A Specifications 1398-PDM-10, 20, 30, 75, and 150B 7KH WDEOHV VWDUWLQJ EHORZ SURYLGH VSHFLILFDWLRQV IRU WKH 8/75$ 3OXV 3'0V DQG WKHLU DFFHVVRULHV 1398-PDM-10, 20, 30, 75, and 150B Specifications Drive Module Type 1398 PDM-10 (1Φ) 1398 PDM-20 (1Φ) 1398 PDM-30 (1Φ) 1398 PDM-75 (3Φ) 1398 PDM-150B (3Φ) Peak Output Current/ Phase 10 amps 20 amps 30 amps 75 amps 150 amps Continuous Output Current/ Phase 5 amps 10 amps 15 amps 35 amps 65 amps Continuous Output Power 1 kW 2 kW
A-2 Specifications 1398-PDM-10, 20, 30, 75, and 150B Specifications (Continued) Drive Module Type 1398 PDM-10 (1Φ) Relative humidity 5% to 95% non-condensing 1398 PDM-20 (1Φ) 1398 PDM-30 (1Φ) 1398 PDM-75 (3Φ) 1398 PDM-150B (3Φ) External Shunt Resistor P/N 9101-1079 Continuous 200 W Shunt Power Peak Shunt Power 1398 PDM-25, 50, 100, and 150 6000 W 1398-PDM-25, 50, 100, and 150 Specifications Positioning Drive Module 1398 PDM-25 1398 PDM-50 1398 PDM-100 1398 PDM-150 Peak Output Current/Phase
Specifications A-3 1398-PDM-25, 50, 100, and 150 Specifications (Continued) Operator Terminals Positioning Drive Module 1398 PDM-25 1398 PDM-50 1398 PDM-100 Fused Disconnect Class RK5 40 amps Class RK5 90 amps Output Bus Voltage 100-340 VDC 100-340 VDC Continuous Output Current 50 amps 100 amps Continuous Shunt Dissipation 600 W 1200 W Peak Shunt Power 20 kW 40 kW Terminal Block Torque 11.0 lb-in (1.25 Nm) 24.0 lb-in (2.
A-4 Specifications Transformers 0XOWL WDS LVRODWLRQ WUDQVIRUPHUV DUH DYDLODEOH IRU OLQH YROWDJH PDWFKLQJ Single Phase Transformer specifications 7KH 3'0 DQG XVH D VLQJOH SKDVH WUDQVIRUPHU Specification Value Rating 3.
Appendix B Options and Accessories PDMs and Optional Accessories 7KH IROORZLQJ WDEOHV FDQ EH XVHG WR RUGHU SURGXFWV 8VH WKH ´,WHP 1XPEHUµ 2UGHU QXPEHU ZKHQHYHU SRVVLEOH 7KH ´$OWHUQDWH 1XPEHUµ 0DQXIDFWXULQJ QXPEHU LV XVHG IRU RUGHULQJ ZKHQ WKH ´,WHP 1XPEHUµ LV QRW DYDLODEOH RU ZKHQ UHVHDUFKLQJ LQIRUPDWLRQ DERXW WKH FRPSRQHQW RU PRGXOH 7KLV WDEOH JLYHV WKH 8/75$ 3OXV 3'0 UHIHUHQFH QXPEHUV Item Number Description Alternate Number 1398-PDM-10 Positioning Drive Module 9101-2185 1398-PDM-20
B-2 Options and Accessories I/F Conversion Card 7KLV WDEOH OLVWV WKH 9 6RXUFLQJ LQWHUIDFH FRQYHUVLRQ FDUG DQG LWV FRQQHFWLRQV FDEOHV Description Alternate Number I/F Conversion Card, 24V Sourcing(1) 9103-0152 Cable, I/F Conversion Card 3ft (1m), 44-0141-003 Cable I/F Conversion Card 10ft (3m), 44-0141-010 (1) Power Supply Modules Publication 1398-5.1 — January 2000 Required for compliance with the European Union Low Voltage Directive (LVD).
Options and Accessories AC Line Filters B-3 7KLV WDEOH OLVWV $& /LQH )LOWHUV UHTXLUHG IRU &( (0& FRPSOLDQFH Description Alternate Number 1398-PDM-10 (10 Amps continuous, single phase) 9101-1517 1398-PDM-20 (23 Amps continuous, single phase) 9101-1518 1398-PDM-30 (36 Amps continuous, single phase) 9101-1387 Multiple drives (1) (50 Amps continuous, single phase) 9101-1388 1398-PDM-75 (36 Amps continuous, three phase) 9101-1389 1398-PDM-150B (50 Amps continuous, three phase) 9101-1575 Mul
B-4 Options and Accessories Cables 7KLV WDEOH OLVWV SRZHU FDEOHV EHWZHHQ WKH 3'0 7HUPLQDO %ORFN 7% DQG WKH 0RWRU 7KH ODVW WKUHH GLJLWV ;;; LQGLFDWH D VWDQGDUG FDEOH OHQJWK IW P IW P IW P DQG IW P PDM Motor Description Alternate Number 1398-PDM-10, 20, 30 or 75 H-2000 or H-3000 Motor 9101-1080-XXX 1398-PDM-10, 20, 30 or 75 H-4000 or F-4000 Motor 9101-1081-XXX ULTRA Series F-2000, 3000 or H-2000, 3000 9101-1381-XXX ULTRA Series F-40
Options and Accessories Transformers B-5 7KLV WDEOH OLVWV VLQJOH DQG WKUHH SKDVH WUDQVIRUPHUV WR EH XVHG ZLWK WKH 8/75$ 3OXV 3'0V Description Alternate Number 3 KVA three phase transformer 0020-5091-001 6 KVA three phase transformer 0020-5091-002 12 KVA three phase transformer 0020-5091-003 18 KVA three phase transformer 0020-5091-004 Auxiliary PSM transformer 0020-5093 3 KVA single phase transformer (1398 PDM-10, 20, 30 or 75) 0020-5097 Motor Identification H - 4 0 3 0 - Q - H 00 AA FA
B-6 Options and Accessories Motor Connectors 7KLV WDEOH OLVWV PRWRU FRQQHFWRUV IRU EXLOGLQJ FDEOHV IRU WKH + ) DQG 1 6HULHV PRWRUV Connector Type Motor Series Straight Right Angle Power connectors H-Series (2000 and 3000) 9101-0325 (MS3106F18-4S) 9101-0398 (MS3108F18-4S Power connectors H and F-Series (4000) 9101-0326 (MS3106F20-4S) 9101-0399 (MS3108F20-4S) Power connectors H and F-Series (6000) 9101-0327 (MS3106F24-22S) 9101-0400 (MS3108F24-22S) Power connectors H-Series (8000)
Options and Accessories Motor Shaft Seal Kits B-7 7KLV WDEOH OLVWV PRWRU VKDIW VHDO NLWV DYDLODEOH IRU WKH + ) DQG 1 6HULHV PRWRUV Description (Outside Dia x Inside Dia x Width) Alternative Number Shaft seal kit, H-2000 motor 22 mm x 12 mm x 7 mm 0041-5056 Shaft seal kit, H-3000 motor 28 mm x 15 mm x 7 mm 0041-5057 Shaft seal kit, H-4000 motor 47 mm x 20 mm x 7 mm 0041-5058 Shaft seal kit, H-6000 motor 80 mm x 38 mm x 8 mm 0041-5059 Shaft seal kit, H-8000 motor 85 mm x 45 mm x 8 mm W 004
B-8 Options and Accessories Publication 1398-5.
Index A Absolute positioning , AC 3-phase power Coils suppressed with RC filters Line filter Installation , Order % Rasmi Roxburgh Schaffner Power transformer Power wiring Accel calculation error Analog to Digital converter Resolution ANSI C62 and C63 Assignable function Home Sequence Complete (output) Assignable functions Digital Outputs At Home output Assignable function Auxiliary power supply Description Logic power
2 Index Jumpers RS-232 operation SW-1 in network SW1-1 SW1-6 SW1-7 Divide by Zero error Documentation Related documentation 3 Drive Not Ready error E Earth ground Electrical Noise Electronic gearing EMC Defined European Directive Noise PDM mounting requirements Performance Requirements Cable shielding Requirements - Flying leads Requirements - Lead length System Installation Emergency Return Emerg
Index European Directive Compliance Directive Emergency Stop Contactor I/O Conversion Card Low Voltage Directive Motors and Cables Excessive Excessive FE error Excessive Speed error External Shunt Description Installation Power dissipation ratings F Faraday shield Fault Encoder Iavg Logic Supply Personality Power Module RAM R/W Reentrancy Watchdog Test Filter types Firmware Installation Flying leads Motor shield
4 Index K KFF KI KP KPZ Out of Range error Out of Range error Out of Range error Out of Range error L Lead length EMC requirements LED Limit Forward , Reverse , Logic Supply Fault LOOP Count Out of Range error Variable Range error M Manuals Math Overflow error MIL-STD-461 Monitor Output Motor Compatibility with PDM Control Description Encoder Mating Connectors , % Mounting Ordering Information % Overtemper
Index PDM-25, 50, 100 or 150 Installation Location Personality Module Fault POS Track Overflow error Positioning Drive Module LEDs Mounting Power cable Motor Shielding Power losses Power Module Fault Power supply Auxiliary Connections Digital I/O I/F 24V Conversion Card Internal Logic Isolating input power Location Module mounting Motor connections Operating environment Operator Terminal Power supply module
6 Index T Terminal block Connections , TEXT Checksum error Transformer Description Isolation Load Regulation (1398 PDM-10, 20, 30, 75, and 150B) Curve Ordering % Outline Diagram (1398-PDM-25, 50, 100, 150) Sizing Troubleshooting, see “Check for Problems in the System” Typographical Conventions 3 Publication 1398-5.
For more information refer to our web site: www.ab.com/motion For Rockwell Automation Technical Support information refer to: www.rockwellautomation.com/support or Tel: (1) 440.646.3434 Publication 1398-5.1 — January 2000 2 Supersedes Publication 1398-5.1 — August 1997 PN 0013-1048-002 Rev A © 2000 Rockwell International Corporation. Printed in the U.S.A..
