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1398 PDM 020 9101 2186 Servonapęd Allen Bradley Manual
1398 PDM 020 9101 2186 Servonapęd Allen Bradley Manual
Installation Manual
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Table of Contents
Preface
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Chapter 1
Overview of the ULTRA Plus PDM )XQFWLRQDO'HVFULSWLRQ
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Chapter 2
Install the ULTRA Plus PDM 0RXQWLQJ
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Chapter 3
Wire the ULTRA Plus PDM 6\VWHP3RZHU&RQQHFWLRQV
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Chapter 5
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Appendix A
Specifications 3'0DQG% $
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Appendix B
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ULTRA Plus 1398-HMI-003 Operator Terminal (front)
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144
Transformer Sizing
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Intro
IMPORTANT ,I\RXDUHXVLQJWKH5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\
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PRGXOHLQSXWYROWDJHRI9$&)RUD9$&LQSXW
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Figure 2.1
Single PhaseTransformer Load Regulation Curve
1 PHASE TRANSFORMER SECONDARY VOLTAGE
RELIANCE MOTION CONTROL
AND CORRESPONDING DC BUS VOLTAGE,
1 PHASE TRANSFORMER
VERSUS DC BUS CURRENT
PART NUMBER kVA
320 226
310 219
NOTES:
300 212
BUS VOLTAGE (VDC)
270 191
2. CURVE SHOWS REDUCTION IN TRANSFORMER SECONDARY VOLTAGE
1
260 184
AND DRIVE MODULE INTERNAL DC BUS VOLTAGE, DUE TO TRANSFORMER
INTERNAL LOSSES, AS BUS CURRENT LOAD INCREASES.
250 177
3. ALL DATA TAKEN WITH TRANSFORMER PRIMARY VOLTAGE HELD
240 170
TO 230 VAC 1 PHASE LINE TO LINE 60 Hz AND WITH SECONDARY
230 163 WIRED FOR 230 VAC LINE TO LINE NO LOAD.
220 156
210 149
C 20625 JL UPDATE TITLE BLOCK __ __
200
50
142 B 19960 BC PDM UPDATE 2-19-92 BC
0 10 20 30 40
BUS CURRENT (ADC) A 19866 BC RELEASED 11-22-91 JH
1
REV ECO BY REVISION DESCRIPTION DATE CHKR
UNLESS OTHERWISE SPECIFIED DRAWN BY DATE DESIGN ENGR DATE
DO NOT SCALE DRAWING
BC 11-22-91 JH 11-22-91
DIMENSIONS ARE IN INCHES
BREAK ALL EDGES .02 MAX
FILLETS AND ROUNDS .02 R MAX DIAG, XFMR LOAD REG
TOLERANCE ON: PART NO.
ANGLES ±1ANGLES ˚
FRACTIONS:±1/64"
9101-1057
DECIMALS.XX±.020 SCALE DWG SIZE SHEET
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Figure 2.2
Three PhaseTransformer Load Regulation Curves
3 PHASE TRANSFORMER SECONDARY VOLTAGE
RELIANCE MOTION CONTROL
310 219
BUS VOLTAGE (VDC)
NOTES:
300 212
12/18 kVA 1 DC BUS VOLTAGE AND CURRENT IS MEASURED AT POS & NEG
290 205 OUTPUT TERMINALS OF THE POWER SUPPLY MODULE.
B-C B-19866,C-19960
Figure 2.3
Single PhaseTransformer Outline Diagram
NOTES:
CONNECTION INSTRUCTIONS
PRIMARY CONNECTIONS
8-32 THD BOLTS 2
(4.17 DIA)
9.20 MAX.
(235)
3kVA TRANSFORMER
ELECTRO-CRAFT P/N 0020-5097
Figure 2.4
Three Phase Transformer Outline Diagram
PART NO.
9101-0131
1 CONNECTION INSTRUCTIONS
PRIMARY
CONNECTIONS
G REF
1
SECONDARY
CONNECTIONS
E ±0.06
B MAX
RELIANCE MOTION CONTROL KVA OVERALL DIMENSIONS MOUNTING HOLES LOCATION SCREW SIZES
C MAX
TRANSFORMER PART NO. RATING
A B C D E F G PRIMARY SECONDARY
0020-5091-001 3 12.50 6.50 9.50 5.50 4.20 3.50 1.15 5-40 2 6-32
0020-5091-002 6 15.25 6.50 12.50 10.50 3.78 2.38 1.36 6-32 8-32
0020-5091-003 12 15.25 8.50 13.25 10.50 5.90 2.38 1.30 6-32 10-32
0020-5091-004 18 22.50 9.00 18.25 16.00 5.38 3.25 1.81 8-32 10-32
.012 REF
D ±0.06
F REF
A MAX
C1 A00761
TM REDRAWN __ __
B-C 19866,20625
NOTES:
A 16383 BC
RELEASED 8-88 JH
REV ECO BY REVISION DESCRIPTION DATE CHKR
DATE DATE
1 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING UNLESS OTHERWISE SPECIFIED DRAWN BY DESIGN ENGR
CONNECTIONS TO TRANSFORMER TERMINAL STRIPS.TERMINAL STRIP SCREW DO NOT SCALE DRAWING BCB 2-5-87
DIMENSIONS ARE IN INCHES
JH 8-5-88
SIZES ARE LISTED IN THE DIMENSION CHART.
BREAK ALL EDGES .02 MAX DIAG,OUTLINE,XFMR,BRU-500/IQ5000
2 USE LUGS DESIGNED FOR #6 SCREW MOUNTING. FILLETS AND ROUNDS .02 R MAX
TOLERANCE ON:
PART NO.
ANGLES ±1ANGLES ˚
FRACTIONS:±1/64"
9101-0131
DECIMALS.XX±.010 SCALE DWG SIZE SHEET
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Mounting Requirements
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Figure 2.5
1398-PDM-10, 20 and 30 Mounting
4.10 8.93
104.1 226.8
AIR
1.05 1.00 1.00 CLEARANCE HOLES FOR #10
26.6 25.4 25.4 (M5) MOUNTING SCREWS EXHAUST
0.27
7.0
Allen-Bradley
Ultra Plus Series
External Shunt
Status
Internal
P7
2 Serial 1
Auxiliary
U10
3
TB2
P6
Serial 2
Computer
P5
Encoder 1
Motor
WARNING:High Voltage
May Exist Up To Five Minutes
After Removing Power
P4
Encoder 2
Auxiliary
DC Bus 14.20
13.75
349.2 360.6
R
5
P3
Motor
S Status/
Analog
I/O
T 1
10
DC Bus+ P2
Digital
Inputs
100-240 Vac 50/60 Hz
DC Bus- And
Outputs
L1 5
L2/N
L1 Aux
L2/N Aux 10
P1
TB1 Digital Inputs
1
SW1
AIR INTAKE
Figure 2.6
1398-PDM-75 Mounting
5.97 8.93
151.7 226.8
AIR EXHAUST
Allen-Bradley
Ultra Plus Series
Status
1
Internal
External Shunt
P7
2 Serial 1
Auxiliary
U10
3
FINAL INSPECTION
TB2
P6
Serial 2
Computer
P5
Encoder 1
Motor
13.75 R 14.20
349.2 360.7
S
5
Motor
P3
T Status/Analog
I/O
1
DC Bus+
10
DC Bus-
P2
Digital Inputs
L1 And Outputs
100-240 Vac 50/60 Hz
L2/N 5
L3
L1 Aux
10
L2/N Aux
P1
TB1 Digital Inputs
1
SW1
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
1.38 246.4
0.45
34.9
11.4 AIR
EXHAUST
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
16.87 17.50
16.15
428.6 444.5
410.2
P2
General Purpose
Inputs And Outputs
P1
General Purpose
Inputs
AIR INTAKE
Figure 2.8
1398-PDM-150B Mounting
5.97 8.93
151.7 226.8
AIR EXHAUST
Allen-Bradley
Ultra Plus Series P8 P9 P10
Status
1 1 1
External Shunt
1
Internal
P7
U10
Serial 1
2 Auxiliary
U10
FINAL INSPECTION
P6
TB2
Serial 2
WARNING: High Voltage May
DC BUS Exist Up To Fifteen Minutes Computer
POT1 POT2 POT3
After Removing Power.
R P5
Encoder 1
Motor
S
Motor
T P4
Encoder 2
Auxiliary
U57
13.75 14.20
349.2 360.7 U57
DC Bus+
U67
U66
P3
DC Bus- Status/Analog U67
U66
I/O
AC Mains (30 Only)
L1
100-240 Vac 50/60 Hz
L2
P2
Digital Inputs
L3 And Outputs U87
U87
Auxiliary
L1 Aux
L2/N Aux
P1
Digital Inputs
TB1
1.25 5.50
[31.8] [139.7]
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Figure 2.9
PSM Auxiliary Transformer mounting
5.50 MAX.
SPECIFICATIONS:
4.38
OUTPUT POWER @ 50/60Hz
110 VAC OUTPUT VOLTAGE
50˚C MAX. TEMPERATURE RISE 500 VA MIN.
CONNECTION INSTRUCTIONS
6.25 4.25
MAX.
9101-0233
X2 X1 0.69
SCHEMATIC SYMBOL
1.
8-32 TERMINAL SCREWS (6) 0.31 H1 H3 H2 H4
INPUT (PRIMARY) CONNECTIONS: H1,H4
480 VAC INPUT: JUMPER H3 to H2
240 VAC INPUT: JUMPER H1 to H3 AND H2 to H4
X2 X1
5.00 MAX
NOTES:
Figure 2.10
PSM-AUX Outline and Connection Diagram
3.50
(89)
1.75
(44.5)
0.50 0.50
(13) (13)
0.25
(6.5)
0.50
(13)
9.00 8.38
(229) (213)
3.00
(77)
2.00
(50)
Motors
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External Shunt
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Figure 2.11
External Shunt (200W) mounting and connection diagram
3.05
(77.5)
2.00 0.50
#10 (M5) (50.8) (12.7)
MTG HOLES (3) 1.00 8.60
(25.4) 0.25 (218.4)
(6.3)
EXTERNAL SHUNT
RESISTOR
2
3
3.40 MIN AIR
(86.3)
EXHAUST
1 2 3 1
2
Terminal
3
TERMINAL
CONNECTION DIAGRAM
NOTES:
INCHES
(mm)
AIR INTAKE
Figure 2.12
External Shunt (900W) mounting and connection diagram
At terminal block,
Cabinet There must be 155mm (6.1 in.) Of
There must be
STATUS
155mm (6.1 in.)
EXTERNAL SHUNT
INTERNAL
of clearance on
2 A1
A2 all sides of
3 COM
345
shunt module
0 12
6
87
TB2
A9
FE
D CB
J5
SERIAL 1
DC Bus
J4
SERIAL 2
S
Motor
J3
AUXILIARY
DC Bus +
DC Bus -
Use twisted conductors
L1
(2 twists per foot)
J2
100-240 VAC 50/60 Hz
L2/N
minimum or a shielded
MOTOR ENCODER
L3
twisted pair
L1 AUX
8 AWG (8.4 mm)
L2/N AUX J1
Connect wires
to terminal block
Operator Terminal
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FRQQHFWRUV
Figure 2.13
Operator Terminal (1398-HMI-002) Dimensions
3.50 0.65 10.50
(88.9) (16.5) (266.7)
5.05 6.00
(128.3) (152.4)
GASKET
Figure 2.14
Operator Terminal (1398-HMI-003) Dimensions
GASKET SUPPLIED
8.11 WITH UNIT 3.86 3.86
0.20
[206.0] [98.0] [98.0]
[5.0]
3.28
[83.25]
3.28
[83.25]
2.22 0.17
[56.5] [4.25]
7.40
1 2 3 4 5 6 7 8 9 10
[188.0]
3.70
Ø 0.14 (8)
[94.0]
3.86 Ø [3.5]
[98.0]
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Figure 2.15
I/F 24 Volt Sourcing Conversion Card Mounting Dimensions
P1
1 26
77.0
(1.9)
P2 1 26
USER
47.0
(1.9)
169.0
(6.7)
77.0
(1.9)
7.5
(0.3)
42.5 85.0
(1.7) (3.4)
35.0 25
(1.4) (1.0)
17.5
(0.7)
170.0
(6.7)
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Figure 2.16
Location of Personality Module
F1 F1
DS1
DS1
U10
U10
Personality
Module
1
1
SW1
SW1
1398 PDM-10, 20, 30, 75, and 150B 1398 PDM-25, 50, 100, and 150
LOGIC BOARD LOGIC BOARD
(component side) (component side)
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Figure 2.19
Recommended installation for EMC
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Figure 2.24
AC Line Filter installation
POOR GOOD
CONDUCTED EMI
PDM PDM
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LINE
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Figure 2.26
Torroid encoder shielding method for brushless servo motors
PDM
BRUSHLESS
MOTOR
ENCODER CABLE
ENCODER
SHIELD
MOTOR CASE
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Figure 2.27
Motor power winding methods to minimize noise emissions
PDM
BRUSHLESS
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R
R
S S
T T
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CHASSIS
TO SINGLE POINT
EARTH GROUND
PDM
BRUSHLESS
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R
S R
S
T 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
S R
S
T T
CHASSIS
MOTOR CASE
TWISTED TOGETHER
TO SINGLE POINT
EARTH GROUND
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Figure 3.1
Power Wiring Diagram for 1398-PDM-10, 20, and 30
MOTOR POWER WIRES R,S,T,GND MOTOR POWER CONNECTOR INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS
IQ TERMINALS
MOTOR POWER MINIMUM PIN SIGNAL
RECOMMENDED
RECOMMENDED TERMINAL(S) POWER WIRE 1.0 Amps AC at 115 Volts AC
MOTOR MATING CONNECTOR A R DRIVE (GAUGE/mmÉ) L1 AUX, L2/N AUX
CONTACT SIZE POWER WIRE 0.5 Amps AC at 230 Volts AC
B S (60˚C
˚ COPPER ONLY)
(GAUGE/mmÉ)
(GAUGE/mmÉ) L1 AUX, L1,L2/N, PDM-10 10.0 AMPS AC
C T 16 AWG/1.5mmÉ
(60˚C
˚ COPPER ONLY) ALL L2/N AUX AC AUXILIARY POWER PDM-20 19.0 AMPS AC
D MOTOR CASE INPUT (OPTIONAL) PDM-30 28.0 AMPS AC
H-2005
H-3007 16 AWG/1.5mmÉ PDM-10 L1,L2/N, 14 AWG/2.5mmÉ NOTE: SLOW BLOW FUSES ARE REQUIRED TO ALLOW FOR INRUSH
CURRENT DURING POWER INITIALIZATION AT THE MAIN
H-3016 16 AWG/1.5mmÉ
AND AUXILIARY TERMINALS. TIME DELAY VERSIONS OF
H-4030 PDM-20 UL CLASS J,CLASS R OR EQUIVALENT FUSES ARE
L1,L2/N, 14 AWG/2.5mmÉ
F-4030 ACCEPTABLE, LOCAL REGULATIONS MUST BE OBSERVED.
H-4050 12 AWG/3.0mmÉ
PDM-30 L1,L2/N, 10 AWG/4mmÉ 10
F-4050 14 AWG/2.5mmÉ
H-4075
F-4075 TERMINAL STRIP
ACCEPTABLE WIRE RANGE DRIVE DRIVE
(GAUGE/mmÉ) MODULE MODULE
22-10 AWG/0.5-6mmÉ
9 9
SUGGESTED RELIANCE TORQUE ALL TERMINALS
TO 11 LB-IN. TB1 3 TB1
TRANSFORMER SIZES PART NUMBER DC BUS DC BUS
4
PDM-30 3.0kVA 0020-5097
R 3 R
S S
T T
9 9
FUSE 7 FUSE 7
BLOCK „XCON… DC+ BLOCK „XCON… DC+
DC- DC-
L1 AC LINE L1
AC LINE FILTER
FILTER L2/N L2/N
MOTOR POWER
L1 AUX L1 AUX CONNECTOR MATING
L2/N AUX L2/N AUX
MOTOR POWER
CONNECTOR
1
1 H-SERIES H-SERIES
F-SERIES F-SERIES
N-SERIES N-SERIES
TERM
MOTORS MOTORS
BLOCK
2 FUSED DISCONNECT
OR CIRCUIT BREAKER
ISOLATION OR AUTO TRANSFORMER L1
SINGLE PHASE (OPTIONAL, NOT REQUIRED WHEN
AC LINE DESIRED INPUT VOLTAGE IS
50/60Hz AVAILABLE DIRECTLY FROM THE 5 COMMON GROUNDING COMMON GROUNDING
LINE)
POINT FOR AMPLIFIER POINT FOR AMPLIFIER
TRANSFORMER
L2 SYSTEM (ONE PER AXIS) SYSTEM (ONE PER AXIS)
CHASSIS
MACHINE COMMON
TO PROTECTIVE GROUNDING BUS BAR
EARTH TERMINAL
NOTES
1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2 TERMINALS
(EXAMPLE: TO RETAIN DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2 POWER DOWN). WHEN USING A THREE PHASE SUPPLY CONNECT THE MAIN
AND AUXILIARY INPUTS TO THE SAME PHASE.
2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IN EUROPE,IF A GROUNDED NEUTRAL IS USED INSTEAD
OF L2 OR L2/AUX, ONLY L1 MAY BE SWITCHED OR FUSED.
3 JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
4 TRANSFORMER SIZES SHOWN ARE FOR MOST APPLICATIONS: APPLICATIONS REQUIRING MAXIMUM PEAK TORQUE AT MAXIMUM MOTOR SPEED MAY REQUIRE A LARGER TRANSFORMER.
SECONDARY VOLTAGE MAY DROP (BASED ON TRANSFORMER LOAD REGULATION PERFORMANCE) WHEN THE MOTOR DELIVERS PEAK TORQUE. THIS DROP IN TRANSFORMER VOLTAGE WILL
LIMIT MAXIMUM MOTOR SPEED WHILE PEAK TORQUE IS REQUIRED. SEE DRAWING 9101-1057 FOR TRANSFORMER LOAD REGULATION OF RELIANCE MOTION CONTROL TRANSFORMER
0020-5097.
DRIVE RATED 100-240 VAC RMS,SINGLE PHASE INPUT VOLTAGE (230 VAC STANDARD).
A 21936 JM RELEASED __ __
5
REV ECO BY REVISION DESCRIPTION DATE CHKR
6. DO NOT DAISY CHAIN DRIVE MODULES. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
UNLESS OTHERWISE SPECIFIED DRAWN BY DATE DESIGN ENGR DATE
DO NOT SCALE DRAWING JM 6-3-96 __ __
7 DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
DIMENSIONS ARE IN INCHES
8. MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE. BREAK ALL EDGES .02 MAX POWER WIRING CONNECTIONS
FILLETS AND ROUNDS .02 R MAX
9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL. TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY. THE AUX INPUT HAS AN TOLERANCE ON:
PART NO.
INTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD BE AS CLOSE ANGLES ±1ANGLES ˚
TO THE DRIVE AS POSSIBLE. FRACTIONS:±1/64" 1398-PDM-10, 9101-2195
DECIMALS.XX±.020 20, and 30 SCALE DWG SIZE SHEET
10 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED. .XXX±.010 N/A C 1 of 1
Figure 3.2
Power Wiring for 1398-PDM-75
MOTOR POWER WIRES R,S,T,GND MOTOR POWER CONNECTOR INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS
MOTOR POWER MINIMUM PIN SIGNAL RECOMMENDED BRU/IQ TERMINALS CURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS)
MATING CONNECTOR RECOMMENDED TERMINAL(S) POWER WIRE 4 L1 AUX,L2/N AUX 1.0 Amps AC at 115 Volts AC
MOTOR A R DRIVE (GAUGE/mmÉ)
CONTACT SIZE POWER WIRE 0.5 Amps AC at 230 Volts AC
B S (60˚C COPPER MIN)
(GAUGE/mmÉ) L1 AUX, L1,L2/N,L3 DM/PDM-75 28.0 Amps at 100-240 Volts AC Three Phase
(GAUGE/mmÉ) C T ALL
(60˚C COPPER MIN) L2/N AUX 16 AWG/1.5mmÉ AC AUXILIARY L1,L2/N DM/PDM-75 28.0 Amps at 100-240 Volts AC Single Phase
D MOTOR CASE
H-4050 POWER INPUT NOTE: POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSH
F-4050 DM/PDM-75 L1,L2/N,
L3 10 AWG/2.5mmÉ (OPTIONAL) CURRENT OF 50A FOR THE MAIN INPUT AND 95A FOR THE
12 AWG/3.0mmÉ 14 AWG/2.5mmÉ AUXILIARY INPUT. DUAL ELEMENT TIME DELAY (SLOW BLOW)
H-4075
FUSES ARE RECOMMENDED. FUSE SIZES MUST BE SELECTED
F-4075 ACCORDING TO LOCAL REGULATIONS.
H-6100 10
F-6100
8 AWG/10.0mmÉ 10 AWG/6.0mmÉ
H-6200
F-6200 TERMINAL STRIP
10 ACCEPTABLE WIRE RANGE DRIVE MODULE
DRIVE MODULE
(GAUGE/mmÉ)
22-10 AWG/0.5-6mmÉ
2 FUSED DISCONNECT
OR CIRCUIT BREAKER L1 11 11
ISOLATION OR AUTO TRANSFORMER
(OPTIONAL, NOT REQUIRED WHEN
THREE PHASE DESIRED INPUT VOLTAGE IS
AC LINE AVAILABLE DIRECTLY FROM THE
50/60Hz LINE)
L2/N
TRANSFORMER 5 COMMON GROUNDING COMMON GROUNDING
L3 POINT FOR AMPLIFIER POINT FOR AMPLIFIER
CHASSIS
SYSTEM (ONE PER AXIS) SYSTEM (ONE PER AXIS)
MACHINE COMMON
NOTES TO PROTECTIVE GROUNDING BUS BAR
EARTH TERMINAL
1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2/N, L3 TERMINALS (EXAMPLE: TO RETAIN
DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2/N, L3 POWER DOWN).
2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IF A GROUNDED NEUTRAL IS USED INSTEAD OF
L2 OR L2/AUX, ONLY L1 MAY BE SWITCHED OR FUSED.
3 JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
4 CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE. REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED, BUT NOT TORQUE. DRIVE RATED 35/75 AMPS FOR
THREE PHASE INPUT, 15/50 AMPS FOR SINGLE PHASE INPUT.
5 DRIVE RATED 100-240 VAC RMS, SINGLE OR THREE PHASE INPUT VOLTAGE (230 VAC STANDARD).
6. DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
7 DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
A 21871 JM RELEASED __ __
8. MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE. REV ECO BY REVISION DESCRIPTION DATE CHKR
UNLESS OTHERWISE SPECIFIED DRAWN BY DATE DESIGN ENGR DATE
9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY, AND ARE REQUIRED TO MEET THE
DO NOT SCALE DRAWING __ __
EUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE. CAUTION: AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND REQUIRE DISCHARGE TIME UPON POWER REMOVAL.
DIMENSIONS ARE IN INCHES
JM 4-19-96
THE AUX INPUT HAS AN INTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD
BE AS CLOSE TO THE DRIVE AS POSSIBLE. BREAK ALL EDGES .02 MAX POWER WIRING CONNECTIONS
FILLETS AND ROUNDS .02 R MAX 75A
10 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED. TOLERANCE ON: PART NO.
ANGLES ±1ANGLES ˚
11 TERMINATE THE MOTOR POWER CABLE SHIELD BY CLAMPING IT TO THE DRIVE WITH THE BRACKET PROVIDED. THIS BRACKET CAN BE USED FOR STRAIN RELIEF IF FRACTIONS:±1/64"
9101-1453
NON-SHIELDED CABLES ARE USED. SNUG BRACKET SCREWS, DO NOT OVERTIGHTEN. NEVER TORQUE OVER 10 LB-IN. THE SHIELDS ON SHIELDED POWER CABLES MUST DECIMALS.XX±.020 SCALE DWG SIZE SHEET
BE GROUNDED AT A MINIMUM OF ONE POINT FOR SAFETY.
.XXX±.010 N/A C 1 of 1
Figure 3.3
Power Wiring for 1398-PDM-150B
MOTOR POWER WIRES R,S,T,GND MOTOR POWER CONNECTOR INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS
RECOMMENDED IQ TERMINALS CURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS)
MOTOR POWER MINIMUM PIN SIGNAL
RECOMMENDED DRIVE POWER WIRE 4 1.0 Amps AC at 115 Volts AC
MATING CONNECTOR A R TERMINAL(S) 2 L1 AUX,L2/N AUX
MOTOR POWER WIRE
(GAUGE/mm ) 0.5 Amps AC at 230 Volts AC
CONTACT SIZE B S (75 C COPPER MIN)
2
2
(GAUGE/mm ) AC AUXILIARY L1,L2,L3 PDM-150B 46.0 Amps at 100-240 Volts AC Three Phase
(GAUGE/mm ) C T L1 AUX, 2
(75 C COPPER MIN) ALL 16 AWG/1.5mm POWER INPUT NOTE: POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSH
D MOTOR CASE L2/N AUX
H-6200 2 2 (OPTIONAL) CURRENT OF 70A (PEAK) FOR THE MAIN INPUT AND 105A (PEAK)
8 AWG/10.0mm 10 AWG/6.0mm L1,L2, 8 AWG/10.0mm 2
FOR THE AUXILIARY INPUT. DUAL ELEMENT TIME DELAY (SLOW
F-6200 PDM-150B
L3 BLOW) FUSES ARE RECOMMENDED. FUSE SIZES MUST BE SELECTED
H-6300 2 2 ACCORDING TO LOCAL REGULATIONS.
8 AWG/10.0mm 8 AWG/10.0mm
F-6300
H-8350 4 AWG/25.0mm
2
8 AWG/10.0mm
2
TERMINAL STRIP
10
2 2 10 ACCEPTABLE WIRE RANGE
H-8500 4 AWG/25.0mm 6 AWG/16.0mm 2
(GAUGE/mm )
2
22-10 AWG/0.5-6mm
MOTOR POWER
L1 AUX L1 AUX CONNECTOR MATING
L2/N AUX L2/N AUX
TB1 TB1 MOTOR POWER
CONNECTOR
1
1 H-SERIES H-SERIES
TERM F-SERIES F-SERIES
BLOCK N-SERIES N-SERIES
5 MOTORS MOTORS
2 FUSED DISCONNECT
OR CIRCUIT BREAKER L1
11 11
ISOLATION OR AUTO TRANSFORMER
(OPTIONAL, NOT REQUIRED WHEN
THREE PHASE DESIRED INPUT VOLTAGE IS
AC LINE AVAILABLE DIRECTLY FROM THE
50/60Hz LINE) L2
MACHINE COMMON
TO PROTECTIVE GROUNDING BUS BAR
EARTH TERMINAL
NOTES
1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2, L3 TERMINALS (EXAMPLE: TO RETAIN
DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2, L3 POWER DOWN).
2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IF A GROUNDED NEUTRAL IS USED INSTEAD OF
L2/N AUX, ONLY L1 AUX MAY BE SWITCHED OR FUSED.
3 JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
4 CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE. REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED, BUT NOT TORQUE. DRIVE RATED 65/150 AMPS (PEAK)
FOR THREE PHASE INPUT.
6. DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
A 22775 JM RELEASED __ __
7 DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
REV ECO BY REVISION DESCRIPTION DATE CHKR
8. MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE.
DRAWN BY DESIGN ENGR
UNLESS OTHERWISE SPECIFIED DATE DATE
9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY, AND ARE REQUIRED TO MEET THE DO NOT SCALE DRAWING JM 5-12-98 __ __
EUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE. CAUTION: AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND MAY REQUIRE DISCHARGE TIME UPON POWER REMOVAL. DIMENSIONS ARE IN INCHES
THE AUX INPUT HAS AN INTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD BREAK ALL EDGES .02 MAX POWER WIRING
BE AS CLOSE TO THE DRIVE AS POSSIBLE. FILLETS AND ROUNDS .02 R MAX 1398-PDM-150B
TOLERANCE ON: PART NO.
10 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED. ANGLES :+/- 1
FRACTIONS: +/- 1/64" 9101-2236
11 TERMINATE THE MOTOR POWER CABLE SHIELD BY CLAMPING IT TO THE DRIVE WITH THE BRACKET PROVIDED. THIS BRACKET CAN BE USED FOR STRAIN RELIEF IF
DECIMALS: .XX +/- .020 SCALE DWG SIZE SHEET
NON-SHIELDED CABLES ARE USED. SNUG BRACKET SCREWS, DO NOT OVERTIGHTEN. NEVER TORQUE OVER 10 LB-IN.
.XXX +/- .010 N/A C 1 of 1
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Figure 3.4
Power Wiring Diagram (1398-PDM-25, 50, 100, and 100)
PART NO.
9101-0411
(GAUGE/mmÉ)
PRODUCT TERMINALS
60˚C COPPER ONLY
6-0 AWG/16-55mmÉ
L1,L2,L3
PSM-125
8 AWG/10mmÉ 4
8
PSM-50 L1,L2,L3 10-4 AWG/6-25mmÉ
POS NEG GND POS NEG GND POS NEG GND POS NEG GND POS NEG GND
AND ALL R,S,T
7
R S T 7
R S T L1 L2 L3 R S T R S T DRIVE MODULES
14-12 AWG/2.5-4mmÉ 4
9 16 AWG/1.5mmÉ 5
MACHINE COMMON
TO PROTECTIVE 3 PHASE TRANSFORMERS F-SERIES AND W-SERIES A R
EARTH TERMINAL MOTORS B S
GROUNDING BUS BAR 208/230/240/380/460/480 VAC PRIMARY, 115/230
NOTES: VAC SECONDARY, 50/60 Hz C T
D MOTOR CASE
1 THE PSM MUST BE CENTERED BETWEEN THE DRIVE MODULES TO MINIMIZE THE DC BUS INDUCTANCE, SO THAT AN RELIANCE
EQUIVILENT NUMBER OF DRIVES ARE LOCATED ON EACH SIDE OF THE PSM. KVA MOTOR TERMINAL BOX
PART NUMBER
MOTOR POWER TERMINAL STRIP
2 FUSE SIZE: PSM-125-UL CLASS RK5 90 AMP (5000 AIC) A DISCONNECTING DEVICE IS REQUIRED FOR SAFETY AND MAINTENANCE. 0020-5091-001
PSM-50-UL CLASS RK5 40 AMP (5000 AIC) 3
0020-5091-002 6
3 NOTES ON SIZING OF POWER TRANSFORMERS AND INPUT WIRES: MOTOR POWER TERMINAL STRIP
0020-5091-003 12
TERMINAL SIGNAL
3 3 0020-5091-004 18 I-5300 AND I-6600 6
a) TRANSFORMER 3 PHASE KVA = X (LINE-TO-LINE SECONDARY VOLTS RMS) X (PER PHASE SECONDARY CURRENT RMS) = MOTORS U S
1000 1000
V R
X (LINE-TO-LINE PRIMARY VOLTS RMS) X (PER PHASE PRIMARY CURRENT RMS). W T
E MOTOR CASE
b) TRANSFORMER 3 PHASE KVA = (SUMMATION OF EACH MOTORS ACTUAL AVERAGE OUTPUT POWER) X (1.2) 1.2 FACTOR ADDS 20%
AS ROUGH ESTIMATE OF DRIVE MODULE & MOTOR LOSSES.
c) SEE DRAWING 9101-0132, TRANSFORMER LOAD REGULATION, TO DETERMINE EFFECT OF PEAK LOADS ON SYSTEM DC BUS VOLTAGE.
4 FOR WIRE GAUGES NOTED: STRIPPED ENDS OF STRANDED WIRES MUST BE FULLY TINNED SO WIRE DIA. STAYS LARGE ENOUGH FOR
PROPER CLAMPING IN POWER SUPPLY MODULE OR DRIVE MODULE TERMINAL. 8 TORQUE TO 24 LB-IN.
5 FOR 16 GAUGE MOTOR POWER WIRE: STRIPPED ENDS OF STRANDED WIRES MUST BE DOUBLED OVER AND FULLY TINNED FOR 9 TORQUE TO 11.5 LB-IN.
PROPER CLAMPING IN DRIVE MODULE TERMINAL.
I-SERIES MOTORS ARE USED WITH BRU-500 DRIVES ONLY. 10
6 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL.
TO BE USED FOR IMPROVING THE SYSTEM'S ELECTROMAGNETIC
A1 A00787 TM CHG'D NOTE 1 5-30-95 RB
COMPATABILITY. WIRING BETWEEN THE POWER SUPPLY AND
7 TERMINAL POST HARDWARE DETAILS:
SPRING DISK WASHERS
M6 TERMINAL POST FILTER SHOULD BE AS SHORT AS POSSIBLE. THE COMMON A 21244 TM RELEASED 2-2-95 BCB
M6 TERMINAL POST M6 NUT GROUND SHOULD BE AS CLOSE TO THE MODULE AS POSSIBLE. REV ECO BY REVISION DESCRIPTION DATE CHKR
M6 NUT FLAT WASHER
CAUTION CONNECTING LUGS 11 WIRE SIZES ARE RECOMMENDATIONS. THE REQUIREMENTS
UNLESS OTHERWISE SPECIFIED DRAWN BY DATE DESIGN ENGR DATE
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Figure 3.5
Auxiliary Power Supply Connections
SAMPLE INPUT POWER WIRING CONFIGURATIONS, PSM-AUX WITH 1398-PDM-25, 50, 100, and 150
EXAMPLE:
POWER SUPPLY DRIVE
EXAMPLE: 240V LINE 9
POWER SUPPLY MODULE (PSM) MODULE
480V LINE DRIVE
8 MODULE (PSM) MODULE
240VAC,
NEG
NEG
POS
POS
3 PHASE L1 L2 L3 R S T
NEG
NEG
GND GND
POS
POS
L1 L2 L3 R S T
480VAC, GND GND
3 PHASE
L1 L2 L3 GND
L1 L2 L3 GND
F2 F3
F3
PSM-AUX
TRANSFORMER
0020-5093
10
CONTROL CIRCUIT
TRANSFORMER
21
240VAC 120VAC
21
PSM-AUX
480VAC 120VAC 9
PSM-AUX
CONTROL CIRCUIT
TRANSFORMER
8 F4
L1 L2 L3 240VAC 120VAC
CUSTOMER'S
F4 CUSTOMER'S
NOTES: 120VAC
120VAC
CONTROL
CONTROL
CIRCUITS
CIRCUITS
L1 L2 L3
8 IN THIS EXAMPLE, PSM-AUX INPUT POWER IS CONNECTED TO AT THE CONTROL CIRCUIT
TRANSFORMER SECONDARY. THEREFORE THE PSM INPUT POWER MUST BE ISOLATED
FROM AND FROM THE 480V INPUT LINE. THE THREE PHASE TRANSFORMER PROVIDES
THE ISOLATION AND ALSO STEPS DOWN THE VOLTAGE.
9 IN THIS EXAMPLE, THE PSM INPUT POWER IS SUPPLIED DIRECTLY FROM THE 3 PHASE LINE.
DIAGRAM, OUTLINE & CONNECTION
THEREFORE, THE PSM-AUX INPUT POWER MUST BE ISOLATED FROM AND FROM THE 240V INPUT LINE.
IN THIS EXAMPLE THE PSM-AUX TRANSFORMER SECONDARY MUST NOT BE CONNECTED TO . PSM-AUX, 1398-PDM-25, 50, 100, and 150
10 SIZE TRANSFORMER FOR 400 VA (PSM-AUX)+ CUSTOMER CONTROL CIRCUIT REQUIREMENTS.
9101-0134 REV D1
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Figure 3.6
PSM interface - internal circuit examples
Figure 3.7
PSM interface - external connection examples
Status Outputs
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Figure 3.8
Power Supply Module jumper location
DS1
DIAGNOSTIC
INDICATOR
LIGHTS
POWER SUPPLY MODULE
CIRCUIT BOARD
(COMPONENT SIDE) TB1
1
A INTERFACE
W1 B 4 CONNECTOR
Internal
External Shunt
2 Internal Internal shunt
regulator resistor 2
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6KXQW.LW : FDQEHXVHG7KHVHH[WHUQDOVKXQWVFDQEHDUUDQJHGWR
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(1)
For sizing purposes, approximately 420 Vpeak will drop across any given resistor assembly.
(2)
Continuous and Peak Power Ratings are given measured with a minimum resistance shunt. Higher Resistances
will decrease Power Rating.
Figure 3.9
External Shunt Wiring Examples
R1
TB2-3 R1 R2 R3
R1 R2
R4 R5 R6
R3 R4
NOTES: TB2-3 R7 R8 R9
Uses 200W units p/n 9101-1079
*Configuration good for all ULTRA Plus PDMs
TB2-3
TB2-1 TB2-1
R1
TB2-3 R1 R2
TB2-3
NOTES:
Uses 900W units p/n 9101-1674
*Configuration good for 1398-PDM-075,150, and 150B units
**Configuration good for 1398-PDM-150 and 150B units only
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RUUHSODFHWKLVIXVH
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SRZHULV2))0DNHVXUHWKDWWKHJUHHQ3605($'</('LV2))
5HPRYHWKH360FRYHU
5HPRYHWKHVKXQWIXVHDQGWHVWZLWKDQRKPPHWHU
IMPORTANT :KHQUHSODFLQJWKH360DQG360
VKXQWIXVHD'&UDWHGIXVHPXVWEHXVHG
5HSODFHWKHVKXQWIXVH
Figure 3.10
Shunt Fuse location
Shunt Resistor
PSM - 50
8 Ampere KLKD-8 or KLM-8
PSM - 125
20 Ampere KLKD-20 or KLM-20
DC Bus Terminals
,QVWDOOWKH360FRYHU
)LJXUHLOOXVWUDWHVWKHSRZHUFRQQHFWLRQVWRWKH2SHUDWRU7HUPLQDO
9$&VLQJOHSKDVH ,WPXVWEHSURSHUO\JURXQGHGWR
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Figure 3.11
Operator Terminal power connections
GROUND (EARTH)
115/230 VAC (NEUTRAL)
115/230 VAC (HOT)
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VXSSO\UDWHGDWDPSVXQOHVVRWKHUZLVHVWDWHGRQWKHODEHO
Figure 3.12
Operator Terminal connections (on back of unit)
SUPPLY
COMMON
+24v
1 2
24 VDC (DC+)
COMMON
1 2 3 4 5 6 7 8 9 10
not
24 VDC RS-232 connector
used
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EHWZHHQYROWVDQGYROWVDUHDOVRVXLWDEOH
• 7KHWHUPLQDOPD\WDNHDVOLWWOHDVP$LQFHUWDLQFLUFXPVWDQFHVVREH
VXUHWKDWWKHFKRVHQSRZHUVXSSO\FDQRSHUDWHFRUUHFWO\ZLWKWKLVORDG
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DVVKRUWDOHQJWKDVLVSRVVLEOHVKRXOGEHXVH,QSDUWLFXODUWKHSRZHUVXSSO\
VKRXOGQRWEHPRXQWHGRQWKHEDFNRIWKHSDQHOZKHQWKH2SHUDWRU
7HUPLQDOLVLQVWDOOHGLQWKHSDQHOGRRUXQOHVVDVKRUWFDEOHUXQFDQEH
DFKLHYHG
• 7KHZLUHXVHGWRFRQQHFWWKH2SHUDWRU7HUPLQDOWRLWVSRZHUVXSSO\VKRXOG
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Figure 3.13
Motor power connections for H, and F-Series motors
+LJKYROWDJHPD\EHSUHVHQWRQWHUPLQDOVRIWKH8/75$
ATTENTION
3OXV3'0
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SDJH
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ATTENTION
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Shield Termination
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ATTENTION
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Figure 3.15
Motor power EMC shield connection
conductive
cable jacket shield area
IMPORTANT 7KHXVHUPD\VXSSO\H[WHUQDO9'&SRZHUE\UHPRYLQJ
ZLUHMXPSHUV:DQG:RQWKH3'0ORJLFERDUGDQG
FRQQHFWLQJWKHH[WHUQDOVXSSO\WRWKH9'&DQGYROW
FRPPRQRQFRQQHFWRUV3DQG3
Figure 3.16
PDM control connections
Operator Terminal
F1 F2 F3 F4
X1 STATUS
1 2 3 YES
X2 MODE
4 5 6 NO
X3 CLEAR
7 8 9 -
X4 0 ENTER
GML PC Compatible
Software Personal Computer
SHIELD
R P5-15
S +5 VDC
P5-14
T ANALOG
P5-13
TS+
G P5-12
TS-
P5-11
I-
P5-10
+5 VDC
P5-9
NC
P5-8
COMMON
P5-7
COMMON
P5-6
I+
Brushless Motor P5-5
B-
P5-4
B+
P5-3
A-
P5-2
A+
P5-1
SHIELD
P4-15
+5 VDC
P4-14
DIR-
P4-13
STEP-
P4-12
STEP+
P4-11
I-
P4-10
+5 VDC
P4-9
DIR+
P4-8
Master Encoder P4-7
COMMON
COMMON
P4-6
I+
P4-5
B-
P4-4
B+
P4-3
A-
P4-2
A+
P4-1
P2
OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM +24 VDC
12
ERROR OUTPUT 8
11
IN POSITION OUTPUT 7
10
HOME SEQUENCE COMPLETE OUTPUT 6
9
8
AT HOME OUTPUT 5
PROGRAM RUNNING OUTPUT 4
7
GENERAL PURPOSE OUTPUT OUTPUT 3
6
GENERAL PURPOSE OUTPUT OUTPUT 2
5
4
GENERAL PURPOSE OUTPUT OUTPUT 1
3
GENERAL PURPOSE INPUT INPUT 16
GENERAL PURPOSE INPUT INPUT 15
2
GENERAL PURPOSE INPUT INPUT 14
1
P1
14 GENERAL PURPOSE INPUT INPUT 13
13
INTERRUPT #2 INPUT 12
12
INTERRUPT #1 INPUT 11
11
ERETURN INPUT 10
10
PAUSE INPUT 9
9
JOG FORWARD INPUT 8
8 JOG REVERSE INPUT 7
7
HOME COMMAND INPUT 6
6
HOME SWITCH INPUT 5
5
START INPUT 4
4
ENABLE INPUT 3
REVERSE LIMIT INPUT 2
3
FORWARD LIMIT INPUT 1
2
1
24 VOLT COMMON
INPUT SWITCHES: RESISTANCE IS 3000 OHM MAXIMUM
Figure 3.17
Typical Digital I/O wiring
INTERNAL
P2
OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM +24 VDC
12 W3 INTERNAL 24 VDC SUPPLY
ERROR OUTPUT 8
11
10
IN POSITION OUTPUT 7
TYPICAL OUTPUT
9
HOME SEQUENCE COMPLETE OUTPUT 6
AT HOME OUTPUT 5 75mA MAX PER OUTPUT
8 500mA TOTAL
PROGRAM RUNNING OUTPUT 4
7
GENERAL PURPOSE OUTPUT OUTPUT 3
6
GENERAL PURPOSE OUTPUT OUTPUT 2
5
24 VOLT COMMON
4
GENERAL PURPOSE OUTPUT OUTPUT 1
3
GENERAL PURPOSE INPUT INPUT 16
GENERAL PURPOSE INPUT INPUT 15
2
GENERAL PURPOSE INPUT INPUT 14
1
P1
14 GENERAL PURPOSE INPUT INPUT 13
13
INTERRUPT #2 INPUT 12
12
INTERRUPT #1 INPUT 11
11
ERETURN INPUT 10
10
PAUSE INPUT 9
JOG FORWARD INPUT 8 3.3 K
9
8 JOG REVERSE INPUT 7 TYPICAL INPUT
7
HOME COMMAND INPUT 6
6
HOME SWITCH INPUT 5
5
START INPUT 4
4
ENABLE INPUT 3
REVERSE LIMIT INPUT 2
3
FORWARD LIMIT INPUT 1
2
24 VOLT COMMON W4
1 INTERNAL 24 VDC SUPPLY
INPUT SWITCHES: RESISTANCE IS 3000 OHM MAXIMUM
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(Continued)
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VXSSOLHGE\WKHXVHUVLQSXWFLUFXLWIURPWKHXVHUYROWSRVLWLYHDQGHDFKLQSXW
ZLOOVLQNP$ZKHQDFWLYH
Digital Inputs
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(Continued)
Digital Outputs
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ATTENTION
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Analog Input
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Figure 3.18
Analog input and output - typical internal circuits
+15 VDC
-15 VDC
+15 VDC
P3 -
+15 VDC
8
MONITOR ANALOG OUTPUT +
7
DAC1 ANALOG OUTPUT
6 +15 VDC
ADC1 ANALOG INPUT -15 VDC
5
ANALOG COMMON +15 VDC
4
RELAY COMMON -
3
ENABLED RELAY
2
READY RELAY +
1
-15 VDC
-15 VDC
Analog Output
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Monitor Output
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Figure 3.19
Enable and Ready Relay - Typical Internal Circuits
P3
+15 VDC
8
8 BIT DAC OUT (MONITOR)
7
12 BIT DAC OUT
6
10 BIT A/D IN
5
ANALOG COMMON
4
RELAY COMMON
3
ENABLED
2
READY NORMALLY NORMALLY
1 OPEN OPEN
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Figure 3.20
Encoder input circuitry example
Encoder 1
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WKHHQFRGHUPRXQWHGWRWKHPRWRU7KLVLVWKHRQO\PRWRUPRXQWHGIHHGEDFN
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Figure 3.21
Encoder 1 connections
SHIELD
R P5-15
S +5 VDC
P5-14
T ANALOG
P5-13
TS+
G P5-12
TS-
P5-11
I-
P5-10
+5 VDC
P5-9
NC
P5-8
COMMON
P5-7
COMMON
P5-6
BRUSHLESS MOTOR I+
P5-5
B-
P5-4
B+
P5-3
A-
P5-2
A+
P5-1
Encoder 2
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VLJQDOVZKHQRQO\WKHPRWRUPRXQWHGHQFRGHULVXVHG7KHIXQFWLRQRIWKH
(QFRGHUSRUWLVVHOHFWHGDVLQSXWRURXWSXW
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EHFRQQHFWHGRQO\DWWKHHQFRGHUHQG+RZHYHULQVRPHDSSOLFDWLRQVLWPD\
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&RQQHFWRU3LQFOXGHVDVHSDUDWHSLQ 3LQ IRUWKLVSXUSRVH5HIHU
WR ´8/75$3OXV3'03RU3WR$X[LOLDU\(QFRGHU 8QWHUPLQDWHG 31
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Figure 3.22
Encoder 2 connections
SHIELD
P4-15
+5 VDC
P4-14
DIR-
P4-13
STEP-
P4-12
STEP+
P4-11
I-
P4-10
+5 VDC
P4-9
DIR+
P4-8
MASTER ENCODER COMMON
P4-7
COMMON
P4-6
I+
P4-5
B-
P4-4
B+
P4-3
A-
P4-2
A+
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Motor Encoder Counts = ( N step pulses ) ---
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Personal Computer RS-232 connections
Operator Terminal
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Figure 3.25
Operator Terminal RS-232 connections
Figure 3.26
Operator Terminal RS-422 connections
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ULTRA Plus PDM connects to the Operator Terminal
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ULTRA Plus to 1398-HMI-003
Pin 1 ULTRA Plus Operator Terminal cable
2 RxD
3 TxD
4
5 COMMON
customer supplied
6 SHIELD jumper
7
8
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ULTRA Plus 1 2 3 4 5 6 7 8 9 10
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Rx
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Figure 3.29
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Figure 3.30
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Figure 3.31
RS-422 Multi-drop connections
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Figure 3.32
RS-232C Daisy-chain connections
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Figure 3.33
Operator Terminal RS-422 multi-drop connections
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customer supplied cabling
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8 Not used
9 Not used
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8 Not used
9 Not used
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Rx
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ULTRA Plus PDM P6 to PC Serial Port (9 pin) (P/N 9101-2024)
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ULTRA Plus PDM P4 or P5 to Auxiliary Encoder (Unterminated) (P/N 9101-2031)
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P4 CONNECTIONS
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MODULE ENCODER
CONNECTOR CONNECTIONS
P4
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P4-12 STEP-
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P4-8 DIR+
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P4-13 DIR-
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Figure 3.38
ULTRA Plus PDM P4 to P4, 2 foot (P/N 9101-2127)
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ULTRA Plus PDM P5 to H, or F-Series Motor Encoder (P/N 9101-2027)
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Specifications
1398 PDM-25, 50, 100, and 1398-PDM-25, 50, 100, and 150 Specifications
150
Positioning 1398 1398 1398 1398
Drive Module PDM-25 PDM-50 PDM-100 PDM-150
Peak Output 25 amps 50 amps 100 amps 150 amps
Current/Phase
Continuous 20 amps 40 amps 50 amps 65 amps
Output
Current/Phase
Continuous 4 kW 8 kW 10 kW 12 kW
Output
Power
Physical Specifications
Weight 15 lb 15 lb 15 lb 21 lb
(5 kg) (5 kg) (5 kg) 10 kg
Operating 32° to 122°F (0° to 50°C)
Temperature
Storage -40° to 176°F (-40° to 80°C)
Temperature
Relative 5% to 95% non-condensing
humidity
External Shunt Modules
Continuous 200 W 900W
Shunt Power
Peak Shunt 6000 W 10kW
Power
Operator Terminals
Terminal 1398-HMI-002 1398-HMI-003
Input voltage 110/240 VAC ±15% 24 VDC ±20% Nominal
Supply 25 Watts 0.5 Amps
Temperature
Operating 32° to 131°F (0° to 55°C) ambient 32° to 104°F (0° to 40°C) ambient
Storage -40° to 158°F (-40° to 70°C) 4° to 176°F (-20° to 80°C) ambient
ambient
Humidity 5% to 95% non-condensing 80% maximum, non-condensing
Weight 7 lb. (3 kg) 2.3 lb. (0.1 kg)
Display Vacuum Fluorescent Display, 4 Vacuum Fluorescent Display, 4
lines by 20 characters lines by 20 characters
Characters 5 mm high Characters 5 mm high
Front panel seal NEMA 4 (IP64) NEMA 4/IP65
NEMA 12 (IP66)
RS-232 cable 9101-2205 9101-2205
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Specification Value
Rating 3.0 kVA
Input 220/ 230/ 240/ 440/ 460/ 480 VAC RMS
Outputa 115/ 230 VAC RMS
Ambient temperature 32° to122°F (0° to 50°C)
Single phase input and output (50/60 Hz)
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Specification Model
TF-03 TF-06 TF-12 TF-18
Rating 3 kVA 6 kVA 12 kVA 18 kVA
Weight 86 lb 135 lb 200 lb 325 lb
31 kg 61 kg 91 kg 148 kg
Input 208/ 230/ 240/ 380/ 460/ 480 VAC RMS
Outputa 115/ 230 VAC RMS
Ambient temperature 32° to122°F (0° to 50°C)
Three phase input and output (50/60 Hz)
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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
FACTORY DESIGNATED SPECIAL OPTIONS
AA = STANDARD FLANGE
AN = NEMA56C FLANGE
OPTIONS
00 = STANDARD
01 = 90 Vdc BRAKE
04 = 24 Vdc BRAKE
OPTICAL ENCODER LINE COUNT*
F = 1000
H = 2000 (S T A N D) A R D
J = 2500
K = 5000
L = 500
M = 3000
N = 1500
MOTOR WINDING KE DESIGNATOR
NOTE: SPECIAL ORDER WINDINGS AVAILABLE
FRAME SIZE
Series DESIGNATOR
F = FERRITE MAGNET
H = LOW INERTIA
N = NEMA
I
F I/F Conversion Card 24VDC Sourcing ,
Faraday shield
Fault I/O
Encoder 24VDC Sourcing
Iavg Iavg Fault
Logic Supply In Position output
Personality Assignable function
Power Module Incremental encoder ,
RAM R/W Input
Reentrancy Isolating input power
Watchdog Test Step and direction
Filter types Installation
Firmware EMC Motors and Cables
Installation Installing for European Union Compliance
Flying leads ,
Motor shield termination Emergency Stop Contactor
Forward Limit I/F Conversion Card
Full Load Amperage Motor guidelines
Fuse Internal
Short Circuit Protection Internal logic power supply ,
Internal shunt
G Invalid Opcode error
Gear IP4X Enclosure
Out Of Range error
GML Ultra Software J
Description Jog
Installation Forward
Ground Reverse
Ground bus bar Jumper
Safety ground PDM internal power supply
Single Point Ground Types PDM Internal shunt connection
Torroid encoder shielding
K Ventilation
KFF
Out of Range error N
KI National Electrical Code
Out of Range error Requirements
KP NEMA enclosure
Out of Range error Noise
KPZ Emission supression diagrams
Out of Range error Operator terminal suppression
Problems
L See Bonding
Lead length
EMC requirements O
LED Operating Environment
Limit Operator Terminal
Forward , Description
Reverse , Installation
Logic Supply Fault Mounting
LOOP Specifications $
Count Out of Range error Start-up Procedure
Variable Range error Optically isolated inputs
Ordering Information
M Cable %
Manuals Motor Mating Connectors %
Math Overflow error Motor Shaft Seal Kits %
MIL-STD-461 Motors %
Monitor Output Transformers %
Motor Output
Compatibility with PDM Control Analog Output
Description Connecting inputs and outputs
Encoder Enabled Relay output
Mating Connectors , % Monitor output
Mounting Ready Relay output
Ordering Information % Sinking signal of output
Overtemperature error
Power leads P
Shaft Seal Kits % Pause input
Shielded power cables , , , PDM
EMC mounting requirements
Thermostat PDM with integral power supply
Mounting PDM with separate power supply
Auxiliary PSM Transformer Peak Overcurrent error
Bonding Personal Computer (PC)
Environment Personality Module
Motors Description
Positioning Drive Module Factory Default Initialization
Requirements Initialization
Shunt Resistor , PDM-10, 20, 30 or 75
PDM-25, 50, 100 or 150 Multi-drop network , ,
Installation Operator Terminal connections ,
Location
Personality Module Fault
POS Track Overflow error
S
Positioning Drive Module
LEDs Safety ground ,
Mounting Schaffner AC Line filter
Power cable S-Curve calculation error
Motor Serial 1 Auxiliary (P7) ,
Shielding Serial 2
Power losses Busy error
Power Module Fault Computer (P6)
Power supply Shielded cable
Auxiliary Encoder
Connections Motor
Digital I/O Shunt Resistor
I/F 24V Conversion Card Connection Diagram ,
Internal Logic Internal in some PDMs
Isolating input power Mounting ,
Location Single Point Ground Types
Module mounting Sinking (active low) I/O
Motor connections Sourcing (active high) I/O
Operating environment Specifications
Operator Terminal 1398 PDM-25, 50, 100, and 150 $
Power supply module 1398-PDM-10, 20, 30, 75, and 150B $
PRECISION Out of Range error Operator Terminal $
Profile Calculation error Transformers $
Program Running output Start Program
Assignable function Start-up Procedure
Programmable Monitor 1398-PDM-10, 20, 30, 75, and 150B
1398-PDM-25, 50, 100 or 150
Motors
Q Operator Terminal
Quadrature signals , Personality Module
Status outputs
Step and direction inputs
R
Storage 3
RAM R/W Fault Suitable filter types
Rasmi AC Line filter Support
Ready output Local product 3
Reentrancy Fault error Technical product assistance 3
Regulatory requirements SW1 dip switch
Related documentation 3 Nework settings
Reverse Limit Unique addresses in network
Roxburgh AC line filter Symbols and Conventions 3
RS-232 , System firmware
Daisy-chain network Location
Jumper System Overview
RS-422
T U
Terminal block Underwriter Laboratories
Connections , Listing
TEXT Checksum error
Transformer
V
Description
Isolation Velocity calculation error
Load Regulation (1398 PDM-10, 20, 30, Ventilation
75, and 150B) Curve
Ordering % W
Outline Diagram (1398-PDM-25, 50, 100, Watchdog
150) Watchdog Reset error
Sizing Watchdog Test Fault error
Troubleshooting, see “Check for Problems in Wording Conventions 3
the System”
Typographical Conventions 3