Allen-Bradley 1398 ULTRA Plus Series Installation Manual
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Allen-Bradley 1398 ULTRA Plus Series Installation Manual

Positioning drive module
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1398
ULTRA Plus Series
Positioning Drive
Module
(Catalog Nos. 1398-PDM-10, -20,
-30, -50, -75, -100, -150, and -150B)
Installation Manual

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Table of Contents
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Summary of Contents for Allen-Bradley 1398 ULTRA Plus Series

  • Page 1 1398 ULTRA Plus Series Positioning Drive Module (Catalog Nos. 1398-PDM-10, -20, -30, -50, -75, -100, -150, and -150B) Installation Manual...
  • Page 2 Important User Information %HFDXVH RI WKH YDULHW\ RI XVHV IRU WKH SURGXFWV GHVFULEHG LQ WKLV SXEOLFDWLRQ WKRVH UHVSRQVLEOH IRU WKH DSSOLFDWLRQ DQG XVH RI WKLV FRQWURO HTXLSPHQW PXVW VDWLVI\ WKHPVHOYHV WKDW DOO QHFHVVDU\ VWHSV KDYH EHHQ WDNHQ WR DVVXUH WKDW HDFK DSSOLFDWLRQ DQG XVH PHHWV DOO SHUIRUPDQFH DQG VDIHW\ UHTXLUHPHQWV LQFOXGLQJ DQ\ DSSOLFDEOH ODZV UHJXODWLRQV FRGHV DQG VWDQGDUGV 7KH LOOXVWUDWLRQV FKDUWV VDPSOH SURJUDPV DQG OD\RXW H[DPSOHV VKRZQ LQ...

  • Page 3: Chapter 2

    Table of Contents Preface ,QWURGXFWLRQ                                              3 :KR 6KRXOG 8VH WKLV 0DQXDO                                3 3XUSRVH RI WKLV 0DQXDO                                     3 &RQWHQWV RI WKLV 0DQXDO                                    3...

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    Chapter 4 3'0    DQG %                            Apply Power for the First Time 3'0   DQG                                3RZHU 6XSSO\ 0RGXOH                                    6WDUWXS 3URFHGXUH IRU 3'0                             ...
  • Page 6 Publication 1398-5.1 — January 2000...

  • Page 7: Preface

    Preface 5HDG WKLV SUHIDFH WR IDPLOLDUL]H \RXUVHOI ZLWK WKH UHVW RI WKH PDQXDO 7KLV Introduction SUHIDFH FRYHUV WKH IROORZLQJ WRSLFV • :KR VKRXOG XVH WKLV PDQXDO • 7KH SXUSRVH RI WKLV PDQXDO • &RQWHQWV RI WKLV PDQXDO • 5HODWHG GRFXPHQWDWLRQ •...
  • Page 8 Preface 5HIHU WR WKH IROORZLQJ PDQXDO IRU WKH GHVFULSWLYH FRQWHQWV RI WKLV LQVWDOODWLRQ Contents of this Manual PDQXDO Chapter Title Contents Preface Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended. Overview Gives a functional description of the ULTRA Plus PDM product series.
  • Page 9 An article on wire sizes and types for grounding electrical equipment National Electrical Code Published by the National Fire Protection Association of Boston, MA. A complete listing of current Allen-Bradley documentation, including Allen-Bradley Publication Index SD499 ordering instructions. Also indicates whether the documents are available on CD-ROM or in multi-languages.

  • Page 10: Publication 1398-5.1 - January

    • LQ DQ DUHD ZKHUH LW FDQQRW EH H[SRVHG WR D FRUURVLYH DWPRVSKHUH • LQ D QRQFRQVWUXFWLRQ DUHD $OOHQ%UDGOH\ RIIHUV VXSSRUW VHUYLFHV ZRUOGZLGH ZLWK RYHU  6DOHV6XSSRUW Allen-Bradley Support 2IILFHV  DXWKRUL]HG 'LVWULEXWRUV DQG  DXWKRUL]HG 6\VWHPV ,QWHJUDWRUV ORFDWHG WKURXJKRXW WKH 8QLWHG 6WDWHV DORQH SOXV $OOHQ%UDGOH\ UHSUHVHQWDWLYHV...

  • Page 11: Publication 1398-5.1 - January

    Chapter Overview of the ULTRA Plus PDM System 7KH 8/75$ 3OXV 3'0 PRWLRQ FRQWURO V\VWHP LV D SRVLWLRQLQJ GULYH V\VWHP Functional Description 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...

  • Page 12: 2Shudwru 7Huplqdo

    Overview of the ULTRA Plus PDM System 7KH HOHFWURQLF JHDULQJ IHDWXUH DOORZV WKH FORVHGORRS D[LV WR IROORZ D VHFRQG PDVWHU HQFRGHU DW D SURJUDPPDEOH UDWLR $ PXOWLD[LV DGGUHVVLQJ VFKHPH PXOWLGURS RSHUDWLRQ DOORZV PXOWLSOH 8/75$ 3OXV 3'0 GULYHV WR EH FRQWUROOHG IURP D KRVW FRPSXWHU RYHU D VLQJOH VHULDO FRPPXQLFDWLRQV OLQN $Q 8/75$ 3OXV 3'0 V\VWHP FRQVLVWV EDVLFDOO\ RI WKH IROORZLQJ •...
  • Page 13 Overview of the ULTRA Plus PDM System Figure 1.2 ULTRA Plus PDM Control System ULTRA PLUS ULTRA PLUS PERSONALITY POWER SUPPLY POSITIONING DRIVE MODULE MODULE MODULE PSM USED ONLY WITH MANUALS 1398-PDM-025 ULTRA PLUS OPERATOR TERMINAL 1398-PDM-050 (Optional) 1398-PDM-100 1398-PDM-150 PERSONAL COMPUTER (Windows™...

  • Page 14: 2Shudwru 7Huplqdo

    Overview of the ULTRA Plus PDM System $IWHU D GLDJUDP LV GRZQORDGHG WR WKH 8/75$ 3OXV 3'0 LW LV WUDQVODWHG LQWR D SURJUDP RU VFULSW LQ WKH QDWLYH ODQJXDJH RI WKH PRWLRQ FRQWUROOHU Positioning Drive Modules 7KH 8/75$ 3OXV 3'0 LV D VHOIFRQWDLQHG VLQJOH D[LV SURJUDPPDEOH PRWLRQ FRQWUROOHU 7KH 8/75$ 3OXV 3'0 SURYLGHV FRQWURO DQG SRZHU IRU WKH EUXVKOHVV VHUYR PRWRU 0RWLRQ SURJUDPV DUH VWRUHG LQ RQERDUG QRQYRODWLOH PHPRU\ 7ZR 5656 VHULDO SRUWV SURYLGH FRPPXQLFDWLRQV ZLWK WKH...
  • Page 15 Overview of the ULTRA Plus PDM System 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 '&...

  • Page 16: 2Shudwru 7Huplqdo

    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...
  • Page 17 Overview of the ULTRA Plus PDM System Transformers 0XOWLWDS 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;...

  • Page 18: Whuqdo 6Kxqw

    Overview of the ULTRA Plus PDM System Shunt Kits 7KH 3'0   DQG % KDV D EXLOWLQ 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 .LW Ω : FDQ EH XVHG 7KHVH H[WHUQDO VKXQWV FDQ EH DUUDQJHG WR SURYLGH PD[LPXP SRZHU GLVVLSDWLRQ DV ORQJ DV WKH PLQLPXP UHVLVWDQFH UHTXLUHPHQW LV PHW 5HIHU...

  • Page 19: Install The Ultra Plus Pdm Components

    Chapter 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 2EVHUYH DOO DSSOLFDEOH ORFDO QDWLRQDO DQG LQWHUQDWLRQDO...

  • Page 20: Install The Ultra Plus Pdm Components

    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  ,(&...

  • Page 21: Publication 1398-5.1 — January

    Install the ULTRA Plus PDM Components 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\ RQHKDOI PD[LPXP SRZHU ORVVHV Maximum power losses for help in sizing enclosures Model Maximum Loss (Watts) 1398-PDM-10...
  • Page 22 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 .9$ RI HDFK D[LV PXVW EH NQRZQ 7KLV FDQ EH GHULYHG E\ FDOFXODWLQJ WKH KRUVHSRZHU IRU HDFK D[LV DQG FRQYHUWLQJ WKDW KRUVHSRZHU LQWR XQLWV I ZDWWV ,I \RX DUH VXSSOLQJ SRZHU WR PRUH WKDQ RQH...
  • Page 23 Install the ULTRA Plus PDM Components 6L]LQJ D WUDQVIRUPHU ZLWK DQ  3'0 DQG + PRWRU 7KH VSHHGWRUTXH FXUYH LQIRUPDWLRQ LV EDVHG XSRQ D 3'0 IMPORTANT PRGXOH LQSXW YROWDJH RI  9$& )RU D  9$& LQSXW YROWDJH WKH PD[LPXP VSHHG LV UHGXFHG E\ KDOI ×...
  • Page 24 Install the ULTRA Plus PDM Components 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 3 kVA TRANSFORMER 0020-5097 NOTES: DC BUS VOLTAGE AND CURRENT IS MEASURED AT MOTOR POWER CIRCUITS INTERNAL TO THE DRIVE MODULE (NOT ACCESSIBLE TO THE USER).
  • Page 25 Install the ULTRA Plus PDM Components Figure 2.2 Three PhaseTransformer Load Regulation Curves 3 PHASE TRANSFORMER SECONDARY VOLTAGE RELIANCE MOTION CONTROL AND CORRESPONDING DC BUS VOLTAGE, 3 PHASE TRANSFORMERS VERSUS DC BUS CURRENT PART NUMBER FOR 3, 6, 12, AND 18 kVA TRANSFORMERS 0020-5091-001 0020-5091-002 0020-5091-003...
  • Page 26 Install the ULTRA Plus PDM Components Figure 2.3 Single PhaseTransformer Outline Diagram NOTES: 1. DIMENSIONS ARE IN INCHES (mm) 2 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) 1/4-20 GROUND STUD SECONDARY CONNECTIONS ARE REQUIRED FOR WIRING CONNECTIONS TO (6.35 DIA) 8-32 THD BOLTS TRANSFORMER TERMINAL STRIPS.
  • Page 27 Install the ULTRA Plus PDM Components Figure 2.4 Three Phase Transformer Outline Diagram PART NO. 9101-0131 CONNECTION INSTRUCTIONS PRIMARY CONNECTIONS G REF SECONDARY CONNECTIONS E ±0.06 B MAX 0.56 ±0.03 DIA THRU (4) 0.25-20 GROUND STUD (TRANSFORMER CHASSIS) 8.0 MIN CLEARANCE RECOMMENDED FOR ACCESS TO WIRING OVERALL DIMENSIONS...
  • Page 28 104.1 226.8 CLEARANCE HOLES FOR #10 1.05 1.00 1.00 EXHAUST (M5) MOUNTING SCREWS 26.6 25.4 25.4 0.27 Allen-Bradley Ultra Plus Series Status Serial 1 Auxiliary Serial 2 Computer Encoder 1 Motor WARNING: High Voltage May Exist Up To Five Minutes...
  • Page 29 1398-PDM-75 Mounting 5.97 8.93 151.7 226.8 0.27 1.99 1.00 1.00 50.5 25.4 25.4 AIR EXHAUST Allen-Bradley Ultra Plus Series Status Serial 1 Auxiliary Serial 2 Computer Encoder 1 Motor WARNING: High Voltage May Exist Up To Five Minutes After Removing Power...
  • Page 30 1398-PDM-25, 50, 100, and 150 Mounting 4.50 114.3 9.93 252.1 1.38 0.25 34.9 9.70 246.4 1.38 0.45 34.9 11.4 EXHAUST Allen-Bradley Ultra Plus Series Serial Port 1 Serial Port 2 Encoder Input 1 Encoder Input 2 Analog I/O And Status 16.87 17.50 16.15...
  • Page 31 8.93 226.8 151.7 0.27 1.25 2.75 2.75 31.8 69.9 69.9 AIR EXHAUST Allen-Bradley Ultra Plus Series Status Serial 1 Auxiliary Serial 2 WARNING: High Voltage May Computer DC BUS Exist Up To Fifteen Minutes POT1 POT2 POT3 After Removing Power.
  • Page 32 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...
  • Page 33 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 0.50 (13) (13) 0.25 (6.5) 0.50 (13) 9.00 8.38 (229) (213) 3.00 (77) 2.00 (50) DI GR M, OUTLINE & CONNECTION DR WING UXILI RY POWER SUPPLY MODULE DOCUMENT NO.

  • Page 34: 0Rwruv

    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 •...

  • Page 35: Whuqdo 6Kxqw

    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 2.11...
  • Page 36 2-18 Install the ULTRA Plus PDM Components Figure 2.12 External Shunt (900W) mounting and connection diagram Cabinet There must be 155mm (6.1 in.) Of clearance on all sides of At terminal block, remove jumper shunt module installed at factory for internal shunt There must be 155mm (6.1 in.) STATUS...

  • Page 37: 2Shudwru 7Huplqdo

    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...
  • Page 38 2-20 Install the ULTRA Plus PDM Components Figure 2.14 Operator Terminal (1398-HMI-003) Dimensions GASKET SUPPLIED 3.86 3.86 8.11 WITH UNIT 0.20 [206.0] [98.0] [98.0] [5.0] 3.28 [83.25] 6.89 6.13 MAX. [175.0] [155.7] 3.28 [83.25] 0.17 2.22 [4.25] [56.5] 7.40 1 2 3 4 5 6 7 8 9 10 [188.0] Not used 24 VDC...
  • Page 39 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...
  • Page 40 2-22 Install the ULTRA Plus PDM Components )XVLQJ IRU WKH 8/75$ 3OXV 3'0V GLIIHUV EHFDXVH RI WKH VHSDUDWH SRZHU PDM Fusing Requirements 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...
  • Page 41 Install the ULTRA Plus PDM Components 2-23 7KH 3HUVRQDOLW\ 0RGXOH LV DOUHDG\ LQVWDOOHG RQ WKH 8/75$ 3OXV 3'0 7KH Personality Module IROORZLQJ SURFHGXUH LV WR EH XVHG LI WKH 3HUVRQDOLW\ 0RGXOH QHHGV WR EH Installation FKDQJHG IRU PDFKLQH VHUYLFLQJ 5HIHU WR )LJXUH  IRU WKH ORFDWLRQ RI WKH 3HUVRQDOLW\ 0RGXOH RQ WKH 8/75$ 3OXV 3'0 ORJLF ERDUG Figure 2.16 Location of Personality Module...
  • Page 42 2-24 Install the ULTRA Plus PDM Components 3'0   DQG  0HDVXUH YROWDJHV DW 3RVLWLYH DQG 1HJDWLYH EXV WHUPLQDOV WR HQVXUH LQFRPLQJ SRZHU LV 2)) ,I D 360$8; LV XVHG PHDVXUH WKH YROWDJH DW / DQG / RI WKH 360$8; WR HQVXUH WKDW LQFRPLQJ SRZHU LV 2))  5HPRYH WKH 8/75$ 3OXV 3'0 FRYHU 3'0   DQG  RQO\   ,QVWDOO 3HUVRQDOLW\ 0RGXOH RQ 8/75$ 3OXV 3'0 ORJLF ERDUG LQ VRFNHW DW...
  • Page 43 Install the ULTRA Plus PDM Components 2-25 $OO 8/75$ 3OXV 3'0V FRPH ZLWK WKH V\VWHP ILUPZDUH LQVWDOOHG 7KHUHIRUH System Firmware XQOHVV \RX DUH XSJUDGLQJ \RXU 8/75$ 3OXV 3'0 WR D QHZHU YHUVLRQ RI Installation ILUPZDUH \RX ZLOO QRW QHHG WR LQVWDOO V\VWHP ILUPZDUH 5HIHU WR )LJXUH  IRU V\VWHP ILUPZDUH ORFDWLRQ Figure 2.17 Location of system firmware...

  • Page 44: 2Shudwru 7Huplqdo

    2-26 Install the ULTRA Plus PDM Components Installing the Firmware EPROMs 6WUD\ HOHFWULFDO GLVFKDUJH FDQ GDPDJH WKH )LUPZDUH ATTENTION (3520V 7XUQ SRZHU 2II GLVVLSDWH DQ\ VWRUHG HOHFWULFDO HQHUJ\ DQG ZHDU D FRQGXFWLYH ZULVW VWUDS ZKLOH KDQGOLQJ WKH 3HUVRQDOLW\ 0RGXOH )DLOXUH WR REVHUYH WKLV VDIHW\ SURFHGXUH FRXOG UHVXOW LQ GDPDJH WR WKH HTXLSPHQW  &KHFN WKDW SRZHU WR WKH 8/75$ 3OXV 3'0 LV 2)) 3'0    DQG %...
  • Page 45 Install the ULTRA Plus PDM Components 2-27 5HIHU WR ´/RFDWLRQ RI MXPSHU DQG ',3 VZLWFKµ RQ SDJH  IRU WKH ORFDWLRQV RI MXPSHUV : : DQG GLS VZLWFK 6: RQ WKH 8/75$ 3OXV 3'0 ORJLF ERDUG Figure 2.18 Location of jumper and DIP switch DIP SWITCH Sw1 JUMPERS 1398 PDM-25, 50, 100, and 150...
  • Page 46 2-28 Install the ULTRA Plus PDM Components Electromagnetic Compatibility Directive ,W LV LPSRVVLEOH WR JXDUDQWHH D VSHFLILF 8/75$ 3OXV 3'0 LQVWDOODWLRQ ZLOO PHHW WKH (0& UHTXLUHPHQWV ZLWKRXW WHVWLQJ 7KH 3'0    DQG % LQVWDOOHG DV GHVFULEHG EHORZ VKRXOG EH FRPSOLDQW ZLWK (XURSHDQ (0&...
  • Page 47 Install the ULTRA Plus PDM Components 2-29 ,PSRUWDQW SRLQWV DUH • &DEOH VKLHOGV PXVW EH ERQGHG WR WKH HQFORVXUH DW DOO HQWU\ SRLQWV LQ RQH RI WZR ZD\V $ PDWLQJ EXONKHDG FRQQHFWRU FDQ EH PRXQWHG RQ WKH HQFORVXUH RU WKH FDEOH MDFNHW PD\ EH UHPRYHG VR WKDW WKH VKLHOG FDQ EH FODPSHG WR WKH HQFORVXUH 7KH PRWRU SRZHU FDEOH VKLHOG PD\ EH WHUPLQDWHG WR WKH 3'0 FKDVVLV RQ WKRVH GULYHV WKDW KDYH WKH PRWRU SRZHU FDEOH EUDFNHW VXSSOLHG ZLWK WKHP ,Q WKLV FDVH WKH PRWRU SRZHU FDEOH VKLHOG GRHV QRW KDYH WR EH...
  • Page 48 2-30 Install the ULTRA Plus PDM Components 7KH 3'0 LQSXW FXUUHQW UDWLQJV DQG VXLWDEOH VXSSO\ ILOWHUV RQH ILOWHU SHU 3'0 DUH OLVWHG EHORZ PDM current ratings and suitable supply filters Current Rating Schaffner Roxburgh φ 1398-PDM-10 FN350-12-29 MDF16 or MIF10 10 A φ...
  • Page 49 Install the ULTRA Plus PDM Components 2-31 Bonding Your System %RQGLQJ LV WKH SUDFWLFH RI FRQQHFWLQJ PHWDO FKDVVLV DVVHPEOLHV IUDPHV VKLHOGV DQG HQFORVXUHV WR UHGXFH WKH HIIHFWV RI HOHFWURPDJQHWLF LQWHUIHUHQFH (0,  8QOHVV VSHFLILHG PRVW SDLQWV DUH QRW FRQGXFWLYH DQG WKH\ DFW DV LQVXODWRUV 7R DFKLHYH D JRRG ERQG EHWZHHQ PRGXOHV DQG WKH VXE SDQHO VXUIDFHV QHHG WR EH SDLQWIUHH RU SODWHG %RQGLQJ PHWDO VXUIDFHV FUHDWHV D ORZLPSHGDQFH H[LW SDWK IRU KLJKIUHTXHQF\ HQHUJ\...
  • Page 50 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...
  • Page 51 Install the ULTRA Plus PDM Components 2-33 Motors and Cables 7KH V\VWHP WHVWV ZHUH PDGH XVLQJ 5RFNZHOO $XWRPDWLRQ$OOHQ%UDGOH\ PRWRUV DQG ERWK VKLHOGHG DQG XQVKLHOGHG SRZHU FDEOHV 7KH VKLHOGHG FDEOHV KDYH D µ SRUWLRQ RI WKH FDEOH MDFNHW VWULSSHG RII H[SRVLQJ WKH VKLHOG DSSUR[LPDWHO\ µ...
  • Page 52 2-34 Install the ULTRA Plus PDM Components I/F 24V Sourcing Conversion Card 7KH 8/75$ 3OXV 3'0 KDV VLQNLQJ DFWLYH ORZ ,2 ZKLFK LV FRPPRQ LQ WKH 86 6RXUFLQJ DFWLYH KLJK ,2V DUH SUHIHUUHG LQ (XURSH 5RFNZHOO $XWRPDWLRQ RIIHUV D ',1 UDLO PRXQWHG FDUG ZKLFK FRQYHUWV WKH ,2 IURP VLQNLQJ WR VRXUFLQJ 7KLV FDUG PXVW EH PRXQWHG LQ WKH VDPH HQFORVXUH DV WKH 3'0 $ XVHU VXSSOLHG H[WHUQDO 9'&...
  • Page 53 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 DUFLQJ DW WKH PDLQ FRQWDFWV...
  • Page 54 2-36 Install the ULTRA Plus PDM Components 3HUKDSV QR RWKHU VXEMHFW UHODWHG WR WKH LQVWDOODWLRQ RI LQGXVWULDO HOHFWURQLF Electromagnetic HTXLSPHQW LV VR PLVXQGHUVWRRG DV HOHFWULFDO QRLVH 7KH VXEMHFW LV FRPSOH[ DQG Compatibility WKH WKHRU\ HDVLO\ ILOOV D ERRN 7KLV VHFWLRQ SURYLGHV JXLGHOLQHV WKDW FDQ PLQLPL]H QRLVH SUREOHPV 7KH PDMRULW\ RI LQVWDOODWLRQV GR QRW H[KLELW QRLVH SUREOHPV +RZHYHU WKH ILOWHULQJ DQG VKLHOGLQJ JXLGHOLQHV DUH SURYLGHG DV FRXQWHU PHDVXUHV 7KH...
  • Page 55 Install the ULTRA Plus PDM Components 2-37 Figure 2.23 EMI Source-Victim Model CONDUCTED EMI SOURCE VICTIM RADIATED VICTIM ,PPXQLW\ WR (0, LV SULPDULO\ GHWHUPLQHG E\ HTXLSPHQW GHVLJQ EXW KRZ \RX ZLUH DQG JURXQG WKH GHYLFH LV DOVR FULWLFDO WR DFKLHYLQJ (0, LPPXQLW\ 7KHUHIRUH LW LV LPSRUWDQW WR VHOHFW HTXLSPHQW WKDW KDV EHHQ GHVLJQHG DQG WHVWHG IRU LQGXVWULDO HQYLURQPHQWV 7KH (0, VWDQGDUGV IRU LQGXVWULDO HTXLSPHQW LQFOXGH (1 ;...
  • Page 56 2-38 Install the ULTRA Plus PDM Components Filtering $V PHQWLRQHG DERYH KLJK IUHTXHQF\ HQHUJ\ FDQ EH FRXSOHG EHWZHHQ FLUFXLWV YLD UDGLDWLRQ RU FRQGXFWLRQ 7KH $& SRZHU ZLULQJ LV RQH RI WKH PRVW LPSRUWDQW SDWKV IRU ERWK W\SHV RI FRXSOLQJ PHFKDQLVPV 7KH $& OLQH FDQ FRQGXFW QRLVH LQWR WKH 3'0 IURP RWKHU GHYLFHV RU LW FDQ FRQGXFW QRLVH GLUHFWO\ IURP WKH 3'0 LQWR RWKHU GHYLFHV ,W FDQ DOVR DFW DV DQ DQWHQQD DQG WUDQVPLW RU UHFHLYH UDGLDWHG QRLVH EHWZHHQ WKH 3'0 DQG RWKHU GHYLFHV...
  • Page 57 VXFFHVVIXOO\ LQWHJUDWHG 2QH PDQXIDFWXUHU FDQQRW EH UHFRPPHQGHG RYHU DQRWKHU PDQXIDFWXUHU 7KH PDFKLQH EXLOGHU LV UHVSRQVLEOH IRU WKH VXLWDELOLW\ RI WKH ILOWHU VHOHFWLRQ LQ D VSHFLILF DSSOLFDWLRQ )XUWKHU LQIRUPDWLRQ LV DYDLODEOH IURP WKH PDQXIDFWXUHUV Rockwell Automation/Allen-Bradley Roxburgh Schaffner PDM/ Power Supply...
  • Page 58 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...
  • Page 59 Install the ULTRA Plus PDM Components 2-41 Figure 2.24 AC Line Filter installation POOR GOOD CONDUCTED EMI CONDUCTED EMI LINE RADIATED RADIATED FILTER RADIATED FILTER CONDUCTED EMI LINE +LJK YROWDJH H[LVWV LQ $& OLQH ILOWHUV ATTENTION 7KH ILOWHU PXVW EH JURXQGHG SURSHUO\ EHIRUH DSSO\LQJ SRZHU )LOWHU FDSDFLWRUV UHWDLQ KLJK YROWDJHV DIWHU SRZHU UHPRYDO %HIRUH KDQGOLQJ WKH HTXLSPHQW YROWDJHV VKRXOG EH PHDVXUHG WR GHWHUPLQH VDIH OHYHOV...
  • Page 60 2-42 Install the ULTRA Plus PDM Components Grounding +LJK IUHTXHQF\ +) JURXQGLQJ LV GLIIHUHQW IURP VDIHW\ JURXQGLQJ $ ORQJ ZLUH LV VXIILFLHQW IRU D VDIHW\ JURXQG EXW LV FRPSOHWHO\ LQHIIHFWLYH DV DQ +) JURXQG GXH WR WKH ZLUH LQGXFWDQFH $V D UXOH RI WKXPE D ZLUH KDV DQ LQGXFWDQFH RI  Q+FP  Q+LQ UHJDUGOHVV RI GLDPHWHU $W ORZ IUHTXHQFLHV LW DFWV DV D FRQVWDQW LPSHGDQFH DW LQWHUPHGLDWH IUHTXHQFLHV DV DQ LQGXFWRU DQG DW KLJK IUHTXHQFLHV DV DQ DQWHQQD 7KH XVH RI JURXQG VWUDSV LV D EHWWHU...
  • Page 61 Install the ULTRA Plus PDM Components 2-43 Shielding and Segregation 7KH (0, UDGLDWLQJ IURP WKH 3'0 HQFORVXUH GURSV RII YHU\ TXLFNO\ RYHU GLVWDQFH 0RXQWLQJ WKH 3'0 LQ D FRQGXFWLYH HQFORVXUH VXFK DV DQ LQGXVWULDO FDELQHW IXUWKHU UHGXFHV WKH UDGLDWHG HPLVVLRQV 7KH FDELQHW VKRXOG EH VHW XS WR DFW DV D )DUDGD\ FDJH 7KH FDELQHW VKRXOG KDYH D KLJK IUHTXHQF\ JURXQG DQG WKH VL]H RI RSHQLQJV VKRXOG EH PLQLPL]HG $OO 8/75$ 3OXV 3'0V PXVW EH PRXQWHG LQ DQ LQGXVWULDO FDELQHW WR PHHW VDIHW\ UHTXLUHPHQWV...
  • Page 62 2-44 Install the ULTRA Plus PDM Components EDFNVKHOO 7KH IROORZLQJ VXJJHVWLRQV DUH UHFRPPHQGHG IRU DOO LQVWDOODWLRQV HVSHFLDOO\ VLQFH WKH\ DUH LQH[SHQVLYH  8VH D VKLHOGHG PRWRU FDEOH WKDW LV WHUPLQDWHG DW ERWK HQGV 7KH VKLHOG VKRXOG EH FRQQHFWHG WR WKH *%% RU FKDVVLV DW WKH 3'0 HQG DQG WKH PRWRU IUDPH DW WKH PRWRU HQG 7KH FRD[LDO FRQILJXUDWLRQ SURYLGHV PDJQHWLF VKLHOGLQJ DQG WKH VKLHOG SURYLGHV D UHWXUQ SDWK IRU +) FXUUHQWV ZKLFK DUH FDSDFLWLYHO\ FRXSOHG IURP WKH PRWRU ZLQGLQJV WR WKH...
  • Page 63 Install the ULTRA Plus PDM Components 2-45 ,I (0, SUREOHPV SHUVLVW DGGLWLRQDO FRXQWHU PHDVXUHV FDQ EH DWWHPSWHG 6HYHUDO VXJJHVWLRQV IRU V\VWHPV PRGLILFDWLRQV IROORZ  $ IHUULWH ´GRXJKQXWµ RU WRUURLG DURXQG D VLJQDO FDEOH PD\ KHOS 7KH IHUULWH ZLOO DWWHQXDWH FRPPRQ PRGH QRLVH EXW ZLOO GR QRWKLQJ IRU GLIIHUHQWLDO PRGH QRLVH 6SHFLILFDOO\ WKLV VKRXOG KHOS 56 FRPPXQLFDWLRQ SUREOHPV Figure 2.26...
  • Page 64 2-46 Install the ULTRA Plus PDM Components Figure 2.27 Motor power winding methods to minimize noise emissions BRUSHLESS MOTOR TWISTED TOGETHER MOTOR CASE CHASSIS TO SINGLE POINT EARTH GROUND BRUSHLESS MOTOR TWISTED TOGETHER CHASSIS MOTOR CASE SHIELD TO SINGLE POINT EARTH GROUND BRUSHLESS MOTOR...
  • Page 65 Chapter 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 7KH XVHU LV UHVSRQVLEOH IRU FRQIRUPLQJ WR 1DWLRQDO ATTENTION (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 $&...
  • Page 66 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 INPUT POWER WIRES MOTOR POWER CONNECTOR DRIVE MODULE INPUT CURRENT REQUIREMENTS IQ TERMINALS MINIMUM RECOMMENDED MOTOR POWER SIGNAL POWER WIRE 1.0 Amps AC at 115 Volts AC RECOMMENDED TERMINAL(S)
  • Page 67 Wire the ULTRA Plus PDM Components Figure 3.2 Power Wiring for 1398-PDM-75 INPUT POWER WIRES MOTOR POWER WIRES R,S,T,GND DRIVE MODULE INPUT CURRENT REQUIREMENTS MOTOR POWER CONNECTOR BRU/IQ TERMINALS CURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS) MINIMUM RECOMMENDED MOTOR POWER SIGNAL POWER WIRE 1.0 Amps AC at 115 Volts AC RECOMMENDED...
  • Page 68 Wire the ULTRA Plus PDM Components Figure 3.3 Power Wiring for 1398-PDM-150B INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS MOTOR POWER WIRES R,S,T,GND MOTOR POWER CONNECTOR IQ TERMINALS CURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS) MINIMUM RECOMMENDED SIGNAL MOTOR POWER 1.0 Amps AC at 115 Volts AC DRIVE POWER WIRE...
  • Page 69 Wire the ULTRA Plus PDM Components 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 $QRWKHU...
  • Page 70 Wire the ULTRA Plus PDM Components Power Supply Module (PSM) 7KH 3RZHU 6XSSO\ 0RGXOH 360 FDQ VXSSO\ '& SRZHU WR DV PDQ\ DV VL[ 8/75$ 3OXV 3'0V 7KUHH SKDVH $& SRZHU  9$& LV WKH RQO\ UHTXLUHG LQSXW SRZHU IRU WKH 360 7KH LQSXW SRZHU PD\ EH RSWLRQDOO\ LVRODWHG WKURXJK D WUDQVIRUPHU )LHOG ZLULQJ PXVW EH FRSSHU ZLWK D PLQLPXP UDWLQJ RI ƒ& 7KH SKDVLQJ RI WKH LQSXW SRZHU / / DQG / LV DUELWUDU\ 7KH HDUWK JURXQG FRQQHFWLRQ LV UHTXLUHG IRU VDIH DQG SURSHU V\VWHP RSHUDWLRQ 7HUPLQDO...
  • Page 71 Wire the ULTRA Plus PDM Components DC Bus Power 7KH '& EXV IURP WKH 360 VXSSOLHV SRZHU WR WKH 8/75$ 3OXV 3'0 3'0   DQG   7KH 360 '& EXV PXVW EH FRQQHFWHG DV VKRZQ LQ 3RZHU :LULQJ 'LDJUDP )LJXUH  RQ SDJH  ZLWK WKH 360 LQ WKH FHQWHU XVLQJ WKH FRQQHFWLRQ ZLUHV SURYLGHG 'R QRW VXEVWLWXWH WKH '&...
  • Page 72 Wire the ULTRA Plus PDM Components 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 240V LINE EXAMPLE: MODULE (PSM) POWER SUPPLY MODULE DRIVE 480V LINE MODULE (PSM) MODULE 240VAC, 3 PHASE...
  • Page 73 Wire the ULTRA Plus PDM Components PSM Interface Logic 7KH 6WDWXV DQG (QDEOH VLJQDOV RQ WKH 360 DUH LQGLFDWHG LQ WKH IROORZLQJ WDEOH WKDW LQWHUIDFH WKH 360 ZLWK WKH 3'0 RU DQRWKHU FRQWURO LOOXVWUDWHV W\SLFDO LQWHUQDO FLUFXLWU\ IRU WKH LQWHUIDFH FRQQHFWLRQV )LJXUH  VKRZV H[WHUQDO FRQQHFWLRQV RI WKH 3'0V PSM Connector Pin #...
  • Page 74 3-10 Wire the ULTRA Plus PDM Components Status Outputs 7KH 6WDWXV RXWSXWV DUH WKH FRQWDFWV RI D QRUPDOO\ RSHQ UHOD\ ZKLFK FORVHV WR LQGLFDWH WKDW WKH 360 LV RSHUDWLQJ SURSHUO\ $Q RSHQ UHOD\ VLJQDOV WKDW QR $& SRZHU LV DSSOLHG WR WKH 360 RU WKDW D 360 IDXOW KDV RFFXUUHG 5HIHU WR WKH DERYH GUDZLQJ IRU FRQQHFWLRQ H[DPSOHV Enable Input 7KH 360 (QDEOH LQSXW LV DQ RSWLFDOO\ LVRODWHG LQSXW ZKLFK FRQWUROV WKH SRZHU...
  • Page 75 Wire the ULTRA Plus PDM Components 3-11 Figure 3.8 Power Supply Module jumper location DIAGNOSTIC INDICATOR LIGHTS POWER SUPPLY MODULE CIRCUIT BOARD (COMPONENT SIDE) INTERFACE CONNECTOR W1 JUMPER SETTING SELECTS: SHORTING JUMPER ACROSS EXTERNAL ENABLE INPUT IS SELECTED. TOP 2 PINS (POSITION A) EXTERNAL CONNECTION IS REQUIRED TO CONNECTOR TB1 SIGNALS ENABLE+ AND ENABLE-.
  • Page 76 3-12 Wire the ULTRA Plus PDM Components 7KH 8/75$ 3OXV 3'0 3'0   DQG % KDV D EXLOWLQ VKXQW External Shunt Connections UHJXODWRU 7KH IROORZLQJ WDEOH GHSLFWV WKH LQWHUQDO VKXQW VHOHFWLRQ ZLWK D IDFWRU\ LQVWDOOHG MXPSHU EHWZHHQ WHUPLQDOV  DQG  5HPRYDO RI WKH LQWHUQDO VKXQW MXPSHU DQG LQVWDOODWLRQ RI D ODUJHU H[WHUQDO VKXQW EHWZHHQ WHUPLQDOV  DQG  DOORZ PRUH SRZHU WR EH GLVVLSDWHG Terminal...

  • Page 77: Whuqdo 6Kxqw

    Wire the ULTRA Plus PDM Components 3-13 7KH H[WHUQDO VKXQW LV HQDEOHG ZKHQ WKH '& %86 LQFUHDVHV WR D VSHFLILF YDOXH  9'&  $Q LQFUHDVH LQ '& %86 YROWDJH PD\ RFFXU ZKHQ WKH DPSOLILHU GHFHOHUDWHV WKH PRWRU DQG LWV ORDG 7KLV LV GXH WR WKH HQHUJ\ IORZ IURP WKH PRWRU WR WKH '&...
  • Page 78 3-14 Wire the ULTRA Plus PDM Components Figure 3.9 External Shunt Wiring Examples 200 Watts 800 Watts 1800 Watts 1 - 200W Unit Configuration* 4 - 200W Unit Configuration* 9 - 200W Unit Configuration* TB2-1 TB2-1 TB2-1 TB2-3 TB2-3 NOTES: Uses 200W units p/n 9101-1079 *Configuration good for all ULTRA Plus PDMs TB2-3...
  • Page 79 Wire the ULTRA Plus PDM Components 3-15 Replacing the PSM Shunt Fuse 7KH '& %XV VKXQW IXVH LV ORFDWHG LQ WKH 3RZHU 6XSSO\ 0RGXOH 7R FKHFN DQG RU UHSODFH WKLV IXVH  0HDVXUH YROWDJHV DW / / DQG / SKDVH WR SKDVH WR HQVXUH LQFRPLQJ SRZHU LV 2)) 0DNH VXUH WKDW WKH JUHHQ 360 5($'<...

  • Page 80: 2Shudwru 7Huplqdo

    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)

  • Page 81: 2Shudwru 7Huplqdo

    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 3.12 Operator Terminal connections (on back of unit) SUPPLY 24 VDC (DC+) COMMON...
  • Page 82 1398-PDM-10, 20, 30, 75, and 150B – screw terminal 1398-PDM-25, 50, 100, and 150 – M6 stud 3. Wire colors shown reflect cables supplied by Rockwell Automation/ Allen-Bradley 6HH )LJXUH  RQ SDJH  IRU FRQQHFWRU SLQ DQG VLJQDO LGHQWLILFDWLRQ RI 16HULHV PRWRUV Figure 3.14 Motor power connections N-Series motors...
  • Page 83 Wire the ULTRA Plus PDM Components 3-19 &DEOH VL]HV DUH LQGLFDWHG LQ WKH DSSURSULDWH GUDZLQJV • 5HIHU WR ´3RZHU :LULQJ 'LDJUDP IRU 3'0  DQG µ RQ SDJH  • 5HIHU WR ´3RZHU :LULQJ IRU 3'0µ RQ SDJH  • 5HIHU WR ´3RZHU :LULQJ IRU 3'0%µ RQ SDJH  •...
  • Page 84 3-20 Wire the ULTRA Plus PDM Components Figure 3.15 Motor power EMC shield connection conductive shield cable jacket area 5HIHU WR ´&DEOHVµ RQ SDJH  IRU D VHOHFWLRQ RI VKLHOGHG PRWRU SRZHU FDEOHV 7KLV VHFWLRQ FRYHUV WKH FRQWURO DQG LQWHUIDFH FRQQHFWLRQV EHWZHHQ WKH 3'0 Digital Inputs and Outputs DQG WKH UHVW RI WKH V\VWHP 7KLV LQFOXGHV 'LJLWDO ,2 $QDORJ ,2 5HOD\ 2XWSXWV (QFRGHUV 6WHS DQG GLUHFWLRQ ,QSXWV DQG 6HULDO 3RUWV 5HIHU...
  • Page 85 Wire the ULTRA Plus PDM Components 3-21 Figure 3.16 PDM control connections Operator Terminal STATUS STATUS MODE MODE CLEAR CLEAR ENTER ENTER PC Compatible Personal Computer Software SHIELD P5-15 +5 VDC P5-14 ANALOG P5-13 P5-12 P5-11 P5-10 +5 VDC P5-9 P5-8 COMMON P5-7...
  • Page 86 3-22 Wire the ULTRA Plus PDM Components Figure 3.17 Typical Digital I/O wiring INTERNAL OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM +24 VDC INTERNAL 24 VDC SUPPLY ERROR OUTPUT 8 IN POSITION OUTPUT 7 TYPICAL OUTPUT HOME SEQUENCE COMPLETE OUTPUT 6 75mA MAX PER OUTPUT AT HOME OUTPUT 5...
  • Page 87 Wire the ULTRA Plus PDM Components 3-23 I/F 24V Sourcing 7KH 8/75$ 3OXV 3'0 KDV VLQNLQJ DFWLYH ORZ ,2 ZKLFK LV FRPPRQ LQ WKH 86 EXW VRXUFLQJ DFWLYH KLJK ,2 LV SUHIHUUHG LQ (XURSH 5RFNZHOO $XWRPDWLRQ$OOHQ%UDGOH\ RIIHUV D ',1 UDLO PRXQWHG LQWHUIDFH FDUG ZKLFK FRQYHUWV WKH ,2 IURP VLQNLQJ WR VRXUFLQJ DFWLYH KLJK  7KLV LQWHUIDFH FDUG PXVW EH PRXQWHG LQ WKH VDPH HQFORVXUH DV WKH GULYH PDM pin connection with the IF 24V Conversion Card...
  • Page 88 3-24 Wire the ULTRA Plus PDM Components (Continued) PDM Connector PDM Pin Wire IF Card Pin Cable Number Color Number Pair P2 General purpose inputs 1 (Input) WHITE Pair 8 and outputs 2 (Input) BLACK Pair 8 3 (Input) BLUE Pair 9 4 (Output) BLACK...
  • Page 89 Wire the ULTRA Plus PDM Components 3-25 Digital Inputs 7KH RSWLFDOO\ LVRODWHG LQSXWV DUH FRQQHFWHG ZLWK DQ LQWHUQDO SXOOXS UHVLVWRU WR 9'& 0DNLQJ D FRQQHFWLRQ WR WKH  YROW FRPPRQ FORVLQJ D VZLWFK ZLOO DOORZ FXUUHQW WR IORZ WKURXJK WKH RSWRLVRODWRU 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 KLW 7KH...
  • Page 90 3-26 Wire the ULTRA Plus PDM Components (Continued) Connector Signal Name Assignable Function P1 General purpose Input 13 Program Select inputs Input 12 Int2 / Program Select Input 11 Int1 / Program Select Input 10 Emergency Return Input 9 Pause Input 8 Jog Forward Input 7...
  • Page 91 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...
  • Page 92 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/&...
  • Page 93 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 $QDORJ &RPPRQ RQ SLQ 3 7KH  ELW '$&...
  • Page 94 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...
  • Page 95 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'& 7KH 8/75$ 3OXV 3'0 ZLOO QRW DXWRPDWLFDOO\ WXUQ RXWSXWV...
  • Page 96 3-32 Wire the ULTRA Plus PDM Components Figure 3.20 Encoder input circuitry example Publication 1398-5.1 — January 2000...
  • Page 97 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...
  • Page 98 3-34 Wire the ULTRA Plus PDM Components Figure 3.21 Encoder 1 connections SHIELD P5-15 +5 VDC P5-14 ANALOG P5-13 P5-12 P5-11 P5-10 +5 VDC P5-9 P5-8 COMMON P5-7 COMMON P5-6 BRUSHLESS MOTOR P5-5 P5-4 P5-3 P5-2 P5-1 Publication 1398-5.1 — January 2000...
  • Page 99 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 PDVWHUIROORZHU V\VWHPV RU IRU HOHFWURQLF JHDULQJ $V DQ DOWHUQDWLYH WKH (QFRGHU  SRUW PD\ DOVR EH XVHG WR RXWSXW HQFRGHU  VLJQDOV ZKHQ RQO\ WKH PRWRU PRXQWHG HQFRGHU LV XVHG 7KH IXQFWLRQ RI WKH...
  • Page 100 3-36 Wire the ULTRA Plus PDM Components Figure 3.22 Encoder 2 connections SHIELD P4-15 +5 VDC P4-14 DIR- P4-13 STEP- P4-12 STEP+ P4-11 P4-10 +5 VDC P4-9 DIR+ P4-8 COMMON MASTER ENCODER P4-7 COMMON P4-6 P4-5 P4-4 P4-3 P4-2 P4-1 Slaving an ULTRA Plus PDM to Another ,Q DSSOLFDWLRQV ZKHUH DQ 8/75$ 3OXV 3'0 QHHGV WR ´IROORZµ...
  • Page 101 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'&...
  • Page 102 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 –...

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    Wire the ULTRA Plus PDM Components 3-39 7KHUH DUH WZR VHULDO SRUWV RQ D 3'0 6HULDO  $X[LOLDU\ 3 DQG 6HULDO  Serial Port Connections &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...
  • Page 104 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 Signal Name RS-232 RS-422 P6 Serial Port 2 No connection RXD+ RXD-...

  • Page 105: 2Shudwru 7Huplqdo

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  • Page 106: 2Shudwru 7Huplqdo

    3-42 Wire the ULTRA Plus PDM Components Figure 3.25 Operator Terminal RS-232 connections ULTRA Plus PDM Operator Terminal Connector COM1 Connector RXD- P7-2 2 TXD TXD- P7-3 3 RXD COM P7-5 7 GND Shield P7-6 Figure 3.26 Operator Terminal RS-422 connections ULTRA Plus PDM Operator Terminal...

  • Page 107: 2Shudwru 7Huplqdo

    Wire the ULTRA Plus PDM Components 3-43 Operator Terminal (screw terminal on back) Pin and Signal names RS-232 RS-422 Common Common Figure 3.27 ULTRA Plus PDM connects to the Operator Terminal ULTRA Plus Positioning Drive Module (1398-PDM) 9101-2205-XXX ULTRA Plus to 1398-HMI-003 ULTRA Plus Operator Terminal cable 3 TxD 5 COMMON...
  • Page 108 3-44 Wire the ULTRA Plus PDM Components Networking ULTRA Plus PDM Controls 2QH RU PRUH 3'0V PD\ EH LQVWDOOHG RQ DQ 56 PXOWLGURS 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 3.28 Dip Switch SW1...
  • Page 109 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 3.30 Dip Switch SW1-7 set ON for daisy-chain mode example 6ZLWFK  RQ WKH ',3 VZLWFK LV QRW XVHG 7KH 3'0 LV VKLSSHG ZLWK DOO VZLWFKHV...
  • Page 110 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 PXOWLGURS 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 3.31...

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    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 3.33...
  • Page 112 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 3.34...
  • Page 113 Wire the ULTRA Plus PDM Components 3-49 5HIHU WR 0RWRU &RQQHFWRUV RQ SDJH % IRU RUGHULQJ LQIRUPDWLRQ DERXW WKHVH Cables DQG RWKHU FDEOHV Figure 3.35 ULTRA Plus PDM P7 to Operator Terminal (P/N 9101-2205) OPERATOR TERMINAL POSITIONING SERIAL PORT MODULE CONNECTOR CONNECTOR 25 PIN FEMALE...
  • Page 114 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 INDEXER/ CONNECTOR ENCODER CONNECTIONS 15 PIN MALE HIGH-DENSITY POSITIONING INDEXER MODULE ENCODER CONNECTOR CONNECTIONS BLACK STEP+ P4-11 STEP+ ORANGE STEP-...
  • Page 115 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 SLAVE AXIS CONNECTOR CONNECTOR 15 PIN MALE 15 PIN MALE HIGH-DENSITY HIGH-DENSITY MASTER AXIS SLAVE AXIS CONNECTOR CONNECTOR SHIELD Figure 3.39 ULTRA Plus PDM P5 to H, or F-Series Motor Encoder (P/N 9101-2027) 15 PIN MALE...
  • Page 116 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=feet) 3.31 12.0±0.5 2.50 START OF BEND RADIUS 45˚ 0.65 0.12 THREAD PROTRUSION MOLDING ADAPTER, ALUMINUM, MARKED WITH ELECTRO-CRAFT 1.34 BLACK COBALT PLATED P/N &...
  • Page 117 Chapter Apply Power for the First Time 2XWOLQHG EHORZ DUH WKH VWHSV WKDW VKRXOG EH IROORZHG ZKHQ DSSO\LQJ SRZHU WR WKH HTXLSPHQW IRU WKH ILUVW WLPH 7KLV SURFHGXUH FRYHUV WKH 8/75$ 3OXV 3'0 0RWRU DQG 2SHUDWRU 7HUPLQDO 5HIHU WR DQG EHFRPH IDPLOLDU ZLWK WKH IROORZLQJ SXEOLFDWLRQV EHIRUH LQVWDOOLQJ DQG XVLQJ *0/ 8OWUD 6RIWZDUH •...
  • Page 118 Apply Power for the First Time 3ULRU WR DSSO\LQJ SRZHU WR WKH 8/75$ 3OXV 3'0 HQVXUH WKDW WKH VXSSO\ YROWDJH LV LQ WKH SURSHU UDQJH ² 9$&   :LWK SRZHU RII HQVXUH WKDW SURSHU FRQQHFWLRQV DUH PDGH DV OLVWHG EHORZ ULTRA Plus PDM Phasing of Phasing Connections...
  • Page 119 Apply Power for the First Time DQG PRWRU FRPELQDWLRQ DV IROORZV D 6HOHFW (QWHU 6HWXSV IURP WKH 2QOLQH 0DQDJHU ZLQGRZ WR GLVSOD\ WKH $[LV 6HWXSV GLDORJ E 6HOHFW ,QLWLDOL]H 30 DQG ([HFXWH WR GLVSOD\ WKH ,QLWLDOL]H 30 GLDORJ F 6HOHFW WKH DSSURSULDWH 8/75$ 3OXV 3'0 W\SH IURP WKH 'ULYH OLVW G 6HOHFW WKH DSSURSULDWH PRWRU W\SH IURP WKH 0RWRU OLVW H 9HULI\ WKH (QFRGHU OLVW GLVSOD\V WKH FRUUHFW OLQH FRXQW IRU WKH PRWRU ,I QHFHVVDU\ VHOHFW WKH SURSHU HQFRGHU UHVROXWLRQ YDOXH...
  • Page 120 Apply Power for the First Time H 6HOHFW &DQFHO WR H[LW WKH (QFRGHU GLDORJ  6HOHFW &ORVH WR H[LW WKH $[LV 6HWXSV ZLQGRZ  (QDEOH WKH 8/75$ 3OXV 3'0 E\ SHUIRUPLQJ RQH RI WKH IROORZLQJ • 7XUQ WKH (QDEOH LQSXW 21 RU •...
  • Page 121 Apply Power for the First Time Power Supply Module  3ULRU WR DSSO\LQJ SRZHU WR WKH 360 HQVXUH WKDW WKH VXSSO\ YROWDJH LV LQ WKH SURSHU UDQJH  9$&  SKDVH   :LWK SRZHU RII UHPRYH WKH 360 FRYHU DQG HQVXUH SURSHU FRQQHFWLRQV KDYH EHHQ PDGH WR WHUPLQDOV / / DQG / DQG WKDW D SURSHU JURXQG LV FRQQHFWHG 3KDVLQJ RI WKH LQSXW SRZHU FRQQHFWLRQV LV DUELWUDU\  'LVFRQQHFW DOO ZLUHV IURP WKH 360 '&...
  • Page 122 Apply Power for the First Time Start-up Procedure for PDM  (QVXUH LQSXW SRZHU WR WKH 360 LV RII  'LVFRQQHFW DOO LQWHUIDFH FDEOHV 33 IURP HDFK 8/75$ 3OXV 3'0  :LWK LQSXW SRZHU VWLOO RII GLVFRQQHFW PRWRU OHDGV IURP 8/75$ 3OXV 3'0 WHUPLQDOV 5 6 DQG 7 9HULI\ ZLWK DQ RKPPHWHU WKDW WKH UHVLVWDQFH EHWZHHQ 8/75$ 3OXV 3'0 WHUPLQDOV 5 WR *1' 6 WR *1' DQG 7 WR *1' LV DERYH N RKPV ,I WKH UHVLVWDQFH LV DFFHSWDEOH UHFRQQHFW WKH...
  • Page 123 Apply Power for the First Time ,I QHFHVVDU\ VHOHFW WKH SURSHU HQFRGHU UHVROXWLRQ YDOXH 6HOHFW 8SGDWH 30 WR LQLWLDOL]H WKH 3HUVRQDOLW\ 0RGXOH ZLWK WKH VSHFLILHG GULYH DQG PRWRU SDUDPHWHUV J $IWHU WKH 3HUVRQDOLW\ 0RGXOH LV SURSHUO\ LQLWLDOL]HG VHOHFW <HV WR UHVHW WKH 8/75$ 3OXV 3'0 DQG H[LW WKH 8SGDWH 30 GLDORJ K 6HOHFW &DQFHO WR H[LW WKH $[LV 6HWXSV GLDORJ  ,I WKH 67$786 /(' LV UHG SHUIRUP WKH IROORZLQJ VWHSV...
  • Page 124 Apply Power for the First Time 6HOHFW &DQFHO WR H[LW WKH GLDORJ  9HULI\ WKH PRWRU LV VWDWLRQDU\ DQG KDV KROGLQJ WRUTXH  &RPPDQG PRWLRQ DQG YHULI\ WKH PRWRU URWDWHV LQ WKH SURSHU GLUHFWLRQ E\ SHUIRUPLQJ RQH RI WKH IROORZLQJ VWHSV •...
  • Page 125 Apply Power for the First Time  'LVFRQQHFW PRWRUV IURP WKH ORDG EHIRUH DSSO\LQJ SRZHU 7KLV SUHYHQWV PHFKDQLFDO GDPDJH VKRXOG D IDXOW RFFXU ,I WKLV LV QRW SRVVLEOH WDNH DGHTXDWH SUHFDXWLRQV LQ FDVH RI D IDXOW  'LVFRQQHFW DOO LQWHUIDFH FDEOHV IURP WKH 8/75$ 3OXV 3'0 DQG UHPRYH WKH LWV FRYHU 3'0   RU  RQO\  &RQQHFW WKH  PRWRU ZLUHV 5 6 7 DQG JURXQG WR WKH SURSHU 8/75$ 3OXV 3'0 ,QVWDOO DOO 8/75$ 3OXV 3'0 FRYHUV DQG FRQQHFW DOO LQWHUIDFH FDEOHV WR WKH 8/75$...
  • Page 126 4-10 Apply Power for the First Time  1RZ WKDW WKH V\VWHP LQVWDOODWLRQ LV YHULILHG UHWXUQ WKH , OLPLW SDUDPHWHU WR D YDOXH DSSURSULDWH IRU WKH DSSOLFDWLRQ Publication 1398-5.1 — January 2000...
  • Page 127 Apply Power for the First Time 4-11 7KH 2SHUDWRU 7HUPLQDO UHTXLUHV QR VSHFLDO VWDUWXS SURFHGXUH 5HIHU Operator Terminal WR 2SHUDWRU 7HUPLQDOV RQ SDJH  IRU ZLULQJ LQVWUXFWLRQV 7KH RSHUDWRU WHUPLQDO GLVSOD\ /(' VKRXOG EH OLW 1R PHVVDJH ZLOO DSSHDU RQ WKH VFUHHQ XQOHVV WKH RSHUDWRU WHUPLQDO LV FRQQHFWHG WR WKH 8/75$ 3OXV 3'0 VHULDO SRUW DQG WKH 8/75$ 3OXV 3'0 VHQGV D PHVVDJH WR WKH RSHUDWRU WHUPLQDO :KHQ WKH 2SHUDWRU 7HUPLQDO LV FRQQHFWHG WR D 8/75$ 3OXV 3'0 SUHVV WKH 6WDWXV...
  • Page 128 4-12 Apply Power for the First Time Publication 1398-5.1 — January 2000...
  • Page 129 Chapter Check for Problems in the System 7KH 8/75$ 3OXV 3'0 V\VWHP LV GHVLJQHG WR SURYLGH GLDJQRVWLF DLGV WKDW KHOS LVRODWH DQ\ SUREOHPV WR D ´PRGXOHµ LQ WKH V\VWHP $ PRGXOH PD\ EH D 8/75$ 3OXV 3'0 3RZHU 6XSSO\ 3'0   DQG   3HUVRQDOLW\ 0RGXOH PRWRU DQG HQFRGHU FDEOHV RU WKH PHFKDQLFDO V\VWHP 7KH 8/75$ 3OXV 3'0 FLUFXLWU\ LV GHVLJQHG WR SUHYHQW SUREOHPV LQ DQ\ RQH PRGXOH IURP GDPDJLQJ DQ\ RWKHU PRGXOH 7KH PRGXODU SDFNDJH DOORZV YHU\ VLPSOH ILHOG...
  • Page 130 Check for Problems in the System GLVSOD\HG RQ WKH RSHUDWRU WHUPLQDO VFUHHQ LI WKH RSHUDWRU WHUPLQDO LV SUHVHQW 7KH /(' ODEHOHG 6<6 )$8/7 RQ WKH RSHUDWRU WHUPLQDO DOVR ZLOO WXUQ RQ UHG WR LQGLFDWH WKDW D IDXOW KDV RFFXUUHG Not lit (OFF) :KHQ SRZHU WR WKH *0/ LV RII WKH 67$786 /(' LV QRW OLW ,I WKH *0/ '&...
  • Page 131 Check for Problems in the System 7KH 8/75$ 3OXV 3'0 KDV  VWDWXV VFUHHQV WKDW PD\ EH DFFHVVHG E\ SUHVVLQJ Operator Terminal Status WKH 67$786 NH\ (DFK WLPH WKH 67$786 NH\ LV SUHVVHG WKH QH[W VWDWXV VFUHHQ Screens LV GLVSOD\HG 7KH %$&.63$&( NH\ FDQ EH XVHG WR VFUROO EDFNZDUGV WKURXJK WKH VWDWXV VFUHHQV 7KH &/($5 .H\ ZLOO UHPRYH WKH VWDWXV GLVSOD\ RU FOHDU WKH SHDN YDOXHV Variable Name...
  • Page 132 Check for Problems in the System 7R UHLQLWLDOL]H D 3HUVRQDOLW\ 0RGXOH WR WKH IDFWRU\ GHIDXOW VHWWLQJV SHUIRUP WKH IROORZLQJ  6HOHFW ,QLWLDOL]H 8/75$ 3OXV 3'0 IURP WKH )LOH PHQX 7KH ,QLWLDOL]H 3HUVRQDOLW\ 0RGXOH ZLQGRZ ZLOO DSSHDU  &OLFN WKH )DFWRU\ 'HIDXOW ,QLWLDOL]DWLRQ WDE  &OLFN WKH )DFWRU\ ,QLWLDOL]H 30 EXWWRQ WR LQLWLDOL]H WKH 30 7KH 3HUFHQW &RPSOHWH LQGLFDWRU GLVSOD\V WKH VWDWXV RI WKH LQLWLDOL]DWLRQ ,I WKHUH LV D IDXOW *0/ 8OWUD 6RIWZDUH FDQ SURYLGH VSHFLILF HUURU PHVVDJHV ,I...
  • Page 133 Check for Problems in the System 7KH IROORZLQJ WDEOH OLVWV WKH IDXOWV WKDW DFWLYDWH WKH (UURU RXWSXW 7KH QXPEHU SUHFHGLQJ WKH IDXOW LV WKH HUURU QXPEHU No. Error Messages Description 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.
  • Page 134 Check for Problems in the System (Continued) No. Error Messages Description 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.
  • Page 135 Check for Problems in the System (Continued) No. Error Messages Description Peak Overcurrent The GML current sensors detected a short circuit in the motor leads. Check motor power cables for shorts. Bus Overvoltage The DC bus voltage exceeded safe levels. This error usually indicates that the power supply shunt is not operating properly.
  • Page 136 Check for Problems in the System Publication 1398-5.1 — January 2000...
  • Page 137 Appendix Specifications 7KH WDEOHV VWDUWLQJ EHORZ SURYLGH VSHFLILFDWLRQV IRU WKH 8/75$ 3OXV 3'0V 1398-PDM-10, 20, 30, 75, and DQG WKHLU DFFHVVRULHV 150B 1398-PDM-10, 20, 30, 75, and 150B Specifications Drive 1398 1398 1398 1398 1398 Module PDM-10 PDM-20 PDM-30 PDM-75 PDM-150B (1 Φ...
  • Page 138 Specifications 1398-PDM-10, 20, 30, 75, and 150B Specifications (Continued) Drive 1398 1398 1398 1398 1398 Module PDM-10 PDM-20 PDM-30 PDM-75 PDM-150B (1 Φ ) (1 Φ ) (1 Φ ) (3 Φ ) (3 Φ ) Type Relative 5% to 95% non-condensing humidity External Shunt Resistor P/N 9101-1079 Continuous...
  • Page 139 Specifications 1398-PDM-25, 50, 100, and 150 Specifications (Continued) Positioning 1398 1398 1398 1398 Drive Module PDM-25 PDM-50 PDM-100 PDM-150 Fused Class RK5 Class RK5 Disconnect 40 amps 90 amps Output Bus 100-340 VDC 100-340 VDC Voltage Continuous 50 amps 100 amps Output Current Continuous 600 W...
  • Page 140 Specifications 0XOWLWDS LVRODWLRQ WUDQVIRUPHUV DUH DYDLODEOH IRU OLQH YROWDJH PDWFKLQJ Transformers Single Phase Transformer specifications 7KH 3'0   DQG  XVH D VLQJOH SKDVH WUDQVIRUPHU Specification Value Rating 3.0 kVA Input 220/ 230/ 240/ 440/ 460/ 480 VAC RMS 115/ 230 VAC RMS Output Ambient temperature...
  • Page 141 Appendix Options and Accessories 7KH IROORZLQJ WDEOHV FDQ EH XVHG WR RUGHU SURGXFWV 8VH WKH ´,WHP 1XPEHUµ PDMs and Optional 2UGHU QXPEHU ZKHQHYHU SRVVLEOH 7KH ´$OWHUQDWH 1XPEHUµ 0DQXIDFWXULQJ Accessories QXPEHU LV XVHG IRU RUGHULQJ ZKHQ WKH ´,WHP 1XPEHUµ LV QRW DYDLODEOH RU ZKHQ UHVHDUFKLQJ LQIRUPDWLRQ DERXW WKH FRPSRQHQW RU PRGXOH 7KLV WDEOH JLYHV WKH 8/75$ 3OXV 3'0 UHIHUHQFH QXPEHUV Item Number...
  • Page 142 Options and Accessories 7KLV WDEOH OLVWV WKH 9 6RXUFLQJ LQWHUIDFH FRQYHUVLRQ FDUG DQG LWV FRQQHFWLRQV I/F Conversion Card FDEOHV Description Alternate Number 9103-0152 I/F Conversion Card, 24V Sourcing 44-0141-003 Cable, I/F Conversion Card 3ft (1m), 44-0141-010 Cable I/F Conversion Card 10ft (3m), Required for compliance with the European Union Low Voltage Directive (LVD).
  • Page 143 Options and Accessories 7KLV WDEOH OLVWV $& /LQH )LOWHUV UHTXLUHG IRU &( (0& FRPSOLDQFH AC Line Filters Description Alternate Number 1398-PDM-10 9101-1517 (10 Amps continuous, single phase) 1398-PDM-20 9101-1518 (23 Amps continuous, single phase) 1398-PDM-30 9101-1387 (36 Amps continuous, single phase) 9101-1388 Multiple drives (50 Amps continuous, single phase)
  • Page 144 Options and Accessories 7KLV WDEOH OLVWV SRZHU FDEOHV EHWZHHQ WKH 3'0 7HUPLQDO %ORFN 7%  DQG WKH Cables 0RWRU 7KH ODVW WKUHH GLJLWV ;;; LQGLFDWH D VWDQGDUG FDEOH OHQJWK  IW P   IW P   IW P  DQG  IW P  Motor Description Alternate...
  • Page 145 Options and Accessories 7KLV WDEOH OLVWV VLQJOH DQG WKUHH SKDVH WUDQVIRUPHUV WR EH XVHG ZLWK WKH Transformers 8/75$ 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...
  • Page 146 Options and Accessories 7KLV WDEOH OLVWV PRWRU FRQQHFWRUV IRU EXLOGLQJ FDEOHV IRU WKH + ) DQG 16HULHV Motor Connectors PRWRUV Connector Motor Series Straight Right Angle Type Power H-Series (2000 9101-0325 9101-0398 connectors and 3000) (MS3106F18-4S) (MS3108F18-4S Power H and F-Series 9101-0326 9101-0399 connectors...
  • Page 147 Options and Accessories 7KLV WDEOH OLVWV PRWRU VKDIW VHDO NLWV DYDLODEOH IRU WKH + ) DQG 16HULHV Motor Shaft Seal Kits PRWRUV Description (Outside Dia x Inside Dia x Width) Alternative Number Shaft seal kit, H-2000 motor 0041-5056 22 mm x 12 mm x 7 mm Shaft seal kit, H-3000 motor 0041-5057 28 mm x 15 mm x 7 mm...
  • Page 148 Options and Accessories Publication 1398-5.1 — January 2000...
  • Page 149 Index  Operator Terminal power supply ,  PDM terminal block ,  Absolute positioning Contents of manual Conventions 3-phase power Conventions used in this manual  Coils suppressed with RC filters  Conversion Card 24V Sourcing Line filter ,  Installation Order ...
  • Page 150 Index  Jumpers Encoder  RS-232 operation Encoder Fault error  , ,  SW-1 in network Feedback   SW1-1 Shield  SW1-6 EPROM Checksum error  SW1-7 EPROMs  Divide by Zero error Installation Documentation Error Related documentation BCD Input Range Drive Not Ready error Bus Overvoltage...
  • Page 151 Index European Directive Compliance  Directive Heat  Emergency Stop Contactor Heat Losses for sizing enclosures  I/O Conversion Card Heat Sink Overtemperature error  Low Voltage Directive  High frequency energy  Motors and Cables Home Excessive  Home Command Excessive FE error Home Not Defined error Excessive Speed error...
  • Page 152 Index Ventilation Out of Range error National Electrical Code Out of Range error  Requirements NEMA enclosure Out of Range error  Noise  Emission supression diagrams Out of Range error  Operator terminal suppression  Problems  See Bonding Lead length  EMC requirements...
  • Page 153 Index , ,  PDM-25, 50, 100 or 150 Multi-drop network  , Installation Operator Terminal connections   Location Personality Module Fault POS Track Overflow error Positioning Drive Module ,  Safety ground LEDs  Schaffner AC Line filter  Mounting S-Curve calculation error...
  • Page 154 Index Terminal block Underwriter Laboratories ,   Connections Listing TEXT Checksum error Transformer Description Velocity calculation error Isolation Ventilation Load Regulation (1398 PDM-10, 20, 30, 75, and 150B) Curve Ordering Outline Diagram (1398-PDM-25, 50, 100, Watchdog 150) Watchdog Reset error Sizing Watchdog Test Fault error Troubleshooting, see “Check for Problems in...
  • Page 156 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 PN 0013-1048-002 Rev A Supersedes Publication 1398-5.1 — August 1997 © 2000 Rockwell International Corporation. Printed in the U.S.A..

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