20P-IN071 - Rockwell Automation
Contents
1. eee pe xa H O XP3 AEF 15 baoocoooo0 S1 B B Co E O O P1 22 23 24 25 26 27 28 29 30 31 32 33 3 35 36 37 38 39 40 OOOOCOOCOCOCOJOOOOOCOCOO _ A B Ciee ZEEE 1234656789012114 6 6 17 B 1 20 OOOO0O 12345678 a SS O00000 O00000 0000 0000000000 z Genereren Wiring the Resolver Interface Board Table 1 Resolver Interface Board TB1 Wire Size and Tightening Torque Wire Size and Type Flexible mm Multi core mm2 Tightening Torque Nem Ibein 0 140 1 500 0 140 1 500 26 16 0 4 3 5 Terminal block TB1 on the resolver interface bottom board provides connection points for an external 24V DC power supply input resolver feedback board voltage status output and resolver feedback board reset input Table 2 on page 12 details the connections The resolver feedback module can be powered via an internal or external customer supplied 24V supply The voltage source is selected by switch S2 on the resolver interface board See Figure 3 on page 13 for the location of switch S2 The customer supplied external 24V power supply2. Rockwell Automation Publication 20P INO71B EN P June 2011 ae I r XA L fo XP3 15 g E XRE Doooo00000 am Et O O O TB1 TB2 O 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 lbecesel CCCCCE O00000 0000 000000000 Tr TEKE COM 123456789012 GME CT 181 20 _ Q0000 OO909000 OOOO0000000 lo000000000 PowerFlex DC Drive Resolver Feedback Option Module Step 4 Install the 1 Secure the three 14 mm 0 6 in shorter stand offs and washers to the Resolver Feedback resolver interface board Tightening torque is 0 7 Nem 6 2 Ibein Board J le Sa ee XR Connectors P2 and P3 pas TmT Install stand offs and washer S1 B B Es cae O O O TB1 TB2 D 22 23 24 25 26 27 28 29 30 3l 32 33 4 3 36 37 38 39 40 iseeeas eeccseg COOCDDOOODOJOCOCOOCOCO abel com ee Se DEBUG 123456789 it 12 1314 5 6 7 8 19 20 O00000 O0000000 eee 2999999999 Be O00 O88 Rockwell Automation Publication 20P INO71B EN P J
3. Loosen but do not remove the screws that secure the top and bottom front cover to the drive then slide the covers off the drive chassis IMPORTANT The HIM assembly is connected via a cable to the control board and therefore will not pull free from the drive until disconnected Continue with Disconnect the HIM Communication Cable on page 5 Tightening torque 1 5 Nem 13 3 Ibein own Loosen screws Disconnect DPI cable O Alen radey PowerFlex CQ Frame D Drives 1 Disconnect the DPI cable from the HIM assembly if installed see Figure 1 on page 5 Loosen but do not remove the four hexalobular screws that secure each of the three covers to the control pan on the drive then slide the covers up and off the drive chassis see Figure 1 on page 5 Tightening torque is noted in the illustration for reassembly IMPORTANT A communication cable connects the HIM assembly to the control board mounted on the control pan Therefore the middle control pan cover and HIM assembly cannot be fully removed from the drive until the cable is disconnected Continue with Disconnect the HIM Communication Cable on page 5 Rockwell Automation Publication 20P INO71B EN P June 2011 Figure 1 Frame D Cover Removal PowerFlex DC Drive Resolver Feedback Option Module l T15 8 UU UUI JU UU OD Tightening torque 1 5
4. Nem 13 Ibein 95554 5 T Ta 3 Loosen SCreWws om fy Disconnect the HIM Communication Cable 9 00000000000000000000000000000000 EA OCC OO a 00000000000000000000000000000000 mar 000000000000000000000000000000000 MTA QOVOOUO OOOO z 000000000000000000000000 00000000 NNO 00000000000000 rreran anh 00000000 c Disconnect DPI cable Rockwell Automation Publi
5. P June 2011 PowerFlex DC Drive Resolver Feedback Option Module Frame A Drives 1 Disconnect the DPI cable from the HIM if installed 2 Loosen the captive screws that secure the bottom front cover to the drive then slide the cover down and off the drive chassis TouvuuuuuUUUUUUOUUD b Disconnect DPI cable enn screws Tightening torque 1 5 Nem 13 3 lbein 3 Press in on the sides at the bottom edge of the cover and at the same time pull the cover toward you to pull it partially off the drive chassis Next at the top of the drive pull the cover forward away from the drive until the pins fit in the keyhole in the top of the cover then carefully lift the cover off of the drive chassis IMPORTANT The HIM assembly is connected via a cable to the control board and therefore will not pull free from the drive until disconnected Continue with Disconnect the HIM Communication Cable on page 5 When metal pin fits in keyhole lift cover off drive chassis Rockwell Automation Publication 20P INO71B EN P June 2011 3 PowerFlex DC Drive Resolver Feedback Option Module Fram 1 2 Frame B sh e B and C Drives Disconnect the DPI cable from the HIM if installed
6. is only needed when using the resolver interface board with a PowerFlex DC frame A drive or Stand Alone Regulator under the following conditions e A resolver is wired to the resolver feedback board terminal block P1 e A digital encoder is wired to the control board e The frame A drive has a fan s Rockwell Automation Publication 20P INO71B EN P June 2011 11 PowerFlex DC Drive Resolver Feedback Option Module Switch S2 on the resolver interface board must be set to the Ext position when using an external 24V DC power supply for the resolver feedback option module Table 2 Resolver Interface Board TB1 Terminal Descriptions Terminal Signal Description 1 oV External power supply input common 2 24V External 24V DC power supply input 3 OK Resolver feedback board voltage status output common 4 OK 5 24V Resolver feedback board voltage status output Vcc OK voltage present and within 5 24V range when connected to a digital input Vcc not OK voltage not present or below 5V when connected to a digital input See Figure 2 below for wiring example 5 R Resolver feedback board reset input common 6 R 24V Resolver feedback board reset input Figure 2 Resolver Feedback Board Voltage Status Wiring Example In this example digital input 2 on drive 1 0 TB2 is configured as an Enable input When the signal from terminals 3 and 4 on TB1 of the Resolver Interface board VCC no
7. Figure 5 Resolver Interface Connection Examples for Clockwise Rotation Count Down Terminal Block P1 Resolver Reverse Polarity of Sine or Cosine Signals i REF HIGH8 A xx i SHIELD7 a REFLOW6 U SINHIGHS D a Sx N iea SHIELD4 J SINLOW3 m HE r COSHIGH2 U xx i cOsLOW1 Ly P REFHIGH8 LA xx f SHIELD F U nS REFLOW6 LIL __ SINHIGHS LA S I SHIELD4 lt y SINLOW3 m U cosHicH2 E A F E St x i cosLowi F 4 J 16 Rockwell Automation Publication 20P IN071B EN P June 2011 PowerFlex DC Drive Resolver Feedback Option Module Step 6 Re place the 1 Close the drive covers in the reverse order as described in Step 2 Open the Protective Covers and Drive on page 2 Co nfi gure the Resolver 2 Configure the resolver feedback option module See the PowerFlex Digital Feedback 0 pti on Module DC Drive User Manual publication 20P UMO001 Rockwell Automation Publication 20P INO71B EN P June 2011 17 1S7A72 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 E mail support drives ra rockwell com Online www ab com support abdrives www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automatio
8. Installation Instructions Allen Bradley PowerFlex DC Drive Resolver Feedback Option Module ATTENTION Only qualified personnel familiar with DC drives and A associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION To avoid an electric shock hazard ensure that all power to the drive has been removed before performing the following i ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook IMPORTANT The Resolver Feedback option module can only be used with PowerFlex DC drives with firmware version 5 002 or higher What This Kit Includes Resolver Feedback circuit board e Resolver Interface circuit board e Two stacker connectors e Four 28 mm stand offs and washers e Three 14 mm stand offs and washers e Seven screws with captive lock washers e Static strap Tools That You Need e Phillips screwdriver PH2 e Hexalobular screwdriver e Nut driver or wrench Flathead screwdrive
9. Per Inch 2 3 twists per inch of wire lay per pair e Inductance per 1000 Feet 0 13 UH 10 as read on a GEN_RAD Model 1658 RLC Digibridge or equivalent e Capacitance Per Pair not to exceed 30 pF ft 0 3 pF as read on a GEN_RAD Model 1658 RLC Digibridge or equivalent e Capacitance Difference Pair to Pair not to exceed 0 6 pF foot as read ona GEN_RAD Model 1658 RLC Digibridge or equivalent e Resistance per 1000 Feet 17 15Q 10 e Insulation Thickness 0 008 in e Conductor Stranding 16 30 e Jacket Thickness 0 018 in e See Table 6 for maximum cable lengths 14 Rockwell Automation Publication 20P INO71B EN P June 2011 PowerFlex DC Drive Resolver Feedback Option Module Table 6 Maximum Resolver Cable Length Maximum Cable Length x1 and x2 Resolver Speed Ratio x5 Resolver Speed Ratio Belden 9730 305 m 1000 ft 183 m 600 ft 417900 207CG 240 m 800 ft 150 m 500 ft Resolver Feedback Option Board Specifications Consideration Description Excitation Frequency 2381 9300 Hz Excitation Voltage 8 26 Vrms Resolver Feedback Voltage 2 Vrms 300 mV Compatible Resolvers The table below specifies which resolvers are compatible with the PowerFlex DC resolver feedback option module Manufacturer Manufacturer Model Catalog Number Advanced Micro Controls Inc R11X C10 7 Reliance Electric 800123 R 800123 1R 800123 2R 800123 S 800123 1S 800123 2S 800123 T 800123 1T 800123 2T flange m
10. cation 20P IN071B EN P June 2011 e Disconnect the HIM communication cable from the connector on the upper right corner of the Control board and remove the bottom cover y All Frames Frame A shown Pull tabs out to isconnect cable PowerFlex DC Drive Resolver Feedback Option Module Step 3 Install the Resolver Interface Board Control board Install stand offs and washers Connector XRE Install stand offs and washers 1 Secure the four 28 mm 1 1 in longer stand offs and washers to the control board Tightening torque is 0 7 Nem 6 2 lbein aar ese WM ll Wlesaeslasnaa saeco XR XA ia oe 0 O O 15 oS E O E O XRE fee XFCD foooooooKK Boooooocoo Se A B O O O 21 Lod O 2i 22 23 24 25 26 27 28 29 30 3 32 33 34 35 36 37 38 39 40 amp QOCDOCOOODOJOOOCOOGOCO A BC A A He 2s ZOOM iP SSC TOS OTE ME eT ee 20 QO000 OOO09000 OOOO0000000 0000000000 Rockwell Automation Publication 20P IN071B EN P June 2011 PowerFlex DC Dr
11. e board See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for encoder wiring recommendations 12 Rockwell Automation Publication 20P INO71B EN P June 2011 PowerFlex DC Drive Resolver Feedback Option Module Table 3 Resolver Interface Board TB2 Terminal Descriptions Terminal Signal Description 1 A Encoder A 2 A Encoder A NOT 3 B Encoder B 4 B Encoder B NOT 5 Z Encoder Z 6 Z Encoder Z NOT 7 Shield Connection point for encoder cable shield Table 4 TB2 Encoder Output Specifications Max Output Current 20 mA Max Output Low Voltage 0 5V 20 mA Min Output High Voltage Vcc 2 6V 20 mA where Vcc 5V or 30V Figure 3 Resolver Interface Board Switch and LED Locations Switch S1 shown in the 24V selection osition XRE i Hoonononn Encoder output voltage LEDs set with S1 ME 3 5V position Green LED 5V ea 12V position bm 24V position Yellow LED 12V y Blue LED 24V y S1 Internal Int supply position ri External Ext supply position a O 2 O Switch S2 shown in the Ext position O TB1 TB2 O Rockwell Automation Publication 20P IN071B EN P June 2011 13 PowerFlex DC Drive Resolver Feedback Option Module Wiring the Resolv
12. er Feedback Board Terminal block P1 on the resolver feedback option top board provides the connection points for a single resolver Table 5 details the connections Table 5 Resolver Feedback Board P1 Terminal Descriptions Terminal Signal Description 8 REF HIGH Positive Reference signal KJ o Q 7 SHIELD Connection point for resolver cable shield ae o Q 6 REF LOW Negative Reference signal Zig o O 5 SIN HIGH Positive Sine signal gid y Q 4 SHIELD Connection point for resolver cable shield Zig a D 3 SIN LOW Negative Sine signal ors P COS HIGH Positive Cosine signal I 1 COS LOW Negative Cosine signal e P1 terminal block part number 1639300000 e P1 terminal block material number BL 3 50 08 90F SN BK BX Recommended Resolver Cable For the best results Belden 9730 or equivalent cable is recommended For retro fit applications where Reliance Electric resolvers 800123 xxx wiring 417900 207CG or Automax systems were used existing wiring may be used assuming it is in good working condition Belden 9730 or Equivalent Cable Attributes e 3 twisted pairs 24 AWG shielded 20 to 80 C 300V e Inductance 0 23 WH ft e Capacitance 12 5 pF ft e Resistance 24 Q 1000 ft e See Table 6 for maximum cable lengths Reliance Electric 417900 207CG Cable Attributes e 3 Twisted Pairs 18 AWG unshielded 80 C 300V e Chrome FPR Jacket Plenum Rated e Twists
13. ive Resolver Feedback Option Module 2 Carefully insert the stacker connector on the back of the resolver interface board into connector XRE on the control board identified in the previous illustration IMPORTANT _ The two pins of the stacker connector that are capped should be to the right of connector XRE when installed on the control board Resolver Control board interface board Resolver interface board XRE connector N Stacker connector Capped pins to ight XRE connector i e ene Control board Bottom view Side view Rockwell Automation Publication 20P INO71B EN P June 2011 PowerFlex DC Drive Resolver Feedback Option Module 3 Secure the resolver interface board to the stand offs using four screws with captive washers Tightening torque is 0 7 Nem 6 2 lbein Resolver interface boar Install screws Pal Install screws
14. n Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20P INO71B EN P June 2011 Copyright 2011 Rockwell Automation Inc All rights reserved Printed in USA
15. ounted Tamagawa TS 2014N181E32 TS 2014N182E32 TS 2014N185E32 TS 2087N1E9 TS 2087N2E9 TS 2087N5E9 TS 2087N11E9 TS 2087N12E9 A A A A A A A A Rockwell Automation Publication 20P INO71B EN P June 2011 15 PowerFlex DC Drive Resolver Feedback Option Module Resolver Wiring Diagrams IMPORTANT The shield connections must only be made at the drive end of the cable resolver end of cable shield is unattached as shown in the diagrams below Grounding both ends of the shielded cable can result in ground loops that could damage the resolver and or drive Also the resolver connections are considered signal level wiring and MUST be run separate from control and power wiring and at least 12 inches apart Figure 4 Resolver Interface Connection Example for Clockwise Rotation Count Up Terminal Block P1 Resolver REF HIGH8 gt SHIELD7 gt REFLOW6 L SINHIGH5S UU J SHIELD4 gt hig sINLOW3 LJ COSHIGH2 U cOsLOWw1
16. r Phillips is a registered trademark of Phillips Screw Company Rockwell 20P INO71B EN P Allen Bradley Rockwell Software Automation PowerFlex DC Drive Resolver Feedback Option Module What You Need to Do To install the resolver feedback option module O Step 1 Remove power from the drive O Step 2 Open the drive O Step 3 Install the resolver interface board O Step 4 Install the resolver feedback board O Step 5 Wire the resolver interface and feedback boards C Step 6 Replace the protective covers and configure the resolver feedback Step 1 Remove Power from the Drive A option module ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e sending an erroneous signal to your system s field devices causing unintended machine motion e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance e Remove and lock out all incoming power to the drive Step 2 Open the Drive e To open frame A drives see Frame A Drives on page 3 e To open frame B and C drives see Frame B and C Drives on page 4 e To open frame D drives see Frame D Drives on page 4 Rockwell Automation Publication 20P INO71B EN
17. t OK the drive is disabled Resolver Interface Drive Control Board Board TB 1 0 TB2 1 E Egi 2 12 3 a 13 Digital Input 2 4 14 5 to TT 15 6 L y 16 Digital Input Common ec 48 24V Supply Common z 19 24V DC Supply 20 Terminal block TB2 on the resolver interface board is used to send the signals from the primary digital encoder installed and wired to the encoder terminal block on the control board to a second follower drive regulator When the outputs on TB2 are used switch S1 on the resolver interface board must be set to match the encoder power supply voltage set for the primary encoder on the follower drive s control board set via switch 21 See the PowerFlex Digital DC Drive User Manual publication 20P UM001 for details on installing a primary digital encoder and using switch S21 on the control board The S1 switch settings correspond to each of the three LEDs on the left side of the resolver interface board and indicate the selected supply voltage as follows e Green LED indicates a 5V supply when lit on e Yellow LED indicates a 12V supply when lit on Blue LED indicates a 24V supply when lit on See Figure 3 on page 13 for the location of switch 1 and corresponding LEDs on the resolver interfac
18. une 2011 9 PowerFlex DC Drive Resolver Feedback Option Module 2 Carefully insert the long pins of the stacker connectors into connectors P2 and P3 on the back of the resolver feedback option board IMPORTANT The end of the stacker connectors with the long pins must connect to the mating connectors P2 and P3 on the resolver feedback option board The end of the stacker connectors with the short pins must connect to the mating connectors P2 and P3 on the resolver interface board 3 Carefully insert the stacker connectors on the back of the resolver feedback option board into connectors P2 and P3 identified in the previous illustration on the resolver interface board Long pins of stacker connector mate Short pins of stacker connector mate with resolver feedback option board ith resolver interface board connectors P2 and eel P2 and P3 connectors connectors Resolver feedback Resolver interface board option board heer Side view 10 Rockwell Automation Publication 20P INO71B EN P June 2011 PowerFlex DC Drive Resolver Feedback Option Module Resolver feedback board Install screws Step 5 Wire the Resolver Interface and Feedback Boards 4 Secure the resolver feedback board to the stand offs using three screws with captive washers Tightening torque is 0 7 Nem 6 2 lbein
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