Distributed Power System Fiber-Optic Cabling
Contents
1. 3 5 Figure 3 3 Fiber Optic Ports and Connectors 3 6 Table of Contents Fiber Optic Cabling Table 1 1 DPS Documentation Table 1 2 Power Max Documentation Binder S 3040 Table of Contents Fiber Optic Cabling Introduction This manual provides guidelines on the fiber optic cabling used to connect AutoMax Distributed Power System Universal Drive Controllers UDC and Power Module Interfaces PMI The cable is immune to electromagnetic interference EMI and eliminates ground loops The fiber optic cable is a part of a point to point serial communication link between the UDC module and the PMI See figure 1 1 The link allows the UDC module to transfer configuration operating system and real time control information to the PMI The PMI in turn sends feedback and status information to the UDC module The UDC module is capable of supporting two links operating independently of each other Data transferred over the fiber optic link is Manchester encoded and is transmitted at a rate of 10M bits per second Fiber optic link specifications are provided in Appendix A AutoMax Processor UDC Module a Fiber Optic Cables Figure 1 1 Fiber Optic Serial Communication Link 1 1 Related Hardware and Software P N 613613 xxS Fiber Optic Cable Cable le2. 36 to 176 F Maximum Pulling Tension 68 Kg 150 16 Minimum Bend Radius 60 mm 3 Maximum Attenuation 3 5 dB per km Nominal Operating Frequency 820 nanometers 50 Micron Fiber Optic Cable Specifications C 1 2 Fiber Optic Cabling Fiber Optic Connector Specifications Recommended Fiber Optic Connector Hot Melt Connector ST compatible Manufacturer e 3M 3M Part Number 6100 Ferrule Ceramic Maximum Attentuation 0 6dB per mated pair Recommended Connector Termination Kit Hot Melt Termination Kit ST compatible Manufacturer 3M Part Number 6150A Recommended Fiber Optic Coupler Rockwell Reliance P N 417135 2A Fiber Optic Connector Specifications D 1 0 2 Fiber Optic Cabling Fiber Optic Cable Assembly Test Set Specifications Recommended Cable Assembly Test Set Fiber Optic Test Set ST Compatible Manufacturer 3M Photodyne 3M Photodyne Part Number 118 Recommended Test Cable Reliance P N 613613 1S Fiber Optic Cable Assembly Test Set Specifications E 1 2 Fiber Optic Cabling Documentation Improvement Form Use this form to give us your comments concerning this publication or to report an error that you have found For convenience you may attach copies of the pages with your comments After you have completed this form please return it to Rockwell Automation RGA Technical Publications 25001 Tungsten R
3. Remove the dust cover caps from the fiber optic cable s connectors Use a lint free cloth moistened with isopropyl alcohol or a can of compressed air to clean the cable s connectors ATTENTION Do not damage the ends of the fiber optic cable connectors by touching or dropping them Do not use factory compressed air to clean the fiber optic ports or connectors because the air may contain impurities that could scratch them Failure to observe this precaution could result in damage to or destruction of the equipment Step 3 Attach the cable s connectors to the ports as shown in figure 3 2 UDC module XMT port blue fiber optic wire UDC module RCV port orange fiber optic wire PMI XMT port orange fiber optic wire PMI RCV port blue fiber optic wire Note that the fiber optic wires are color coded Typically the wires are orange and blue The wires used in your installation may be of a different color but they should be installed in the same manner as described here Note that both of the fiber optic wires are the same Align the connector s pin with the slot in the module s port See figure 3 3 Push the connector onto the port Turn the connector clockwise until it locks onto the port s two pins Do not bend or kink the wire when you attach it to the port Bending the wire sharply could break the fiber inside ATTENTION Turn off lock out and tag the power to both the rack containing the UDC module and to its corresponding P
4. bit 15 of register 101 drive A or register 1101 drive B If the UDC module s COMM OK LED remains off try replacing the fiber optic connectors Re initiate the loop back test again If the COMM OK LED remains off replace the fiber optic cable Re initiate the loop back test If the UDC module s COMM OK LED does light turn the loop back test off by setting bit 15 of registers 101 or 1101 to zero and go to step 4 Step 4 To test the cable using the fiber optic transmitter re connect the fiber optic cable to the ports Instead of connecting the other end of the fiber optic cable to the UDC module s XMT and RCV ports connect the cables together using a fiber optic coupler P N 417135 2A Cycle power to the PMI If the PMI s COMM OK LED remains off reconnect the original fiber optic cable to the UDC module s ports and re initialize the AutoMax rack s Cycle power to the PMI If the COMM OK LEDs still do not light systematically replace the PMI the UDC module and the fiber optic cable 4 2 DRV FLT LEDs The red DRV FLT LEDs on the UDC module are normally off If the LEDs are on check the status of bit 15 of register 202 drive A and register 1202 drive B If bit 15 is equal to one the drive fault was caused by a fiber optic communication problem Continue with the troubleshooting procedures in section 4 1 4 2 Fiber Optic Cabling Fiber Optic Link Specifications Maximum Distance 62 5 micron cable 750
5. DC module s green COMM OK LED will be on For the PMI its COMM OK LED will be turned on when it is properly connected to a powered up UDC module containing both an operating system and a valid parameter object file The LEDs will remain on as long as messages are being received correctly on the fiber optic link The COMM OK LEDs may be on even though communication errors have been detected If two or more communication errors of the same type have been received sequentially or a message has been lost the COMM OK on the receiving end will go off and will stay off for as long as the condition exists Note that in this case the DRV FLT LEDs on the UDC module will be turned on as described in section 4 2 Note that the COMM OK LEDs will remain on even though a drive fault has stopped the drive unless communication errors caused the drive fault If the COMM OK LEDs on either the UDC module or the PMI are off there is problem with the fiber optic link The loop back tests allow you to check the operation of individual parts of the fiber optic system To run the loop back tests you will need a fiber optic test cable Reliance P N 613613 15 and a fiber optic coupler Reliance P N 417135 2 You will need to use only one of the test cable s wires Note that for diagnostic purposes only there is sufficient optical power to conduct the loop back tests which effectively double the length of the fiber optic link Use the following loop back test proc
6. Distributed Power System Fiber Optic Cabling Instruction Manual S 3009 3 6 Rockwell Automation Throughout this manual the following notes are used to alert you to safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product The thick black bar shown at the margin of this paragraph will be used throughout this manual to indicate new or revised text or figures ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment The information in this user s manual is subject to change without notice Belden is a registered trademark of Belden Inc STO is a registered trademark of AT amp T AutoMax and PowerMax are trademarks of Rockwell Automation 1998 Rockwell International Corporation Introduc
7. MI hardware before viewing the fiber optic cable or transmitter under magnification Viewing a powered fiber optic transmitter or connected cable under magnification may result in damage to the eye For additional information referto ANSI Publication Z136 1 1981 Failure to observe this precaution could result in bodily injury Step 4 If the COMM OK LEDs do not light as described in section 4 1 follow the troubleshooting procedures in that section 8 4 Fiber Optic Cabling 6 UNIVERSAL DRIVE CONTROLLER EM 57652 CARD OK OS OK COMM OK DRV A FLT COMM B OK DRV B FLT TEST SWITCHES e BLUE FIBER OPTIC CABLE FIBER OPTIC BLUE WIRE Figure 3 2 Fiber Optic Cable Assembly Connections Fiber Optic Link Installation 3 5 ST Connector a Slot Pins lt Pin Figure 3 3 Fiber Optic Ports and Connectors RCV 3 6 Fiber Optic Cabling Fiber Optic Link Testing and Troubleshooting This chapter describes how to test and troubleshoot the fiber optic link 4 4 COMM OK LEDs Under normal operating conditions i e there is an operating system loaded a UDC module is properly connected to a powered up PMI the U
8. al Loss Cable Loss Connector Loss Using the example in figure 3 1 Cable Loss Total Cable Length x Cable Attenuation 1 1dB 309Km 3 5dB Km e ConnectorLoss of Connector Pairs x Connector Attenuation 1 24 2 additional pairs 0 6dB Total Loss Cable Loss 4 Connector Loss 2 3 dB 1 1dB 1 2 dB Since 2 3dB total loss is less than 2 6dB power budget the system will work as designed Installation Planning Use the following procedure to design a fiber optic link that will achieve maximum signal isolation and cable protection in a specific environment with minimal fiber optic cable usage You will need to select the tools and personnel that are required for fiber optic cable assembly and installation Unless you have in house expertise with fiber optic cable assemblies and installation we recommend that you contact an experienced contractor for making up and installing fiber optic cables Step 1 Identify the actual location of the UDC module and the PMI s using an equipment floor plan Step 2 Identify the tentative fiber optic cable route Route the cables to allow easy access in the future Step 3 Identify the environmental conditions temperature humidity hazardous chemicals along the route Step 4 Determine how to bypass physical obstructions walkways heat sources furnaces caustic chemicals along the route Step 5 Determine the best type of fiber optic cable installation conduit raceway wiring t
9. e acids caustics and other hazardous chemicals The minimum bend radius is 60mm 3 Do not exceed the cable s maximum recommended pulling tension Be sure to use a cable pulling lubricant to reduce friction when pulling the cable Attaching Fiber Optic Connectors Typically short fiber optic cables are shipped with their connectors attached You may need to attach connectors if replacement cables are needed if the fiber optic link is being altered or if the cable is very long Refer to Appendices B C and D for cable and connector specifications Appendix D also lists the name of the recommended fiber optic connector kit This kit contains detailed instructions that describe how to attach the connectors to the fiber optic cable Refer to Appendix E for the name of the recommended cable assembly test set Test the cable after installation or require certification by the contractor Certification should detail the test results including signal losses Fiber Optic Link Installation 3 3 Connecting a Fiber Optic Cable Between UDC Module and the PMI Use the following procedure to connect a fiber optic cable P N 613613 5 between the UDC module and the PMI Step 1 Remove the dust cover caps from the fiber optic ports on the UDC module and the PMI Clean the ports with a can of compressed air Save the dust caps All fiber optic connectors and ports when not in use should be covered with dust cover caps Step 2
10. edures to isolate the problem Step 1 Stop all tasks that are running on the UDC module Remove the existing fiber optic cable from the PMI s XMT and RCV ports Attach one of the wires of the test cable from the XMT port to the RCV port Cycle power to the PMI the COMM LED remains off remove the test cable and replace the PMI If the PMI s COMM OK LED lights remove the test cable and go to step 2 Step 2 Remove the existing fiber optic cable from the UDC module s XMT and RCV ports Attach one of the wires of the test cable from the XMT port to the RCV port Use the AutoMax Programming Executive s I O Monitor to initiate the loop back test by setting bit 15 of register 101 drive A or register 1101 drive B Fiber Optic Link Testing and Troubleshooting 4 1 the COMM LED remains off remove the test cable and replace the UDC module If the UDC module s COMM OK LED lights turn the loop back test off by setting bit 15 of registers 101 or 1101 to zero Then remove the test cable and go to step 3 Step 3 To test the original cable using the UDC module s fiber optic transmitter re connect the original fiber optic cable to the UDC module s ports Instead of connecting the other end of the fiber optic cable to the XMT and RCV ports connect the cables together using a fiber optic coupler P N 417135 2 Use the AutoMax Programming Executive s I O Monitor to initiate the loop back test by setting
11. ion may result in damage to the eye For additional information referto ANSI publication Z136 1 1981 Failure to observe this precaution could result in bodily injury 2 2 Connectors The fiber optic connectors must be ST Compatible Multimode Connectors with ceramic ferrules Refer to Appendix D for more information A coupler is required when connecting two fiber optic cables together An ST Compatible Multimode Coupler or equivalent is recommended Refer to Appendix D for more information Fiber Optic Cable Assembly Components 2 1 2 2 Fiber Optic Cabling Fiber Optic Link Installation 3 1 The fiber optic link installation should conform to all applicable codes ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment Optical Power Budget Fiber optic communication depends on the launched light signal reaching the receiver at a level high enough to be detected A power budget calculation determines the amount of losses present in the fiber optic link and the result is then compared to the total amount of optical power available from the fiber optic transmitter The transmitter must be capable of launching more optical power than what is lost in the system The total amount of optical power power budget provided by the fiber optic transmitters is 2 6dB which inc
12. ludes the losses of the connectors on the module faceplates The maximum cable length is 750 meters 2500 feet with 62 5 micron cable and 200 meters 660 feet with 50 micron cable The minimum cable length for both 62 5 micron cable and 50 micron cable is 1 meter 3 3 feet A sample fiber optic link for power budget calculations is shown in figure 3 1 UDC Module 4 5m Connectors Connectors 4 5m 1 Cable Cable Segment Cable Segment Segment Figure 3 1 A Sample Fiber Optic Link for Power Budget Calculations As shown in figure 3 1 the sample fiber optic link is composed of three segments the end segments are 4 5 meters long while the middle segment is 300 meters Since the power budget value 2 6dB has factored in one connector pair already only two more connector pairs have to be accounted for in the power budget calculation Fiber Optic Link Installation 3 1 3 2 main requirement for reliable fiber optic link operation is that the total system loss must be less than the power budget Use the following equations to calculate the losses present in the system Power Budget Calculation Cable Loss Total Cable Length x Cable Attenuation 3 5dB Km Connector Loss of Connector Pairs x Connector Attenuation 0 6dB Tot
13. meters 2500 feet 50 micron cable 200 meters 660 feet Minimum Distance 62 5 micron cable 1 meter 3 3 feet 50 micron cable 1 meter 3 3 feet Optical Power Budget 62 5 micron cable 2 6dB includes one pair of connectors 50 micron cable 0 7dB includes one pair of connectors no additional connectors are allowed Fiber Optic Repeaters Should not be used to increase the operational distance of the link Fiber Optic Link Specifications A 1 2 Fiber Optic Cabling 62 5 Micron Fiber Optic Cable Specifications Cable Size 62 5 micron core 125 micron cladding 900 micron buffer Recommended Manufacturer Belden Belden Part Number 225362 breakout cable Number of Fibers per Cable 42 Outside Diameter 7mm 275 Jacket Material PVC Operating Temperature 20 to 80 36 to 176 F Maximum Pulling Tension 68 Kg 150 16 Minimum Bend Radius 60 mm 3 Maximum Attenuation 3 5 dB per km Nominal Operating Frequency 820 nanometers 62 5 Micron Fiber Optic Cable Specifications B 1 2 Fiber Optic Cabling 50 Micron Fiber Optic Cable Specifications Cable Size 50 micron core 125 micron cladding 900 micron buffer Recommended Manufacturer Belden Belden Part Number 227302 breakout cable Number of Fibers per Cable 42 Outside Diameter 5mm 2 Jacket Material PVC Operating Temperature 20 to 80
14. ngth xx is specified in meters P N 613613 15 Fiber Optic Test Cable One meter test cable with connectors attached P N 417135 2A Fiber Optic Coupler Introduction 1 1 1 2 Related Publications The documentation that describes the SD3000 SF3000 SA500 SA3000 and SA3100 DPS drives is contained in separate binders Most of the manuals are tailored to describe the hardware and or software features in detail for each drive type Table shows the associated document part number for each drive type Table 1 1 DPS Documentation Document Part Number SD SF3000 SA500 SA3000 SA3100 Binder Binder Binder Binder Document S 3000 5 3002 5 3001 5 3053 DPS Overview 5 3005 5 3005 5 3005 5 3005 UDC Module 7 5 3007 5 3007 5 3007 Fiber Optic Cabling 8 3009 8 3009 5 3009 5 3009 Configuration amp Programming S 3006 5 3044 5 3042 5 3056 85 30362 Power Module Interface 5 3008 5 3018 5 3019 5 3057 Power Module 9 3037 5 3018 9 30203 5 3058 S 3029 Diagnostics Troubleshooting amp Start Up 5 3011 5 3022 5 3021 5 3059 Guidelines D C Bus Supply N A 5 3017 Information Guide 5 3012 5 3024 5 3023 5 3054 1 03000 2 SF3000 3 Medium Power 4 High Power 1 2 Fiber Optic Cabling 1 2 1 1567 Power Max Documentation 1567 Power Max medium voltage AC drives also operate under the control of the AutoMax DPS system The 1567 Power Max binder S 3040 contains the following man
15. oad Cleveland Ohio 44117 Fax 216 266 7120 Publication Name Publication Number Publication Date Comments Your Name Date Company Name Phone Address Thank you for your comments Technical Writing Internal Use Date DIF Number Follow Up Action 6 Rockwell Automation Rockwell Automation 24703 Euclid Avenue Cleveland Ohio 44117 216 266 7000 6 Rockwell Automation Printed in U S A 3009 3 March 1998
16. ray Refer to R E 704201 80 in your system documentation for the appropriate method Step 6 Calculate the total length of the fiber optic cable Step 7 Calculate the optical power budget as described in section 3 1 3 2 Fiber Optic Cabling 3 3 3 4 Step 8 Document the fiber optic cable layout This document should be maintained for the life of the installation Step 9 Determine the number of fiber optic cable components that are needed Refer to Appendices B C and D for more information on recommended components Installation Guidelines The fiber optic cable must be handled by experienced personnel prior to and during installation Improper handling may result in damage to the cable ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment Use the following guidelines to protect the cable Label the fiber optic cable with the network drop UDC module slot and channel either A or B Route the fiber optic cable to protect it from abrasion vibration moving parts and personnel traffic Be sure the cable does not touch abrasive surfaces such as concrete which could wear through and damage the cable s outer jacket Be sure to locate the fiber optic cable away from temperatures greater than 80 176 F Protect the fiber optic cable from oil greas
17. tion 1 1 Related Hardware and Software 8 1 1 1 2 Related 0 02 2210 1 2 1 2 1 1567 Power Max 1 3 Fiber Optic Cable Assembly Components 24 Gables tetti haftet m xa ek cea 2 1 222 21 Fiber Optic Link Installation 3 1 Optical Power 3 1 3 2 Installation Planning cce tene 3 2 3 3 Installation Guidelines 3 3 3 3 3 5 Connecting a Fiber Optic Cable Between a UDC Module the PMI 3 4 Fiber Optic Link Testing and Troubleshooting 44 COMM OK LEDS 5 hr nee it rap eta ter e tree dene dnt etae 4 1 4 2 DRV FET LEDS ii EO em ERREUR ed 4 2 Fiber Optic Link Specifications 4 0000000 enne A 1 62 5 Micron Fiber Optic Cable 5 B 1 50 Micron Fiber Optic Cable C 1 Fiber Optic Connector Specifications 0 1 Fiber Optic Cable Assembly Test Set Specifications E 1 Table of Contents Fiber Optic Cabling Figure 1 1 Fiber Optic Serial Communication Link 1 1 Figure 3 1 Sample Fiber Optic Link for Power Budget Calculations 3 1 Figure 3 2 Fiber Optic Cable Assembly
18. uals Table 1 2 Power Max Documentation Binder S 3040 Document Document Part Number DPS Overview UDC Module Fiber Optic Cabling Medium Voltage Inverter 12 Pulse Diode Rectifier PMI Subsystem Drive Configuration amp Programming Liquid Cooling System Installation Guidelines Drive Information Guidelines Introduction 1 4 Fiber Optic Cabling Fiber Optic Cable Assembly Components Fiber optic cable assemblies are composed of two main components the connectors and the cable itself 2 1 Cable The UDC module and the PMI require a 62 5 micron duplex fiber optic cable The recommended 62 5 micron fiber optic cable is Belden cable 225362 Mohawk cable M92021 or equivalent This cable has PVC outer jacket and an internal Kevlar strength member This cable is a breakout type of cable which contains two individually insulated fiber optic wires fibers This cable may be used in areas where the ambient temperature will not exceed 80xC 176xF Note that 50 micron fiber optic cable is an acceptable substitute for 62 5 micron cable Refer to Appendices A B and C for more information ATTENTION Turn off lock out and tag the power to both the rack containing the UDC module and to its corresponding PMI hardware before viewing the fiber optic cable or transmitter under magnification Viewing a powered fiber optic transmitter or connected cable under magnificat
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