Home

1398-5.1 JAN00 ULTRA Plus Series Positioning

1. 10 20 30 BUS CURRENT ADC N N 40 233 226 219 212 205 198 191 184 177 170 163 156 149 142 RELIANCE MOTION CONTROL 1 PHASE TRANSFORMER PART NUMBER kVA 0020 5097 3 NOTES 1 DC BUS VOLTAGE AND TRANSFORMER SECONDARY VOLTAGE VAC RMS LINE TO LINE 3 PHASE CURRENT IS MEASURED AT MOTOR POWER CIRCUITS INTERNAL TO THE DRIVE MODULE NOT ACCESSIBLE TO THE USER 2 CURVE SHOWS REDUCTION IN TRANSFORMER SECONDARY VOLTAGE AND DRIVE MODULE NTERNAL DC BUS VOLTAGE DUE TO TRANSFORMER INTERNAL LOSSES AS BUS CURRENT LOAD INCREASES 3 ALL DATA TAKEN WITH TRANSFORMER PRIMARY VOLTAGE HELD TO 230 VAC 1 PHASE LINE TO LINE 60 Hz AND WITH SECONDARY WIRED FOR 230 VAC LINE TO LINE NO LOAD 20625 JL UPDATE TITLE BLOCK 19960 BC PDM UPDATE 2 19 92 BC gt WO 19866 BC RELEASED 11 22 94 JH REV ECO BY REVISION DESCRIPTION DATE CHKR UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING DIMENSIONS ARE IN INCHES BREAK ALL EDGES 02 MAX FILLETS AND ROUNDS 02 R MAX DRAWN BY DATE DESIGN ENGR DATE BC 11 22 91 JH 11 22 91 DIAG XFMR LOAD REG TOLERANCE ON ANGLES 1ANGLES FRACTIONS 1 64 DECIMALS XX 020 XXX 010 PART NO 9101 1057 SCALE DWG SIZE SHEET 1 1 A 1 of 1 Publication 1398 5
2. Motor Connectors This table lists motor connectors for building cables for the H F and N Series motors 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 4000 MS3106F20 4S MS3108F20 4S Power H and F Series 9101 0327 9101 0400 connectors 6000 MS3106F24 22S MS3108F24 22S Power H Series 8000 9101 0328 9101 0401 connectors MS3106F32 17S MS3108F32 17S Power N Series 9101 1557 Solder connectors MS3116F14 5S Solder KPT08F14 5S Solder PTO8E14 5S Solder MS3126F14 5S Crimp KPSEO8F14 5s Crimp PTO8SE14 5S Crimp Encoder H Series and 9101 0329 9101 0402 connectors F Series MS3106F20 29S MS3108F20 29S Encoder N Series 9101 1558 Solder connectors MS3116F14 19S Solder KPTO8F14 19S Solder PTO8E14 19S Solder MS3126F14 19S Crimp KPSEO8F1 4 198 Crimp 14 195 Crimp Brake connectors H Series and 9101 0330 9101 0403 F Series MS3106F12S 3S MS3108F12S 3S Brake connectors N Series 9101 1698 Solder Publication 1398 5 1 January 2000 93116 12 35 Solder MS3126F12 3S Crimp PTO8F12 3S Solder 08 12 35 Crimp ZA PTO8E12 3S Solder PTO8SE12 3S Crimp Motor Shaft Seal Kits motors Description Outside Dia x Inside Dia x Width Options and Accessories
3. 52 5 1 4 Wire the ULTRA Plus Components 3 35 Encoder 2 See Figure 3 22 on page 3 36 showing the connections of Encoder 2 which provides an optional second encoder It can be used as position feedback directly from the load or as a master input for relative positioning master follower systems or for electronic gearing As an alternative the Encoder 2 port may also be used to output encoder 1 signals when only the motor mounted encoder is used The function of the Encoder 2 port is selected as input or output Encoder 2 and signal names The will accept differential line driver quadrature signals from a 5 volt incremental encoder The PDM accepts A B and I Index signals from the encoder with A leading B for clockwise rotation Connections are provided for A A B B I I 5 volts and common signals The I and I signals do not need to be connected if not needed The Encoder 2 signal wires to the PDM should be shielded The shield should be connected only at the encoder end However in some applications it may be necessary to connect the shield at the PDM end of the cable also Connector P4 includes a separate pin Pin 15 for this purpose Refer to ULTRA Plus PDM P4 or P5 to Auxiliary Encoder Unterminated P N 9101 2031 on page 3 50 Connector Pin Signal Name P4 Encoder input 2 1
4. 8 AWG 10 0mm 10 AWG 6 0mmE TERMINAL STRIP ACCEPTABLE WIRE RANGE DRIVE MODULE GAUGE mm 22 10 AWG 0 5 6mmE iN g g TORQUE ALL TERMINALS gt IN 9 TO 11 LB IN ul 9X ae A AX BLOCK F4 x FUSE A A BLOCK AC LINE FILTER ACLINE 9 4 FILTER 1 MOTOR POWER CONNECTOR MATING In MOTOR POWER F TE CONNECTOR H SERIES H SERIES F SERIES F SERIES N SERIES N SERIES MOTORS MOTORS _2 FUSED DISCONNECT OR CIRCUIT BREAKER ISOLATION OR AUTO TRANSFORMER f oo OPTIONAL NOT REQUIRED WHEN THREE PHASE DESIRED INPUT VOLTAGE IS AC LINE oo AVAILABLE DIRECTLY FROM THE LINE 34 COMMON GROUNDING COMMON GROUNDING Gi CORNER POINT FOR AMPLIFIER POINT FOR AMPLIFIER SYSTEM ONE PER AXIS SYSTEM ONE PER AXIS N MACHINE COMMON NOTES TO PROTECTIVE EAA TERNA GROUNDING BUS BAR L1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF L1 L2 N L3 TERMINALS EXAMPLE TO RETAIN DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1 L2 N L3 POWER DOWN L 2 A SUPPLY DISCON
5. f 5 gt Z 15 PIN MALE NP d HIGH DENSITY NOS 10 SERIES CONNECTOR PS 9101 2027 010 MOTOR CABLE ENCODER CONNECTOR T NI GREEN Oye PIN A m i BLACK i B A WIRE COLOR PAIRED B w BLUE Ww B WIRES 5 3 i i c 5 5 4 BLACK D B 1 YELLOW J 1 5 5 E 1 BLACK iB ABS ms J BROWN w ABS i BLACK i 5VDC ae a RED a 5V COM P5 6 Y BLACK Y 5VDC WHITE J j 5V CABLE TERMINATION AT MATING CONNECTOR COM ns BLACK COMM SOLDER PINS SHOWN 15 a ORANGE v TS 5 12 i R T5 paii BLACK 15 SHIELD T T t C ENCODER 3 7H CASE Publication 1398 5 1 January 2000 3 52 Wire the ULTRA Plus Components Figure 3 40 ULTRA Plus PDM P5 to N Series Motor Encoder 9101 1474 0 395 1 16 E E feet 3 31 12 0 0 5 2 50 START OF BEND RADIUS 0 12 THREAD PROTRUSION MOLDING ADAPTER ALUMINUM MARKED WITH ELECTRO CRAFT BLACK COBALT PLATED P N amp REV MANUFACTURERS P N amp REV AND DATE CODE CONNECTOR ITT CANNON KPSE05E14 19S A71 4 40 RETRACTABLE MACHINED THUMBSCREW WIRING DIAGRAM wo 2 2 a a YELLOW BROWN PIN6 PIN 11 PIN 15 PIN 10 05 14 195 71 CONNECTOR FACE VIEW 15 POSITION HIGH DENSITY 45 D SUB PLUG WITH MALE PIN CONTACTS FACE VIEW 0 DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 BOTH
6. AVAILABLE DIRECTLY FROM THE LINE RR YE MODULE INPUT CURRENT REQUIREMENTS L1 AUX L2 N AUX PDM 10 PDM 20 PDM 30 1 0 Amps AC at 115 Volts AC 0 5 Amps AC at 230 Volts AC 10 0 AMPS AC 19 0 AMPS AC 28 0 AMPS AC NOTE SLOW BLOW FUSES ARE REQUIRED TO ALLOW FOR INRUSH CURRENT DURING POWER INITIALIZATION AT THE MAIN AND AUXILIARY TERMINALS TIME DELAY VERSIONS OF UL CLASS J CLASS R OR EQUIVALENT FUSES ARE ACCEPTABLE LOCAL REGULATIONS MUST BE OBSERVED fuse BLOCK T 1 n ren DRIVE MODULE r MOTOR POWER y eun C Ey HSERIES ESERIES N SERIES MOTORS COMMON GROUNDING POINT FOR AMPLIFIER SYSTEM ONE PER AXIS _ MACHINE COMMON TO PROTECTIVE GROUNDING BUS BAR NOTES EARTH TERMINAL J MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1 L2 TERMINALS EXAMPLE TO RETAIN DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1 12 POWER DOWN WHEN USING A THREE PHASE SUPPLY CONNECT THE MAIN AND AUXILIARY INPUTS TO THE SAME PHASE A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE amp SAFETY LOCAL REGULATIONS SHOULD BE OBSERVED IN EUROPE F A GROUNDED NEUTRAL IS USED INSTEAD OF L2 OR L2 AUX ONLY 1 1 MAY BE SWITCHED OR FUSED A JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT SEE DRAWING 9101 1328 FOR TERMINAL WIRING OF EXTE
7. An overview of the ULTRA Plus Positioning Drive ULTRA Plus Brochure 1398 2 0 A description and specifications for the ULTRA Series family ULTRA Series Product Data 1398 2 0 Information to help you install and set up your GML Ultra software GML Ultra Getting Started 1398 5 10 Manual Step oriented information that will help you use GML Ultra to GML Ultra User Manual 1398 5 11 program your ULTRA Plus system Reference material that explains the theory behind how you program GML Ultra Reference Manual 1398 5 12 your ULTRA Plus for your application needs 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 A glossary of industrial automation terms and abbreviations Allen Bradley Industrial AG 7 1 Conventions Used in this Manual Automation Glossary The following conventions are used throughout this manual Bulleted lists such as this one provide information not procedural steps Numbered lists provide sequential steps or hierarchical information Words that you type or select appear in bold When we refer you to another location the section or chapter name appea
8. 2 3 4 5 l Index 6 Common 7 Common 9 5 VDC 250 mA maximum 10 Index 15 Shield Publication 1398 5 1 January 2000 3 36 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Figure 3 22 Encoder 2 connections Les SHEL lt 14 lt eee lt P4 13 COMMON 6 COMMON n P4 9 lt m DIR MASTER ENCODER Slaving an ULTRA Plus PDM to Another In applications where an ULTRA Plus PDM needs to follow another ULTRA Plus PDM using electronic gearing the P4 connections may be used to provide a simple method of wiring the motor encoder signals from the master ULTRA Plus PDM to the Encoder 2 input of the follower slave ULTRA Plus PDM The master ULTRA Plus PDM needs to be configured to output its motor encoder signals on P4 A standard cable is available for this purpose Refer to ULTRA Plus PDM P4 to P4 2 foot P N 9101 2127 on page 3 51 Wire the ULTRA Plus Components 3 37 Step and Direction Inputs Figure 3 23 illustrates connections of the PDM which can accept step and direction inputs on P4 These inputs provide a standard interface to an indexer If the step and direction inputs on P4 are used the Encoder 2 port may still be used as Encoder 1 out but not for connections to an auxiliary encoder input Step and direction inputs and
9. 010 lolo 2 POTS olel ojo S u57 14 20 y 360 7 gt u67 wr usr u66 Us 87 usr B JE amp amp EEEE EEE A EEEE E E w AIR INTAKE AIR INTAKE AIR INTAKE Publication 1398 5 1 January 2000 2 14 Install the ULTRA Plus PDM Components 1398 25 50 100 and 150 Power Supply Module The power supply module should be centrally located to minimize the distance between it and the PDM modules The higher current rating PDM modules should be located closest to the power supply module PSM Auxiliary Transformers Figure 2 9 shows the mounting diagram and connections for the PSM Auxiliary Transformer Figure 2 9 PSM Auxiliary Transformer mounting 5 50 MAX i 438 SPECIFICATIONS A 8 32 TERMINAL SCREWS 6 031 Z 8 0 MIN CLEARANCE RECOMMENDED FOR ACCESS TO WIRING 5 00 MAX NOTES AN RING OR SPADE LUG CONNECTORS NOT PROVIDED ARE REQUIRED FOR WIRING CONNECTIONS TO THE TRANSFORMER OUTPUT POWER 50 60Hz 110 VAC OUTPUT VOLTAGE 50 C MAX TEMPERATURE RISE 500 VA MIN NOMINAL OPERATING VOLTAGES CONNECTION INSTRUCTIONS 9101 0233 SCHEMATIC SYMBOL H1 H3 H2 H4 X2 X1 480 OR 240 INPUT 120 OUTPUT 460 OR 230 INPUT 115 OUTPUT 440 O
10. 2 21 PDM Fusing Requirements 2 22 Short Circuit Protection ce osses e 2l eA 2 22 Personality Module 2 23 Publication 1398 5 1 January 2000 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Installing the Personality Module PM 2 23 System Firmware 2 25 Installing the Firmware EPROMS 2 26 Jumper and DIP 5 2 26 Regulatory 2 27 Electromagnetic Compatibility 2 28 Bonding Your System 2 31 Motors and Cables 0 0 0 0 ccc eee nee 2 33 Low Voltage 2 33 Electromagnetic Compatibility 2 36 Filtering aane e n htt pr PEE 2 38 AC Line Filter Selection 2 40 2 42 Shielding and 2 43 Chapter 3 Syst m Power ConncchOns vos ove ec pede toss ace RR dtes 3 1 1398 PDM 10 20 75 and 150 3 1 1398 PDM 25 50 100 150 3 5 External Shunt Connections 3 12 Replacing the PSM Shunt 3
11. Select Online from the Diagram menu to display the Online Manager window Initialize and load the appropriate Personality Module files for the PDM 10 11 12 13 Apply Power for the First Time 4 3 and motor combination as follows Select Enter Setups from the Online Manager window to display the Axis Setups dialog Select Initialize PM and Execute to display the Initialize PM dialog Select the appropriate ULTRA Plus PDM type from the Drive list Select the appropriate motor type from the Motor list Verify the Encoder list displays the correct line count for the motor If necessary select the proper encoder resolution value Select Update PM to initialize the Personality Module with the specified drive and motor parameters After the Personality Module is properly initialized select Yes to reset the PDM and exit the Update PM dialog Select Cancel to exit the Axis Setups dialog If the STATUS LED is red perform the following steps Select Enter Setups to access the Axis Setups dialog Select I O Status Monitor and press Execute to view the I O Status Monitor which displays the fault Correct any fault conditions Refer to Error Messages and Error Output on page 5 4 for diagnostic assistance Close the I O Status Monitor Select Cancel to exit the Axis Setups dialog Double click the Reset Drive block in the Online Manager command window to reset the ULTRA Plus PDM Verify the STATUS LED is green If
12. Single phase input and output 50 60 Hz Refer to Single PhaseTransformer Load Regulation Curve on page 2 6 and Refer to Single PhaseTransformer Outline Diagram on page 2 8 Three Phase Transformer specifications The 1398 PDM 25 50 100 and 150 have a separate power supply module and use a three phase transformer Refer to Three PhaseTransformer Load Regulation Curves on page 2 7 and Refer to Three Phase Transformer Outline Diagram on page 2 9 Specification Model TF 03 TF 06 TF 12 TF 18 Rating 3 kVA 6 kVA 12 18 kVA Weight 86 Ib 135 Ib 200 Ib 325 Ib 31 kg 61 kg 91 kg 148 kg Input 208 230 240 380 460 480 VAC RMS Output 115 230 VAC RMS Ambient temperature 32 to122 F 0 to 50 C Three phase input and output 50 60 Hz Appendix B Options and Accessories PD Ms and Optional The following tables can be used to order products Use the Item Number Accessories Order number whenever possible The Alternate Number Manufacturing number is used for ordering when the Item Number is not available or when researching information about the component or module This table gives the ULTRA Plus PDM reference numbers Item Number Description J Alternate Number 1398 PDM 20 Positioning Drive Module 9101 2186 1398 PDM 25 Positioning Drive Module 9101 3058 1398 PDM 30 Positioning Drive Module 9101 2187 1398 PDM
13. Allen Bradley 1398 ULTRA Plus Series Positioning Drive Module Catalog Nos 1398 PDM 10 20 30 50 75 100 150 and 150B Installation Manual Rockwell Automation Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole ot part without written permission
14. S I 3 R Eq als CHASSIS ch E m P MOTOR CASE 4 SHIELD l TO SINGLE POINT EARTH GROUND PDM BRUSHLESS MOTOR COMMON MODE CHOKE i 10 20 TURNS ON COMMON FERRITE TORROID CORE R S R S T T CHASSIS Ah A MOTOR CASE TO SINGLE POINT EARTH GROUND Publication 1398 5 1 January 2000 Chapter 3 System Power Connections Wire the ULTRA Plus PDM Components This chapter explains the wiring requirements of an ULTRA Plus PDM system The user is responsible for conforming to National ATTENTION P 8 ATTENTION Electrical Codes and all other applicable local codes Failure to conform to codes can result in damage to the equipment or severe bodily injury 1398 PDM 10 20 75 and 150B The 1398 PDM 10 20 and 30 require single phase AC power 100 to 240 VAC The 1398 PDM 75 and 150B require three phase AC power 100 to 240 VAC The input power may be optionally isolated through a transformer Field wiring must be copper with a minimum rating of 60 C The phasing of L1 and L2 N to the 1398 PDM 10 20 and 30 is arbitrary The phasing of the 1398 PDM 75 and 150B is L1 L2 N and L3 The earth ground connection is required for safe and proper system operation Terminal block connections should be torqued to 11 Ib in 1 25 Nm The 1398 PDM 10 20 75 and 150B does not contain supply fuses or disconnecting devices These must be supplied by the machine builder and connected externally
15. numeric keypad F1 2 F3 F4 programmable keys rms 1 2 YES m L4 LS JL JIN Ce 2 J 8 J 9 L Overview of the ULTRA Plus System 1 7 Transformers Multi tap single phase and three phase isolation transformers are available in a vatiety of power ratings for line voltage matching Refer to Transformers on page B 5 Auxiliary Power Supply Module PSM An auxiliary power supply module PSM AUX is available to supply DC power to the logic supplies of up to four ULTRA Plus PDMs if the PSMs are OFF The PSM AUX uses single phase 115 VAC power as the input This option is only necessary for the 1398 PDM 25 50 100 and 150 with the separate power supply module The remaining ULTRA Plus PDMs have an integral power supply The PSM AUX option is useful if ULTRA Plus PDM logic power is needed to stay ON even when the motor supply the PSM is off Absolute positioning is one example of when the PSM AUX would be useful since position information is maintained as long as logic power is on Another example would be maintaining ULTRA Plus PDM logic power so the serial interface could be used for troubleshooting and diagnostics Refer to PSM AUX Outline and Connection Diagram on page 2 15 for additional information on installing the PSM AUX and optional PSM AUX isolation transformer See a listing of Refer to Power Supply Modules on page B 2
16. 325 VDC nominal with 230 VAC input Check that the green PSM READY LED is on and that all three red LEDs are off and that the PSM fans are operating 4 Disconnect input power and check that the green LED goes off and the DC bus voltage falls to less than 15 VDC within one second 5 Remove PSM cover Reconnect the DC bus wires to the PSM terminals marked and ensuring that proper polarity is maintained Install the PSM cover ATTENTION Do not substitute the DC bus wires provided with wires of a different length or gauge Failure to observe this precaution may result in damage to or destruction of the ULTRA Plus PDM Publication 1398 5 1 January 2000 4 6 Apply Power for the First Time Publication 1398 5 1 January 2000 Start up Procedure for 1 Ensure input power to the PSM is off 2 Disconnect all interface cables P1 P7 from each ULTRA Plus PDM 3 With input power still off disconnect motor leads from ULTRA Plus PDM terminals R S and T Verify with an ohmmeter that the resistance between ULTRA Plus PDM terminals R to GND S to GND and T to GND is above 500k ohms If the resistance is acceptable reconnect the motor leads to the ULTRA Plus terminals marked S and 4 Verify that the DC bus wires are connected to each ULTRA Plus PDM with proper polarity 5 Connect all interface cables P1 P7 to the ULTRA Plus PDMs ATTENTION Perform the initial power up with the motor shaft
17. At low frequencies it acts as a constant impedance at intermediate frequencies as an inductor and at high frequencies as an antenna The use of ground straps is a better alternative to wires However the length to width ratio must be 5 1 or better yet 3 1 to remain a good high frequency connection The ground system s primary purpose is to function as a return current path It is commonly thought of as an equipotential circuit reference point but different locations in a ground system may be at different potentials This is due to the return current flowing through the ground systems finite impedance In a sense ground systems are the sewer systems of electronics and as such are sometimes neglected The primary objective of a high frequency ground system is to provide a well defined path for HF currents and to minimize the loop area of the HF current paths It is also important to separate HF grounds from sensitive circuit grounds A single point parallel connected ground system is recommended Figure 2 25 shows single point grounds for both series daisy chain and parallel separate connections Multiple PDMs should be connected to the AC source in a parallel fashion Figure 2 25 Single point ground types PARALLEL CONNECTION POO GROUND BUS BAR Publication 1398 5 1 January 2000 A ground bus bar or plane should be used as the single point where circuits are grounded This will minimize common ground
18. Cam Profile Overflow 5 6 Delay Out of Range 5 5 Divide by Zero 5 5 Drive Not Ready 5 6 Encoder Fault 5 7 EPROM Checksum 5 7 Excessive FE 5 6 Excessive Speed 5 6 Gear Out Of Range 5 5 Heat Sink Overtemperature 5 6 Home Not Defined 5 5 lavg Fault 5 6 Invalid Opcode 5 5 KFF Out of Range 5 5 KI Out of Range 5 5 KP Out of Range 5 5 KPZ Out of Range 5 5 Logic Supply Fault 5 6 LOOP Count Out of Range 5 5 LOOP Variable Range 5 5 Math Overflow 5 5 Motor Overtemperature 5 6 Peak Overcurrent 5 7 Personality Fault 5 7 POS Track Overflow 5 6 Power Module Fault 5 6 PRECISION Out of Range 5 5 Profile Calculation 5 5 RAM R W Fault 5 7 Reentrancy Fault 5 5 Serial 2 Busy 5 6 TEXT Checksum 5 7 Watchdog Reset 5 7 Watchdog Test Fault 5 7 Error output Assignable function 3 27 Multiple axis 3 28 European Directive Compliance Directive 2 28 Emergency Stop Contactor 2 35 I O Conversion Card 2 34 Low Voltage Directive 2 33 Motors and Cables 2 33 Excessive Excessive FE error 5 6 Excessive Speed error 5 6 External Shunt Description 1 8 Installation 2 17 Power dissipation ratings 3 13 F Faraday shield 2 38 Fault Encoder 5 7 lavg 5 6 Logic Supply 5 6 Personality 5 7 Power Module 5 6 RAM R W 5 7 Reentrancy 5 5 Watchdog Test 5 7 Filter types 2 39 Firmware Installation 2 25 Flying leads Motor shield termination 2 29 Forward Limit 3 26 Full Load Amperage 2 22 Fuse Short Circuit Protection 2 22 G Gear Out Of Range error 5 5 GM
19. disconnected from a load and the shaft key removed Improper wiring or undiscovered shipping damage could result in undesired motor motion Be prepared to remove power if excessive motion occurs 6 Make sure that the motor is disconnected from the load before applying power This prevents mechanical damage should a fault occur 7 Apply input power and check the LEDs The green DC BUS LED should turn on to indicate power is applied The bicolor STATUS LED should turn green The ULTRA Plus PDM is in a fault condition if the STATUS LED is red Continue with the following instructions and perform Step 9 to clear any faults 8 Select Online from the Diagram menu to display the Online Manager window 9 Initialize and load the appropriate the Personality Module files for the ULTRA Plus PDM and motor combination as follows a Select Enter Setups from the Online Manager window to display the Axis Setups dialog b Select Initialize PM and Execute to display the Initialize PM dialog c Select the appropriate ULTRA Plus PDM from the Drive list d Select the appropriate motor type from the Motor list e Verify the Encoder list displays the correct line count for the motor Apply Power for the First Time 4 7 If necessary select the proper encoder resolution value Select Update PM to initialize the Personality Module with the specified drive and motor parameters g After the Personality Module is properly initialized
20. installation operation and field maintenance of the ULTRA Plus PDM Publication 1398 5 1 January 2000 Preface 2 Contents of this Manual Publication 1398 5 1 January 2000 Refer to the following manual for the descriptive contents of this installation manual Chapter Title Contents Preface Describes the purpose background and scope of this manual Also specifies the audience for whom this manual is intended 1 Overview Gives a functional description of the ULTRA Plus product series 2 Install ULTRA Plus PDM Provides mounting information for the Components ULTRA Plus PDM system 3 Wire the ULTRA Plus PDM Provides connection information for the Components ULTRA Plus PDM system 4 Apply Power for the First Outline steps when applying power to Time equipment for the first time 5 Check for Problems in the Diagnostic aids that help isolate problems System to a system module AppendixA Specifications Provides physical electrical environmental and functional specifications for the AppendixB Options and Accessories Provides identification numbers and descriptions of the ULTRA Plus PDM and related products Related Documentation Preface 3 The following documents contain additional information concerning related Allen Bradley products To obtain a copy contact your local Allen Bradley office or distributor For this information Read This Document Document Number
21. prov toeren DONGTSOALE DRAWING BCB 25 87 Dmensionsanemwincnes BOB 29E ssas BREAK ALL EDGES 02 MAX DIAG OUTLINE XFMR ERU FILLETS AND ROUNDS 02 R TOLERANCE ON pari ANGLES FRACTIONS 1 64 9101 0131 DECIMALS oeoo 200005 n D 1 Publication 1398 5 1 January 2000 2 10 Install the ULTRA Plus Components Mounting Requirements Position the ULTRA Plus in a vertical position on a flat solid surface that meets the mounting requirements for weight humidity and temperature listed in Appendix A The following diagrams list dimensional mounting requirements Figure 2 5 1398 PDM 10 20 and 30 Mounting 10 pe 8 93 104 1 226 8 AIR Mee sea EXHAUST pal A E 2 WARNINGHigh Voltage May Exist Up To Five Minutes After Removing Power En Auxiliz 13 75 14 20 349 2 360 6 9 CI LO KO KOT KOT I Publication 1398 5 1 January 2000 AIR INTAKE Install the ULTRA Plus PDM Components 2 11 Figure 2 6 1398 PDM 75 Mounting 5 97 8 93 151 7 226 8 r 0 27 4 7 0 50 M AIR EXHAUST 13 75 14 20 8492 360 7 Status Analo og 2 Digital dun uts And puts 8 s 3 8 i Digital Inpu T T AIR INTAKE AIR INTAKE
22. 2 8 3 Input BLUE 3 Pair 9 4 Output BLACK 4 Pair 9 5 Output GREEN 5 Pair 10 6 Output BLACK 6 Pair 10 7 Output BROWN 7 Pair 11 8 Output BLACK 8 Pair 11 9 Output GREEN 9 Pair 12 10 Output BLUE 10 Pair 12 11 Output WHITE 11 Pair 13 12 24 volts GREEN 12 Pair 13 N A RED N A Pair 14 N A ORANGE N A Pair 14 N A RED N A Pair 15 N A BROWN N A Pair 15 On the user input side of the I F card the I O requires a separate clean 24VDC nominal supply There is no galvanic connection from one side of the I F card to the other and the 24VDC user supply must be grounded on the negative side to the protective earth system The supply should be between 20 to 30VDC and capable of supplying the loads imposed by the output loading plus 8 mA for each input used The supply must be fused adequately to protect the cables used Output loads must be connected between the output and 24 volt ground and must be 470 ohms or more impedance The interface outputs are rated at 50mA Cabling should be 1 5mm2 maximum The inputs must be supplied by the users input circuit from the user 24 volt positive and each input will sink 8mA when active Refer to I F Conversion Card on page B 2 for the interface card and cable manufacturing numbers Wire the ULTRA Plus PDM Components 3 25 Digital Inputs The optically isolated inputs are connected with an internal pull up resistor to 24VDC Making a connection to the 24 vol
23. 2205 XXX Pin 4 ULTRA Plus to 1398 HMI 003 ULTRA Plus Operator Terminal cable P7 2 RxD a 50 11 3 TxD amp 6 eo 4 T 5 COMMON ra us 9 2 o 5 6 SHIELD Y customer supplied jumper O 7 8 9 ULTRA Plus 123456789 10 Operator Terminal 1398 HMI 003 Tx IMPORTANT RS 232 operation Publication 1398 5 1 January 2000 Rx RTS CTS COMMON TxA TxB RxA RxB COMMON A jumper customer supplied must be installed between pins 3 and 4 of the ULTRA Plus Operator Terminal for 3 44 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Networking ULTRA Plus PDM Controls One more PDMs may be installed on an RS 422 multi drop network or an RS 232 daisy chain network If more than one PDM is on the network each PDM must have a unique address selected on the SW1 DIP switch panel which is illustrated in Figure 3 28 Figure 3 28 Dip Switch SW1 OFF Figure 3 29 illustrates the dip switch setting for address 5 Switches SW1 1 through SW1 6 are used to select the address Switch SW1 1 is the least significant bit and SW1 6 is the most significant bit of the binary address If the address is set to anything other than 0 the will not communicate until its address has been selected use Axis Select under the Communications menu Changing the address on the dip switch will
24. 3 4 Refer to Power Wiring Diagram 1398 PDM 25 50 100 and 100 on page 3 5 Standard cables supplied by Rockwell Automation Allen Bradley are not intended for applications where frequent flexing occurs Maat Motor power connectors are for assembly purposes only They should not be connected or disconnected while power is applied to the drive Failure to observe this precaution could result in damage to the equipment or severe bodily injury ATTENTION Do not tin solder the exposed leads on cables Solder contracts over time and may loosen the connection Failure to observe this precaution could result in damage to the equipment or severe bodily injury Shield Termination ATTENTION Shielded power cables must be grounded at a minimum of one point for safety Failure to observe this precaution could result in damage to the equipment or severe bodily injury Rockwell Automation Allen Bradley motor power cables are shielded The power cable is designed to be terminated at the drive during installation A small portion of the cable jacket is stripped which exposes the shield wires The exposed area must be clamped at the left front of the drive chassis using the clamp provided near the bottom It is critical for EMC performance that the shield wires be clamped against the area of the chassis which is not painted This section of the chassis is labeled with the chassis ground symbol Publication 13
25. 32 767 Check that the value is correct Calculations The calculation listed has exceeded the internal 30 S Curve system limit The limit is determined at run time based 31 Accel on the Scale parameter Check the velocity and 32 Velocity acceleration values under the Parameter menu Publication 1398 5 1 January 2000 5 6 Check for Problems in the System Publication 1398 5 1 January 2000 Continued 33 Error Messages lavg Fault Description The average current output of the GML exceeded safe levels for the motor or GML Check for correct connection of the motor encoder to the GML or of the motor leads to the GML Other possible causes are motor stall or end of travel condition excessive duty cycle or no DC bus voltage This can also occur if the drive is enabled and there is power supplied to the L1 and L2 N AC AUX inputs but not to the L1 and L2 N AC main inputs this provides logic voltage but no DC bus voltage 34 Excessive FE The following error has exceeded the Following Error Limit for a time greater than the Following Error Time Possible causes are loss of encoder feedback low gain settings a commanded velocity or acceleration that exceeds system capabilities or entries for Following Error Limit and or Following Error Time that are beyond system capabilities 35 Excessive Speed Commanded velocity of a move exceeded the Overspeed value set under Velocity Acceleration in the
26. 5 for a description of each fault On some machines you may want the ULTRA Plus PDM to continue running even after some faults occur This is accomplished by setting Disable on Fault to Partial In this case the following faults are disabled Iavg fault Motor Overtemperature Soft Forward Limit and Soft Reverse Limit All faults will cause the Error output to turn ON if enabled However if Disable on Fault is set to Partial and a fault listed above occurs the ULTRA Plus PDM will remain enabled and execute motion programs normally The Error output in this case serves as an alarm and a programmable logic controller PLC or other controller can then gracefully shut down the machine without damaging the tooling or work piece Check for Problems in the System 5 5 The following table lists the faults that activate the Error output The number preceding the fault is the error number No Error Messages Description 3 2ms Reentrancy Fault The system did not finish the required calculations in the previous 2ms position loop update in time for the next position loop update 4 Math Overflow A math overflow occurred a calculation exceeded the internal system limit Check the values of the variables used in the program 5 Divide by Zero A division by zero calculation was attempted Check the values of the variables used in the program 6 LOOP variable range A variable used as the count for a LO
27. 50 Positioning Drive Module 9101 3059 1398 PDM 75 Positioning Drive Module 9101 2188 1398 PDM 100 7 Positioning Drive Module 9101 3060 1398 PDM 150 Positioning Drive Module 9101 3061 1398 PDM 150B Positioning Drive Module 9101 2234 Fuse Drive Module F1 1 Amp 9101 0228 for 24 VDC circuits Bussman MDL 1 or Littelfuse 313 001 1 Requires use of 1398 PSM XXX Power Supply This table shows optional ULTRA Plus PDM accessories Item Number Description Alternate Number 1398 HMI 002 ULTRA Plus Operator Terminal 110 240 VAC 9101 2196 1398 HMI 003 ULTRA Plus Operator Terminal 24 VDC 9101 2209 1398 SR9P External Shunt Kit 900W 9101 1697 External Shunt Kit 200W 9101 1183 Personality Module Replacement Kit 9101 2226 f The Personality Module is programmed with standard factory default settings If replacing a previously installed Personality Module user programs and user selected parameters must be re entered into the new Personality Module memory Publication 1398 5 1 January 2000 B 2 Options and Accessories I F Conversion Card Power Supply Modules Publication 1398 5 1 January 2000 This table lists the 24V Sourcing interface conversion card and its connections cables Description Alternate Number I F Conversion Card 24V Sourcing 9103 0152 Cable I F Conversion 3ft 1m 44 0141 003 Cable I F Conversion Card 10ft 3m 44 0141 010 1 Required f
28. 75 C COPPER MIN c EA ALL LZNAUX 16 AWG 1 5m POWER INPUT NOTE POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSH OPTIONAL CURRENT OF 70A PEAK FOR THE MAIN INPUT AND 105A PEAK 8 AWG 10 0mmi 10 AWGI 6 0mni L142 CL 8 AWGHO 0mrh FOR THE AUXILIARY INPUT DUAL ELEMENT TIME DELAY SLOW X BLOW FUSES ARE RECOMMENDED FUSE SIZES MUST BE SELECTED Baud cm ACCORDING LOCAL REGULATIONS 4 AWG 25 0mm 8 AWG 10 0mmi TERMINAL STRIP AWGI 25 0mmi 6 AWG 16 0mm ACCEPTABLE WIRE RANGE GAUGE mm 22 10 AWG O 5 6mm TORQUE ALL TERMINALS DRIVE MODULE DRIVE MODULE TO 11 LB IN v 12 6 AWG 8 0 14mm TORQUE ALL TERMINALS I Ts TO 12 LB IN me AS R EN s 2 H ruse 27 Hg BLOCK XcON H a Ac UNE He ELTER ro HO j MOTOR POWER Lt AUK CONNECTOR MATING MOTOR POWER N CONNECTOR p Um H SERIES H SERIES F SERIES F SERIES N SERIES N SERIES MOTORS MOTORS N 2 FUSED DISCONNECT OR CIRCUIT BREAKER m ISOLATION OR AUTO TRANSFORMER 9 o amp 3 OPTIONAL NOT REQUIRED WHEN DESIRED INPUT VOLTAGE IS 1 0 E AVAILABLE DIRECTLY FROM THE 50 60Hz LINE TRANSFORMER COMMON GROUNDING COMMON GR
29. Cables Motor power cables with connectors are available in four standard lengths 3 7 15 and 23 meters 10 25 50 and 75 ft Motor encoder cables with connectors and fifteen pin D connectors are available in the four standard lengths Nine pin serial cables are available in 3 and 7 meter 10 ft and 25 ft lengths Refer to Cables on page B 4 Motor Connectors Mating connectors are available if you choose to build your own motor cables Refer to Motor Connectors on page B 6 Publication 1398 5 1 January 2000 1 8 Overview of the ULTRA Plus System Publication 1398 5 1 January 2000 Shunt Kits The 1398 PDM 10 20 75 and 150B has a built in shunt regulator If the application requires a higher continuous power dissipation the ULTRA Plus PDM provides easy access for an external shunt connection Factory available External Shunt Kit 25Q 200W or an External Shunt Kit 18Q 900W can be used These external shunts can be arranged to provide maximum power dissipation as long as the minimum resistance requirement is met Refer to PDMs and Optional Accessories on page B 1 Personal Computer PC uset supplied PC is required to run GML Ultra Software The minimum computer requirements to run this software are contained in the GML Ultra Software manuals Chapter 2 Mounting Install the ULTRA Plus PDM Components This chapter explains the physical installation of the individual components associated wi
30. EM LINE FILTER CONDUCTED EMI M pi ATTENTION High voltage exists in AC line filters The filter must be grounded properly before applying power Filter capacitors retain high voltages after power removal Before handling the equipment voltages should be measured to determine safe levels Failure to observe this precaution could result in personal injury The only reasonable filtering at the PDM output terminals is the use of inductance Capacitors would slow the output switching and deteriorate the PDM performance A common mode choke can be used to reduce the PDM emissions This will reduce emission coupling through the PDM back to the AC line However the motor cable still carries a large HF voltage and current In fact the motor cable length directly affects the amplitude and frequency of the emissions on the AC line Therefore it is very important to segregate the motor cable from the AC power cable For applications where long motor cables are required the need for AC line filtering increases Publication 1398 5 1 January 2000 2 42 Install the ULTRA Plus Components SERIES CONNECTION Grounding High frequency HF grounding is different from safety grounding A long wire is sufficient for a safety ground but is completely ineffective as an HF ground due to the wire inductance As a rule of thumb a wire has an inductance of 8 nH cm 20 nH in regardless of diameter
31. ENDS Publication 1398 5 1 January 2000 Chapter 4 1398 PDM 10 20 30 75 and 150B Apply Power for the First Time Outlined below are the steps that should be followed when applying power to the equipment for the first time This procedure covers the ULTRA Plus PDM Motor and Operator Terminal Refer to and become familiar with the following publications before installing and using GML Ultra Software e 1398 5 10 GML Ultra Getting Started Manual e 1398 5 11 GML Ultra User Manual and e 1398 5 12 GML Ultra Reference Manual These start up procedures assume that the equipment is properly mounted and wired but power has not been applied The instructions also assume that a PC with GML Ultra loaded into the default directory c ult is connected to the unit You can start GML Ultra Software by double clicking on the GML Ultra Software icon ATTENTION High voltage is present on the terminals of the ULTRA Plus PDM After removing power check for remaining voltage before making or removing any connection Failure to observe this safety procedure could result in personal injury or damage to equipment Publication 1398 5 1 January 2000 4 2 Apply Power for the First Time Publication 1398 5 1 January 2000 1 Prior to applying power to the ULTRA Plus ensure that the supply voltage is in the proper range 100 240 VAC 2 With power off ensure that proper connections are made as listed bel
32. EXTERNAL CONNECTIONS FER eE lomo Co 7 Publication 1398 5 1 January 2000 3 10 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Status Outputs The Status outputs are the contacts of a normally open relay which closes to indicate that the PSM is operating properly An open relay signals that no AC power is applied to the PSM or that a PSM fault has occurred Refer to the above drawing for connection examples Enable Input The PSM Enable input is an optically isolated input which controls the power output of the power supply module The PSM Enable input is turned on by sourcing current through the opto isolator Refer to PSM interface external connection examples on page 3 9 for connection examples The input is only functional if jumper W1 is in the optional position A Refer to Power Supply Module jumper location on page 3 11 With the jumper in the enable input activated position optional Position A the PSM is enabled if the enable input is ON With the enable input OFF the PSM DC bus is turned OFF and the dissipative shunt is turned ON to quickly discharge the DC bus capacitors and dynamically brake synchronous motots This is to allow time for the PDMs to power up and apply the enable signal to the PSM if the PSM is to remain ON ATTENTION If the PSM is disabled during a power up the DC bus voltage will be present for at least two 2 seconds be
33. Enable the jog inputs or Double click on the Jog Axis block in the Online Manager window to access the Jog Axis dialog Select Execute from the Jog Axis dialog to rotate the motor The direction and speed of rotation may be changed in the Jog Axis block Select Cancel to exit the Jog Axis dialog Select ESTOP in the Online Manager command window to halt motion stop program execution and set Feedback OFF Remove input power The LEDs should turn off within ten seconds Start up of an ULTRA Plus PDM system involves starting a Power Supply Module PSM and at least one ULTRA Plus PDM The PSM is checked first and then the PDMs Perform the start up procedure on all the PDMs attached to the PSM at the same time Maiti Dangerous voltages may exist after power is removed Check DC bus voltage each time power is removed before working on the Power Supply Module or ULTRA Plus PDM Apply Power for the First Time 4 5 Power Supply Module 1 Prior to applying power to the PSM ensure that the supply voltage is in the proper range 120 240 VAC 3 phase 2 With power off remove the PSM cover and ensure proper connections have been made to terminals L1 L2 and L3 and that a proper ground is connected Phasing of the input power connections is arbitrary 3 Disconnect all wires from the PSM DC bus terminal posts marked and Install the PSM cover then turn on input power Verify that DC bus voltage is in the proper range
34. LB IN AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL TO BE USED FOR IMPROVING THE SYSTEM S ELECTROMAGNETIC COMPATABILITY WIRING BETWEEN SHORT AS POSSIBLE THE COMMON GROUND SHOULD BE AS CLOSE TO THE MODULE AS POSSIBLE FILTER SHOULD BE AS WIRE SIZES ARE RECOMMENDATIONS THE REQUIREMENTS OF LOCAL REGULATIONS MUST BE OBSERVED POWER WIRES MUST MOTOR POWER WIRES R S T GND MOTOR POWER MINIMUM MATING CONNECTOR RECOMMENDED CONTACT POWERWIRE GAUGEImm GAUGEIm MOTOR 16 5 JA 12 AWGIS 0mm 14 AWGDSmm A T2AWGAmm AV 8 AWGI amp mm 8 AWG l0mm 4AWGI21 6mmE 6AWG f mm aWeromm TERMINAL BLOCK SAWGHEmm 4 H SERIES S SERIES F SERIES AND W SERIES MOTORS E 1 5300 AND 1 6600 MOTORS eN MOTOR POWER CONNECTOR IGNAT R s MOTOR TERMINAL BOX MOTOR POWER TERMINAL STRIP MOTOR POWER TERMINAL STRIP TERMINAL SIGNAL V 5 R MOTOR CASE 1 IE POWER SUPPLY AND A REV CHG D NOTE 1 53095 RB RELEASED 22 REVISION DESCRIPTION DATE CHKR 21244 Eco BY FRAC DONGT SCALE DRAWING TM DIMENSIONS ARE IN INCHES BREAK ALL EDGES 02 MAX FILLETS AND ROUNDS 02 R MAX TOLERANCE ON ANGLES ANGLES DECIMALS 020 1 24 95 CO 53095
35. P6 5 Shield P6 6 ULTRA Plus Personal Computer Serial Port P6 25 pin Serial Connector Connector RXD P6 2 TXD P6 3 COM P6 5 Shield P6 6 Refer to Networking on page 3 44 for RS 422 connections between an ULTRA Plus PDM and the host computer Publication 1398 5 1 January 2000 Wire the ULTRA Plus PDM Components 3 41 Operator Terminal 1398 HMI 002 The optional Operator Terminal connects to the PDM through Serial port 1 P7 The cable connects to the COM1 connector on the back of the Operator terminal P7 at Serial Port 1 on PDM In the default configuration the PDM expects an 1398 HMI 00X Operator Terminal to be connected so if a another terminal is used the PDM must be configured propetly Refer to the GML Ultra Software manuals PDM Connector Pin Signal Name RS 232 RS 422 P7 Serial Port 1 1 No connection RXD 2 RXD RXD 3 TXD TXD 4 No connection TXD 5 Common Common COM connector on the back of the Operator Terminal The COM1 connector is a twenty five pin male D connector The Operator Terminal may be wired using RS 232C for distances up to 15 meters 50 feet For longer distances RS 422 should be used Refer to the GML Ultra Software manuals for details on configuring Serial port P7 for RS 422 use Operator Terminal Connector Pin Signal Name COM1 1 Chassis ground 2 TXD RS 232 transmit 3 RXD RS 232 receive 14 TXD RS 422 transmit 15 T
36. PDM 10 20 30 75 and 150B Curve 2 6 Transformer Outline Diagram 1398 PDM 10 20 30 75 and 150B 2 8 Transformer Outline Diagram 1398 PDM 25 50 100 150 2 9 Digital Assignable output functions 3 27 Multiple outputs 3 27 Digital to Analog Converter DAC Resolution 3 29 Dip Switch Publication 1398 5 1 January 2000 2 Index Publication 1398 5 1 January 2000 Jumpers 2 26 RS 232 operation 3 46 SW 1 in network 3 40 SW1 1 3 44 SW1 6 3 44 SW1 7 3 44 Divide by Zero error 5 5 Documentation Related documentation P 3 Drive Not Ready error 5 6 E Earth ground 3 1 Electrical Noise 2 36 Electronic gearing 3 36 EMC Defined 2 36 European Directive 2 28 Noise 2 36 PDM mounting requirements 2 29 Performance 2 27 Requirements 2 28 Cable shielding 2 29 Requirements Flying leads 2 29 Requirements Lead length 2 29 System Installation 2 36 Emergency Return 3 26 Emergency stop contactor 2 35 EMI Bonding 2 31 Defined 2 36 Model 2 36 Problems 2 45 Source Victim Model 2 37 Standards 2 37 EN 60529 IEC 529 2 2 61000 4 X series 2 37 Enable Assignable Function 3 26 Enable Input 3 10 Enabled output 3 31 Enclosure Faraday cage 2 43 2 33 Metal 2 2 NEMA 2 2 Shielding 2 43 Sizing 2 3 Encoder Encoder Fault error 5 7 Feedback 3 31 3 33 3 35 Shield 3 35 EPROM Checksum error 5 7 EPROMs Installation 2 26 Error BCD Input Range 5 5 Bus Overvoltage 5 7 Bus Undervoltage 5 6 Calculation 5 5
37. Parameter menu 36 Cam Profile Overflow The target follower position in a cam profile could not be calculated 37 POS Track Overflow The target follower position with tracking mode active could not be calculated 38 Serial Port 2 Busy A PRINT or READ statement was attempted to serial port 2 while the system was reserving the port for other functions 39 Drive Not Ready The Ready to Run signal from the drive indicates a fault in the drive 40 Motor Overtemperature The temperature sensor in the motor windings indicated that the motor temperature has exceeded the rating Check for mechanical binding undersized motor or duty cycle too high Power Module Fault or Heat Sink Overtemperature This fault typically indicates that the amplifier is trying to supply currents above its rating to the motor Check for mechanical binding excessive duty cycle or faulty motor wiring 1398 PDM 10 20 30 75 and 150B The power module has detected excessive internal temperature or excessive current to the motor On earlier power modules this fault indicates the heat sink temperature has exceeded the rated temperature 1398 PDM 25 50 100 and 100 The heat sink temperature has exceeded the rating 42 Bus Undervoltage or Logic Supply Fault The DC Bus voltage is too low or power supplies for the amplifier circuitry were below the nominal output voltage This indicates a pr
38. Publication 1398 5 1 January 2000 2 12 Install the ULTRA Plus Components Figure 2 7 1398 PDM 25 50 100 and 150 Mounting 4 50 9 93 2521 0 25 4 9 70 2464 0 45 AIR Y i EXHAUST 4 5 Allen Bradley Ultra Plus Series I n D n 10 16 15 eer 17 50 5 428 6 444 B 4102 5 n n E mn n n m n n n n n mn nmn H H JB n WARNING Do No Apply Power With Cover Removed Do Net Remove Cover Wit Power Apod gorau logos May Exe Up To Minos Afer rower y yvy AIR INTAKE Publication 1398 5 1 January 2000 13 75 349 2 Install the ULTRA Plus PDM Components 2 13 Figure 2 8 1398 PDM 150B Mounting 100 240 Vac 50 60 Hz AC Mains 30 Only gt 4 8 93 226 8 External Shunt Internal DC Bus L3 L2 N Aux Allen Bradley Ultra Plus Series WARNING High Voltage May Exist Up To Fifteen Minutes After Removing Power Serial 1 Auxiliary P6 Serial 2 Compute P5 Encoder 1 Motor P4 Encoder 2 Auxiliary P3 Status Analog L P2 Digital Inputs And Outputs P Digital Inputs AIR EXHAUST u10
39. The only input to the PSM is 100 240 VAC single or three phase power The input power may be optionally isolated through a transformer The output is a two wire DC bus The PSM requires no adjustments protects itself provides troubleshooting diagnostics and has a built in solid state soft charge of the DC bus capacitors It also includes a built in dissipative shunt regulator that provides quick discharge of the DC bus capacitors and doubles as an emergency synchronous motor dynamic brake Motors A wide range of Allen Bradley H Series F Series and N Series permanent magnet synchronous motors are available for use with the ULTRA Plus modules Each motor includes an integrally mounted encoder Most motors are available with options including spring set brake and or shaft oil seal Military Standard MS connectors are standard for all H Series and F Series motots Personality Module PM The Personality Module is a nonvolatile memory device which stores the information necessary to customize an ULTRA Plus PDM for a specific application The PM holds parameters to match the encoder feedback motor and the drive as well as user programs and parameters A Personality Module may be physically removed and transferred to another ULTRA Plus PDM if the replacement of a PM is necessary to simplify servicing the machine Manuals This installation manual contains all the information required for mounting and wiring the motor and UL
40. ULTRA Plus Components Figure 3 20 Encoder input circuitry example Publication 1398 5 1 January 2000 Wire the ULTRA Plus PDM Components 3 33 Encoder 1 Figure 3 21 illustrates the connections of Encoder 1 which must connect to the encoder mounted to the motor This is the only motor mounted feedback necessary for control of the motor velocity This encoder is also normally used for position feedback Encoder 1 and signal names The Encoder 1 interface also includes connections for the normally closed thermostat in the motor windings and for an analog start up signal required for proper operation Connector Pin P5 Encoder input 1 1 Signal A B B l Index Common Common No connection oO CO N DMD om A N 5 VDC Index TS thermostat TS thermostat Analog absolute position 5 VDC a N N gt 99 N Shield Publication 1398 5 1 January 2000 3 34 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Figure 3 21 Encoder 1 connections 03072 5 15 SHIELD 5 VDC BRUSHLESS MOTOR lt P5 14 5 13 ANALOG P5 12 S Pte e P540 psg 79 NC I P5 8 P57 COMMON P5 6 COMMON P5 5 lt 54 4 P5 3 4
41. allows a system variable to be monitored The variable to be monitored is selected in the Monitor menu Variable Monitor Set Up dialog box Monitor output an signal names The monitor output is a 10 volt analog signal with 8 bit resolution Refer to the GML Ultra Software for information about the use of this output Connector Pin Signal Name Analog 1 0 and status 4 Analog Common 7 Programmable Monitor Publication 1398 5 1 January 2000 3 30 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Ready Relay Output See Figure 3 19 on page 3 30 illustrating the Ready output P3 1 which is a normally open relay contact that closes when the PDM is powered up if no faults exist within the PDM Ready relay output and signal names Relay Common P3 3 is the common of this contact This contact is rated 0 3 at 24 VDC The Ready output will open if a system fault occurs Connector Pin Signal Name Analog 1 0 and status 1 Ready Relay output 3 Relay Common Figure 3 19 Enable and Ready Relay Typical Internal Circuits 15 VDC 8 BIT DAC OUT MONITOR 12 BIT DAC OUT 10 BIT A D IN ANALOG COMMON RELAY COMMON ENABLED x x READY NORMALLY NORMALLY OPEN OPEN Wire the ULTRA Plus Components 3 31 Enabled Relay Output The Enabled output P3 2 is a normally open relay contact The Enabled output closes when
42. cause prolonged arcing in the contactor The contactor could catch fire in extreme cases A contactor was simulated in most EMC tests by breaking the motor lead and taking it through large rail mounted terminals This simulates a closed contactor which is acceptable as the contactor would be closed for normal operation of the PDM The method of connection of the screen and ground cables was as shown below The shields should be unbraided rather than soldering a drain wire to the shield Connection lengths should be minimized Figure 2 22 Emergency Stop Contactor Wiring Resistor QO Resistor 044 __ _ Resistor O O T E R O R Drive 4 2 30 H S Motor T OO E GND Om GND aie Isolated terminal TY C Unbraided shield 4 Grounded terminal or stud Enclosure wall zu The safety ground GND and shield connections are permanently connected This is essential for electrical safety TIP The safety ground is not connected to local ground at the point where the contactor is inserted in the lines but the shield is This is done for EMC reasons Publication 1398 5 1 January 2000 2 36 Install the ULTRA Plus Components Electromagnetic Compatibility Publication 1398 5 1 January 2000 Perhaps no other subject related to the installation of industrial electronic equipment i
43. connections are not segregated from each other then the EMI on the PDM side of the filter can couple over to the source side of the filter thereby reducing or eliminating the filter effectiveness The coupling mechanism can be radiation or stray capacitance between the wires The best method of achieving this is to mount the filter where the AC power enters the enclosure Figure 2 24 on page 2 41 contrasts a good installation with a poor one 3 When multiple power cables enter an enclosure an unfiltered line can contaminate a filtered line external to the enclosure Therefore all lines must be filtered to be effective The situation is similar to a leaky boat All the holes must be plugged to prevent sinking 4 If the filter is mounted excessively far from the it may be necessary to mount it to a grounded conductive surface the enclosure to establish a high frequency HF connection to that surface To achieve the HF ground the surface interface between the filter and the structure should be free from paint or any other insulator This may require paint removal from the inside of a cabinet or panel Install the ULTRA Plus PDM Components 2 41 AC Line Filter installation Figure 2 24 POOR CONDUCTED PDM CONDUCTED LINE H RADIATED EM FILTER RADIATED p EM GOOD PDM RADIATED
44. connectors P1 and P2 Wire the ULTRA Plus Components 3 21 Figure 3 16 PDM control connections Operator Terminal GML PC Compatible pH Software Personal Computer R ps 45 SHIELD S p5 14 15 VDC T 5 13 ANALOG G PEE P5 10 4 psg c9 VDC Pss COMMON psg c COMMON n Brushless Motor PES P53 1 P5 2 Pei eM p4 15 SHIELD A 4P4 4 9VDC DRE lt 4 12 P4 SIEPF 0 P4 10 lt p4g c 5VDC pag DIR Master Encoder COMMON COMMON P4 6 lt ___ ci if P4 5 A P4 4 P4 3 P4 2 T T 15VDIC 8 BIT DAC OUT MONITOR gt 12 BIT DAC QUT 10 A D IN ANALOG COMMON RELAY COMMON ENABLED READY a SOoSsooesor 24 VDC 44 ERROR OUTPUT8 IN POSITION OUTPUT 7 lt HOME SEQUENCE COMPLETE OUTPUT 6 AT HOME OUTPUT 5 PROGRAM RUNNING OUTPUT 4 GENERAL PURPOSE OUTPUT OUTPUT 3 GENERAL PURPOSE OUTPUT OUTPUT2 GENERAL PURPOSE OUTPUT OUTPUT 1 GENERAL PURPOSE INPUT INPUT 16 GENERAL PURPOSE INPUT INPUT 15 2 GENERAL PURPOSE INPUT INPUT 14 OUTPUT LOADS RESISTANCE IS 330 OHM MINIMUM GENERAL PURPOSE INPUT INPUT 13 INTERRUPT 2 INPUT 12 INTERRUPT 1 INPUT 11 ERETURN INPUT 10 19 PAUSE INPUT 9 sg JOG FORWARD INPUT 8 s JOG REVERSE INPUT 7 7 COMMAND IN
45. enclosure with no active method of heat dissipation the following approximate equation is used T 4 08 8 11 Where is temperature difference between inside air and outside ambient CF Q is heat generated in enclosure Watts and A is enclosure surface area ft The exterior surface of all six sides of an enclosure is calculated as 144 2dw 2dh 2wh Where d depth w width and h height are in inches Publication 1398 5 1 January 2000 2 4 Install the ULTRA Plus PDM Components Publication 1398 5 1 January 2000 Transformer Sizing ULTRA Plus PDM systems do not require isolation transformers A transformer may be required however to match the voltage requirements of the controller to the available service size a transformer for ULTRA Plus PDM the power output of each axis must be known This can be derived by calculating the horsepower for each axis and converting that horsepower into units f watts If you are suppling power to more than one motor and PDM simply add the KW ratings together from each calculation to get a system KW total Definitions KW power or real power KVA apparent power Transformer KVA rating Sum of average output power of each axis x 2 0 Calculations are multiplied by a factor to compensate for the power and loss elements within a power system A factor of 2 0 is used with a single phase system and a factor of 1
46. for safety and maintenance purposes Publication 1398 5 1 January 2000 3 2 Wire the ULTRA Plus PDM Components Figure 3 1 Power Wiring Diagram for 1398 PDM 10 20 and 30 MOTOR POWER WIRES R S T GND MOTOR POWER CONNECTOR INPUT POWER WIRES RECOMMENDED POWER WIRE DRIVE TERMINAL S GAUGE mm 5 60 C COPPER ONLY ALL MOTOR POWER MINIMUM MOTOR MATING CONNECTOR RECOMMENDED CONTACT SIZE POWER WIRE GAUGE mm GAUGEImm ibe COPPER ONLY PIN SIGNAL A R B c T D MOTOR CASE 16 AWG 1 5mm PDM 10 14 AWG 2 5mmE 16 AWG 1 5mmE 14 AWG 2 5mmE N X 12 AWGI3 0mm T N 14 AWG 2 5mm PDM 30 12 40 AWG Amm PDM 20 TERMINAL STRIP ACCEPTABLE WIRE RANGE DRIVE GAUGE mm 22 10 AWG 0 5 6mmE NI MODULE N 9N TORQUE ALL TERMINALS RE CE TO 11 LB IN PARTNUMBER N 0020 5097 gt SUGGESTED TRANSFORMER SIZES PDM 30 3 0kVA FUSE 7 BLOCK XCON H SERIES F SERIES N SERIES MOTORS A FUSED DISCONNECT OR CIRCUIT BREAKER 16 AWG T 5MM AC AUXILIARY POWER INPUT OPTIONAL COMMON GROUNDING POINT FOR AMPLIFIER TRANSFORMER SYSTEM ONE PER AXIS CHASSIS ISOLATION OR AUTO TRANSFORMER SINGLE PHASE 157 OPTIONAL NOT REQUIRED WHEN ACLINE J DESIRED INPUT VOLTAGE 18 50 60Hz 5
47. have successfully passed all EMC tests but shows some sensitivity to radiated fields 10V m in the encoder feedback circuit when the serial lead is connected Care must be taken in screening and grounding with both the serial lead and the motor feedback lead or nuisance tripping may occur The PDM end connector for these leads is a D type and screened backshells should be used with the screen properly terminated There is no requirement for a transformer in this design and a common mode choke for the motor leads is included in the PDM Publication 1398 5 1 January 2000 2 30 Install the ULTRA Plus PDM Components Publication 1398 5 1 January 2000 The PDM input current ratings and suitable supply filters one filter per PDM are listed below PDM current ratings and suitable supply filters PDM Current Rating Schaffner Roxburgh 1398 PDM 10 10 10A FN350 12 29 MDF16 or MIF10 1398 PDM 20 10 19A FN350 20 29 MDF18 or MIF23 1398 PDM 30 10 28A FN350 30 33 MDF36 or MIF32 1398 PDM 75 36 28 A FN351 36 33 MDF336 or MIF330 1398 PDM 150B 30 50 MDF 350 Roxburgh filters may be ordered directly from Rockwell Automation in the United States or Europe Part numbers and ratings are indicated below Roxburgh filters available directly from Rockwell Automation Roxburgh Current Rating Rockwell USA Rockwell Crewe MDF18 10 18A NONE 48 0428 MDF36 10 36A 9101 1387 48 0429 MDF3
48. input is high for motion in the forward direction The direction input should change a minimum of 4 microseconds before the first step pulse in that direction The distance moved given an input of N step pulses is a function of the software gear ratio set in the PDM The number of encoder counts moved is Motor Encoder Counts N step pulses Motor Encoder Counts The distance the motor moves N step pulses The number of pulses from an indexer t The software gear ratio The signal wires from the indexer should be shielded and the shield connected to the chassis of the device generating the signals In some cases it may be necessary to connect the shield at the PDM end of the cable at P4 15 Serial Port Connections Wire the ULTRA Plus Components 3 39 There are two serial ports on a PDM Serial 1 Auxiliary P7 and Serial 2 Computer P6 The Operator Terminal is connected to the PDM through Serial port P7 Serial port P6 is used as the programming port for a PC that is running GML Ultra Software SP6 is also the serial port used for Host communications Data may be sent to or received from either serial port by an application program The application may use a PRINT statement to send data and a READ statement to receive data Refer to the GML Ultra Software manuals for detailed information Several parameters select the operating mode for serial communications Both ports support either RS 232C or RS 422 communication
49. line filters to reduce the conducted EMI emitting from the PDM This allows nearby equipment to operate undisturbed In most cases an AC line filter will not be required unless other sensitive circuits are powered off the same AC branch circuit The basic operating principle is to minimize the high frequency power transfer through the filter An effective filter achieves this by using capacitors and inductors to mismatch the source impedance AC line and the load impedance PDM at high frequencies For Rockwell Automation Allen Bradley PDMs brought into use in Europe the use of the correct filter is essential to meet emissions requirements Detailed information on filters is included in the PDM specific document Transformers should also be used as specified in the PDM manual Install the ULTRA Plus PDM Components 2 39 The following table shows suitable filter types for Rockwell Automation Allen Bradley products The filters identified are manufactured by Schaffner or Roxburgh and are widely available from commercial sources Filters manufactured by Rasmi have also been tested successfully for EU compliance There are many AC line filter manufacturers whose products could be successfully integrated One manufacturer cannot be recommended over another manufacturer The machine builder is responsible for the suitability of the filter selection in a specific application Further information is available from the manufacturers Rockwell Autom
50. motor and its load This is due to the energy flow from the motor to the DC BUS When the energy transferred from the rotating inertia causes the DC BUS voltage to exceed 420 VDC the shunt is enabled and excess energy is dissipated as heat Internal Shunt Dissipation Ratings Shunt Rating 1398 1398 1398 1398 PDM PDM PDM PDM 10 30 75 150b Continuous W 50 0 180 0 Peak kW 45 10 0 19 0 If the application requires a higher continuous power dissipation the ULTRA Plus PDM provides easy access for an external shunt connection If an external shunt is connected the shunt jumper between terminals 1 and 2 should be removed Factory available External Shunt Kit 200W or a External Shunt Kit 900W can be used These external shunts can be arranged to provide maximum power dissipation as long as the minimum resistance requirement is met Refer to External Shunt Wiring Examples on page 3 14 for different configurations External Shunt Dissipation Power Ratings Shunt Rating 1398 1398 1398 1398 PDM PDM PDM PDM 10 30 75 150b Minimum Resistance 30 0 18 0 9 0 Ohms 10 1 Continuous Power 0 8 1 8 2 4 4 0 8 0 kw Peak Power kW 2 6 0 10 0 19 0 For sizing purposes approximately 420 Vpeak will drop across any given resistor assembly V Continuous and Peak Power Ratings are given measured with a minimum resistance shunt Higher Resistances will decrease Power Rating Publicatio
51. not be recognized by the PDM until a Hard Reset is performed or power is removed Figure 3 29 Dip Switch SW1 set for address 5 example OFF See Figure 3 29 on page 3 44 showing the setting of SW1 7 ON for the daisy chain mode Switch SW1 7 is used to select the mode of operation of the serial port 1 If SW1 7 is OFF serial port 1 functions as an independent serial Wire the ULTRA Plus Components 3 45 port If SW1 7 is ON serial port 1 and serial port 2 are linked together daisy chained Any data that is received on one serial port is automatically transmitted out the other serial port Figure 3 30 Dip Switch SW1 7 set ON for daisy chain mode example OFF Switch 8 on the DIP switch is not used The PDM is shipped with all switches set to OFF for independent operation of the serial ports and the address set to 0 If there is only one in the system all of the switches on DIP switch SW1 should be OFF Publication 1398 5 1 January 2000 3 46 Wire the ULTRA Plus Components Port 2 TXD P6 TXD P6 RXD P6 RXD P6 COM P6 SW1 7 OFF SW1 7 ON AXIS 1 Publication 1398 5 1 January 2000 XD RXD RXD GND 3 2 IO 2 5 P6 Port 2 P7 Port 1 RS 422 Multi Drop See Figure 3 31 on page 3 46 illustrating the connections needed for multiple PDMs which can be linked with an RS 422 multi drop configuration Remember to set a diffe
52. oe eae ten Rt Us B 2 AC Line PAGES aie ee iB eae Ehe trieste ees tes B 3 Cables er e e D e i ds B 4 ELATISTOLINICLS x Eee eid dee a dde B 5 Motor 1 B 5 Motor Conn ctots cxx cup d E Ru RR A ERA ER uda s B 6 Motor Shaft Seal B 7 Publication 1398 5 1 January 2000 Publication 1398 5 1 January 2000 Preface Introduction Who Should Use this Manual Purpose of this Manual Read this preface to familiarize yourself with the rest of the manual This preface covers the following topics e Who should use this manual The purpose of this manual Contents of this manual Related documentation Conventions used in this manual Product receiving and storage responsibility Allen Bradley support Use this manual if you are responsible for designing installing programming or troubleshooting the ULTRA Plus PDM If you do not have a basic understanding of the ULTRA Plus PDM contact your local Allen Bradley representative for information on available training courses before using this product This manual describes the function and installation of the ULTRA Plus Positioning Drive Module PDM products and standard Rockwell Automation Allen Bradley motors recommended for use with the ULTRA Plus PDM It is intended for engineers or technicians directly involved in the
53. of system firmware U57 SYSTEM U66 U67 FIRMWARE 4 U87 1398 PDM 10 20 30 75 and 150B 1398 PDM 25 50 100 and 150 LOGIC BOARD LOGIC BOARD i component side component side Publication 1398 5 1 January 2000 2 26 Install the ULTRA Plus Components Jumper and DIP Switches Publication 1398 5 1 January 2000 Installing the Firmware EPROMs ATTENTION Stray electrical discharge can damage the Firmware EPROMs Turn power Off dissipate any stored electrical energy and wear a conductive wrist strap while handling the Personality Module Failure to observe this safety procedure could result in damage to the equipment 1 Check that power to the ULTRA Plus is OFF 1398 PDM 10 20 30 75 and 150B Measure voltage between ULTRA Plus PDM terminals marked L1 and L2 N and L3 on 1398 PDM 75 and 150B to ensure incoming power is OFF Also measure voltage between terminals marked L1 AUX and L2 N AUX if used to ensure power is OFF The green DC BUS LED and the bicolor STATUS LED should be OFF 1398 PDM 25 50 100 and 150 Measure voltages at Positive and Negative bus terminals to ensure incoming power is OFF If a PSM AUX is used measure the voltage at L1 and L2 of the PSM AUX to ensure that incoming power is OFF 2 Remove the ULTRA Plus PDM cover 1398 PDM 25 50 100 and 150 only 3 Install the four EPR
54. select Yes to reset the ULTRA Plus PDM and exit the Update PM dialog h Select Cancel to exit the Axis Setups dialog 10 If the STATUS LED is red perform the following steps a Select Enter Setups to access the Axis Setups dialog Select I O Status Monitor and press Execute to view the I O Status Monitor which displays the fault c Correct any fault conditions Refer to Error Messages and Error Output on page 5 4 for diagnostic assistance d Close the I O Status Monitot e Select Cancel to exit the Axis Setups dialog f Double click the Reset Drive block in the Online Manager command window to reset the ULTRA Plus g Verify the STATUS LED is green It the STATUS LED is red return to Step a 11 Verify the fan is operating by checking that air is blowing from the top of the ULTRA Plus PDM 12 Disable the ULTRA Plus PDM by performing one of the following Turn the Enable input OFF or Double click on the Feedback block to access the Feedback dialog Set State OFF and select Execute Select Cancel to exit the dialog 13 Select Enter Setups to access the Axis Setups dialog from the Online Manager window 14 Verity the encoder increments and decrements properly as follows a Select Encoder Test and Execute from the Axis Setups dialog to display the Encoder Test dialog b Select Zero Counts to reset the Count value to 0 c Rotate the motor shaft clockwise and verify that the Count value increases Rotat
55. signal names The step and direction inputs require a source to drive a 10 mA load at 5 VDC TTL levels are compatible as long as the input current is sufficient These optically isolated inputs are suitable for open collector drivers on the inputs The source of the step and direction signals must provide power for the opto isolators as well as step and direction signals The figure below illustrates the connections for active high and active low signals to the step and direction inputs Connector Pin Signal Name P4 Encoder input 2 8 DIR 11 STEP 12 STEP 13 DIR 15 Shield Figure 3 23 Step and direction input connections Step and Direction Active High Step and Direction Active Low Indexer POSITIONING MODULE Indexer POSITIONING MODULE Step 470 P4 11 Step 470 P4 12 i Dir 470 P4 13 e Je ES Step Dir Indexer Common Publication 1398 5 1 January 2000 3 38 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 The input resistance provides the proper current limit for a 5 VDC signal External resistance in series with the step and direction lines to limit current to 10 mA allows operation with voltages greater than 5 VDC 1 8 RE 0 47 10 NEU RE External resistance Vcc Signal Voltage The step input is active low and will accept a square wave input with a maximum frequency of 800 kHz The direction
56. the STATUS LED is red return to Step a Verify the fan is operating by checking that air is blowing from the top of the ULTRA Plus PDM Disable the ULTRA Plus PDM by performing one of the following Turn the Enable input OFF or Double click on the Feedback block to access the Feedback dialog Set State OFF and select Execute Select Cancel to exit the dialog Select Enter Setups to access the Axis Setups dialog from the Online Manager window Verify the encoder increments and decrements properly as follows Select Encoder Test and Execute from the Axis Setups dialog to display the Encoder Test dialog Select Zero Counts to reset the Count value to 0 Rotate the motor shaft clockwise and verify that the Count value increases Rotate the motor shaft counterclockwise and verify that the Count value decreases Publication 1398 5 1 January 2000 4 4 Apply Power for the First Time 1398 PDM 25 50 100 and 150 Publication 1398 5 1 January 2000 e Select Cancel to exit the Encoder dialog 14 Select Close to exit the Axis Setups window 15 Enable the ULTRA Plus PDM by performing one of the following Turn the Enable input ON or Double click on the Feedback block set State ON and select Execute Select Cancel to exit the dialog 16 Verity the motor is stationary and has holding torque 17 Command motion and verify the motor rotates in the proper direction by performing one of the following steps
57. the coupling mechanism between the source and victim This can be achieved by filtering shielding and grounding Publication 1398 5 1 January 2000 2 38 Install the ULTRA Plus Components Publication 1398 5 1 January 2000 Filtering As mentioned above high frequency energy can be coupled between circuits via radiation or conduction The AC power wiring is one of the most important paths for both types of coupling mechanisms The AC line can conduct noise into the PDM from other devices or it can conduct noise directly from the PDM into other devices It can also act as an antenna and transmit or receive radiated noise between the PDM and other devices One method to improve the EMC characteristics of a PDM is to use an isolation AC power transformer to feed the amplifier its input power This minimizes inrush currents on power up and provides electrical isolation In addition it provides common mode filtering although the effect is limited in frequency by the interwinding capacitance Use of a Faraday shield between the windings can increase the common mode rejection bandwidth shield terminated to ground or provide differential mode shielding shield terminated to the winding Common mode noise is present on all conductors IMPORTANT ode eis n presento a i referenced to ground Differential mode noise is present on one conductor referenced to another conductor An alternative is to use AC
58. virtually unnecessary The primary consideration is to ensure that the fans are operational and ULTRA Plus PDM is operated in a properly sized and ventilated enclosure with proper fusing The GML and PSM each have LEDs on the front These LEDs provide a first level of diagnostics Positioning Drive Module STATUS LED All GMLs have a STATUS LED on the top front right hand corner This LED may appear green red or opaque OFF Green The LED on the ULTRA Plus PDM indicates the present status of the GML During normal operation when no fault conditions exist this LED is green This LED turns red to indicate that the GML has detected a fault Red If a fault is detected the LED turning red indicates there is a fault in the system This does not indicate that the GML should be replaced immediately many fault conditions are caused by problems external to the GML The specific fault information is available from the serial ports Fault messages are Publication 1398 5 1 January 2000 5 2 Check for Problems in the System Publication 1398 5 1 January 2000 displayed on the operator terminal screen if the operator terminal is present The LED labeled SYS FAULT on the operator terminal also will turn on red to indicate that a fault has occurred Not lit OFF When power to the GML is off the STATUS LED is not lit If the GML DC BUS LED is ON and the STATUS LED is OFF there may be a failure in the logic power supply
59. 00 inside front cover 3 50 0 65 88 9 16 5 CIC 5 05 6 00 128 3 152 4 y qu EE 2 GASKET Install the ULTRA Plus PDM Components 2 19 Operator Terminal Figure 2 13 and Figure 2 14 on page 2 20 illustrate the dimensions of the two available Operator Terminals All dimensions are in inches mm Allow fifty millimeters two inches clearance above and below the Operator Terminal for airflow and 100 millimeters four inches clearance behind to allow for cable connectots Refer to Specifications on page A 1 for additional technical information Figure 2 13 Operator Terminal 1398 HMI 002 Dimensions 10 50 266 7 2 4 C pisPLAY L svsraur jcow 1 X2 X3 X4 Publication 1398 5 1 January 2000 2 20 Install the ULTRA Plus Components Figure 2 14 Operator Terminal 1398 HMI 003 Dimensions GASKET SUPPLIED 8 11 3 86 3 86 206 0 WITH UNIT 98 0 98 0 Eo F2 F3 F4 6 89 CS 4 ENTER 740 123456789 10 199 0 i 6 egal Eanna o o Notused 24VDC RS 232 connector 3 28 183 25
60. 00 and 150 Publication 1398 5 1 January 2000 Specifications 1398 PDM 10 20 30 75 and 150B Specifications Continued Drive 1398 Module PDM 10 Type 1d Relative humidity 5 to 95 non condensing 1398 PDM 150B 39 External Shunt Resistor P N 9101 1079 Continuous 200W Shunt Power Peak Shunt 6000 W Power 1398 PDM 25 50 100 and 150 Specifications Positioning 1398 1398 1398 1398 Drive Module PDM 25 PDM 50 PDM 100 PDM 150 Peak Output 25 amps 50 amps 100 amps 150 amps Current Phase Continuous 20 amps 40 amps 50 amps 65 amps Output Current Phase Continuous 4 kW 8 kW 10 kW 12 kW Output Power Physical Specifications Weight 15 lb 15 Ib 15 lb 21 Ib 5 kg 5 kg 5 kg 10 kg Operating 32 to 122 F 0 to 50 C Temperature Storage 40 to 176 F 40 to 80 C Temperature Relative 5 to 95 non condensing humidity External Shunt Modules Continuous 200 W 900W Shunt Power Peak Shunt 6000 W 10kW Power Power Supply 1398 PSM 50 1398 PSM 125 Module Line Voltage 100 to 240 100 to 240 VAC Input VAC 50 60 Hz Operator Terminals Specifications 3 1398 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 C
61. 1 January 2000 Figure 2 2 Three PhaseTransformer Load Regulation Curves Install the ULTRA Plus Components 2 7 BUS VOLTAGE VDC 330 320 310 300 290 280 270 260 250 3 PHASE TRANSFORMER SECONDARY VOLTAGE VERSUS DC BUS CURRENT AND CORRESPONDING DC BUS VOLTAGE FOR 3 6 12 AND 18 kVA TRANSFORMERS 233 226 219 212 NOTES N 205 2 18 KVA TRANSFORMER SECONDARY VOLTAGE VAC RMS LINE TO LINE 3 PHASE 198 IN AN 191 6 kVA 184 10 20 3 kVA 40 50 60 70 80 BUS CURRENT ADC 90 TO 177 7 1N DC BUS VOLTAGE AND CURRENT IS MEASURED AT POS amp NEG OUTPUT TERMINALS OF THE POWER SUPPLY MODULE 2 CURVES SHOW REDUCTION IN TRANSFORMER SECONDARY VOLTAGE INTERNAL LOSSES AS BUS CURRENT LOAD INCREASES 3 ALL DATA TAKEN WITH TRANSFORMER PRIMARY VOLTAGE HELD WIRED FOR 230 VAC LINE TO LINE NO LOAD RELIANCE MOTION CONTROL 3 PHASE TRANSFORMERS PART NUMBER kVA 0020 5091 001 3 0020 5091 002 6 0020 5091 003 12 0020 5091 004 18 D THE DRIVE MODULE DC BUS VOLTAGE DUE TO TRANSFORMER 480 VAC 3 PHASE LINE TO LINE 60 Hz AND WITH SECONDARY 20625 JL UPDATE TITLE BLOCK B 19866 C 19960 16383 BC 8 5 88 JH RELEASED ECO BY REV UNLESS OTHERWISE SPECIFIED REVISION DESCRIPTION DATE DRAWN BY DESIGN ENGR C
62. 15 Operator Terminals nica cues shel eet cepa pa NER Dee a 3 16 Power Connections 1398 1 002 3 16 Power Connections 1398 1 005 3 17 Motors zat Ou eee M ere are eR UE 3 18 Power GConnectOns oaa cd A ea eR EE 3 18 Shield Termination 3 19 Digital Inputs and 3 20 IP 24V Sourcing ciens duce eta o C Ret ats na 3 23 Digtal Apus esto Oe Veit Oboe pan 3 25 Digtal Outputs 4 co vesc eae he paar erii d 3 27 Connecting Inputs and Outputs 3 27 AnalosInput 22 23 0 ben RR iade RES Dr Rd 3 28 Analog CUED aa Mid dro dd coi Mea ded Da AA MJ 3 29 Monitot Outputs ter io a eek rcd te 3 29 Ready Relay 3 30 Enabled Relay Qutp t cain a oe eh etude ne niaurus 3 31 Encoder ov ee bUUU ua Wee d AIT ERA 3 33 p WSOP gre ORO S d edet tM x 3 35 Slaving an ULTRA Plus PDM to 3 36 Step and Direction 1 3 37 Serial Port 3 39 Host Computers 2a yas 3 39 Operator Terminal ssis 0o OS eot ehe toe e bel 3 41 Nebvotking 2122s ge aee 43 e IW RAI TU EP TuS 3 44 edu Errat oan E le 3 49 Apply Power for the First Time Check f
63. 1677 XXX or angle motor connector 9101 1679 XXX 1398 PDM 10 20 30 or 75 for H 6000 F 6000 9101 2179 XXX Motor Power Cable ULTRA Plus to 1 0 Conversion Card 3 foot Cable 44 0141 003 ULTRA Plus to I F 24V Conversion Card 10 foot 44 0141 010 Cable t RS 232 cables are available in 3m and 7m 10 and 25 ft lengths only Publication 1398 5 1 January 2000 Options and Accessories B 5 Transformers This table lists single and three phase transformers to be used with the ULTRA Plus PDMs Description Alternate Number 3KVAthree phase transformer 0020 509 001 6 KVA three phase transformer 0020 5091 002 12 KVA three phase transformer 0020 5091 003 18 KVA three phase transformer 0020 5091 004 Auxiliary PSM transformer 0020 5093 3 KVA single phase transformer 1398 PDM 10 20 30 or 75 0020 5097 Motor Identification H 4030 Q H 00 AA A A A A FACTORY DESIGNATED SPECIAL OPTIONS AA STANDARD FLANGE AN NEMAS56C FLANGE OPTIONS 00 STANDARD 01 90 BRAKE 04 24 OPTICAL ENCODER LINE COUNT F 1000 H 2000 STANDARD J 2500 K 5000 L 500 M 3000 N 1500 MOTOR WINDING Kg DESIGNATOR NOTE SPECIAL ORDER WINDINGS AVAILABLE FRAME SIZE Series DESIGNATOR F FERRITE MAGNET H LOW INERTIA N NEMA Not all line counts are available on all motors Publication 1398 5 1 January 2000 B 6 Options and Accessories
64. 2 23 Location 2 23 Personality Module Fault 5 7 POS Track Overflow error 5 6 Positioning Drive Module LEDs 5 1 Mounting 2 14 Power cable Motor 2 33 Shielding 3 19 Power losses 2 3 Power Module Fault 5 6 Power supply Auxiliary 1 7 Connections 3 16 Digital 1 0 3 20 I F 24V Conversion Card 3 24 Internal Logic 3 5 Isolating input power 3 1 Location 2 14 Module mounting 2 14 Motor connections 3 18 Operating environment 2 2 Operator Terminal 3 17 Power supply module 1 5 PRECISION Out of Range error 5 5 Profile Calculation error 5 5 Program Running output Assignable function 3 27 Programmable Monitor 3 29 0 Quadrature signals 3 31 3 35 R RAM R W Fault 5 7 Rasmi AC Line filter 2 39 Ready output 3 30 Reentrancy Fault error 5 5 Regulatory requirements 2 27 Related documentation P 3 Reverse Limit 3 26 Roxburgh AC line filter 2 39 RS 232 3 42 3 46 Daisy chain network 3 39 Jumper 3 43 RS 422 Index 5 Multi drop network 3 39 3 44 3 46 Operator Terminal connections 3 47 3 48 S Safety ground 2 35 2 42 Schaffner AC Line filter 2 39 S Curve calculation error 5 5 Serial 1 Auxiliary P7 3 39 3 41 Serial 2 Busy error 5 6 Computer P6 3 39 Shielded cable Encoder 3 35 Motor 3 4 Shunt Resistor Connection Diagram 2 17 2 18 Internal in some PDMs 3 13 Mounting 2 17 2 18 Single Point Ground Types 2 42 Sinking active low 1 0 2 34 Sourcing active high 1 0 2 34 Specifications 1398 PDM 25 50 100 and 150 A 2 1398
65. 24V Sourcing Conversion Card The ULTRA Plus PDM has sinking active low I O which is common in the US Sourcing active high I Os are preferred in Europe Rockwell Automation offers a DIN rail mounted card which converts the I O from sinking to sourcing This card must be mounted in the same enclosure as the PDM IMPORTANT A user supplied external 24VDC power supply is required for this option ULTRA Plus PDM I F Conversion Card Description Alternate Number I F Conversion Card 24V Sourcing 9103 0152 Cable I F Conversion Card 3ft 1m 44 0141 003 Cable I F Conversion Card 10ft 3m 44 0141 010 1 Required for compliance with the European Union Low Voltage Directive LVD It must be mounted in the same enclosure as ULTRA Plus PDM Install the ULTRA Plus PDM Components 2 35 Emergency Stop Contactor Some machines require that a contactor be inserted between the motor and PDM for emergency stop purposes A hazard analysis of the machine will determine if this is needed If used the contactor must not simply break the motor current it must switch a 3 phase resistive load in parallel with the motor windings The three resistors will provide dynamic braking and a category zero stop The resistors also can prevent continuous arcing at the main contacts when breaking DC currents such as when the motor is at stall Simply breaking the motor current can result in very high voltages due to motor inductance which can
66. 3 13 79 5 6 26 b 7 27 159 0 184 7 460 0 14 8 3 86 3 5 98 0 RECOMMENDED PANEL CUTOUT DIMENSIONS Publication 1398 5 1 January 2000 Install the ULTRA Plus PDM Components 2 21 I F Conversion Card 24VDC Sourcing Figure 2 15 illustrates the dimensions of the I F 24V Conversion Card and the DIN mounting panel All dimensions are in millimeters inches are approximate conversions The conversion card must be mounted in the same enclosure as the ULTRA Plus PDM to comply with the EU LVD directive Figure 2 15 I F 24 Volt Sourcing Conversion Card Mounting Dimensions 000000000000000000000000 ip ama ame ame ame dme ss om mon meme gnam 000000000000000000000000 47 0 4 1 9 gt p 169 0 4 6 7 77 0 1 9 75 gt 0 3 No 42 5 85 0 1 7 3 4 _ 6 7 gt Publication 1398 5 1 January 2000 2 22 Install the ULTRA Plus Components PDM Fusing Requirements Publication 1398 5 1 January 2000 Fusing for the ULTRA Plus PDMs differs because of the separate power supply for some models Short Circuit Protection In the United States the National Electrical Code specifies that fuse selection must be based on the motor s Full Load Amperage FLA which is not to be confused with the PDM input current The largest fuse allowed under any circumstanc
67. 36 30 36A 9101 1389 48 0430 MDF50 1 50A 9101 1388 NONE MDF350 30 50A 9101 1575 NONE MDF370 36 70A 9101 1390 NONE MIF10 16 10A 9101 1517 NONE MIF23 10 23 9101 1518 NONE 1 MDF50 amp MDF370 can be used for multiple PDMs A supply filter for the auxiliary supply is unnecessary as a filter 1s included in the 1398 PD M 10 20 30 75 and 150B ATTENTION Shielded power cables must be grounded at a minimum of one point for safety Failure to observe this safety procedure could result in personal injury or damage to equipment Install the ULTRA Plus PDM Components 2 31 Bonding Your System Bonding is the practice of connecting metal chassis assemblies frames shields and enclosures to reduce the effects of electromagnetic interference EMI Unless specified most paints are not conductive and they act as insulators To achieve a good bond between modules and the sub panel surfaces need to be paint free or plated Bonding metal surfaces creates a low impedance exit path for high frequency energy Figure 2 20 illustrates recommended bonding practices for painted panels enclosures and mounting brackets Improper bonding blocks that direct exit path and allows high frequency energy to travel elsewhere in the cabinet Excessive high frequency energy can effect the operation of other microprocessor controlled equipment Figure 2 20 Recommended bonding practices Stud mounting the sub pan
68. 5 is used with a three phase system This factor should minimize the effects of the secondary line voltage sagging in the transformer during peak current periods Speed RPM x 1 in 746 Watts x KVA RNA 63 025 HP lt 1000Watts IMPORTANT If you are using the Rockwell Automation Allen Bradley system sizing program the average speed and average torque data has already been calculated and can be used in the above equation If you are not sure of the exact speed and torque in your application another approach is to look at the speed torque curve for your PDM motor combination and use the values for the worst case continuous speed and torque Install the ULTRA Plus Components 2 5 Sizing a transformer with an 1398 PDM 30 and H 4075 motor IMPORTANT The speed torque curve information is based module input voltage of 230 VAC For 115 VAC input voltage the maximum speed is reduced by half 3000RPM x 751b in 746Watts KVA 63 025 HP 0 Transformer Size 5 3KVA Publication 1398 5 1 January 2000 2 6 Install the ULTRA Plus PDM Components Figure 2 1 Single PhaseTransformer Load Regulation Curve 330 320 310 300 290 280 270 BUS VOLTAGE VDC 260 250 240 230 220 210 200 VERSUS DC BUS CURRENT 3 kVA TRANSFORMER 1 PHASE TRANSFORMER SECONDARY VOLTAGE AND CORRESPONDING DC BUS VOLTAGE
69. 7 and U87 should be replaced 52 TEXT Checksum The text EPROM failed the checksum test at power up The text EPROM U57 should be replaced Publication 1398 5 1 January 2000 5 8 Check for Problems in the System Publication 1398 5 1 January 2000 Appendix A Specifications 1398 PDM 10 20 30 15 and The tables starting below provide specifications for the ULTRA Plus PDMs 150B and their accessories 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 Type 19 19 19 39 Peak Output 10 amps 20 amps 30 amps 75 amps 150 amps Current Phase Continuous 5 amps 10 amps 15 amps 35 amps 65 amps Output Current Phase Continuous 1 kW 2 kW 3 kW 7 kW 15 kW Output Power Electrical Specifications Line Voltage 100 240 100 240 100 240 100 240 100 240 VAC Input VAC VAC VAC VAC 50 60 Hz Continuous 50 W 50 W 50 W 50 W 180W Shunt Power Peak Shunt 4 5 kW 4 5 kW 4 5 kW 10 kW 19 kW Power Continuous 2 4 kW 2 4 kW 2 4 kW 4 kW 8 kW Shunt External Peak Shunt 6kW 6 kW 6 kW 10 kW 19 kW External Physical Specifications Weight 15 Ib 15 Ib 15 Ib 21 Ib 31 Ib 5 kg 5 kg 5 kg 10 kg 14 kg Operating 32 to 140 F 0 to 50 C Temperature Storage 40 to 176 F 40 to 80 C Temperature Publication 1398 5 1 January 2000 A 2 1398 PDM 25 50 1
70. 8 PSM 50 class R fuses rated 40A and e 1398 PSM 125 class fuses rated 90A Refer to Power Supply Modules on page B 2 for product numbers Personality Module Installation Install the ULTRA Plus PDM Components 2 23 The Personality Module is already installed on the ULTRA Plus PDM The following procedure is to be used if the Personality Module needs to be changed for machine servicing Refer to Figure 2 16 for the location of the Personality Module on the ULTRA Plus PDM logic board Figure 2 16 Location of Personality Module aa Fi 41051 i U10 U10 Personality Module 4 1 swi swi 1398 PDM 10 20 30 75 and 150B 1398 PDM 25 50 100 and 150 LOGIC BOARD LOGIC BOARD component side component side Installing the Personality Module PM ATTENTION Stray electrical discharge can damage the personality module Turn power Off dissipate any stored electrical energy and wear a conductive wrist strap while handling the Personality Module Failure to observe this safety procedure could result in damage to the equipment 1 Check that power to the ULTRA Plus PDM is OFF 1398 PDM 10 20 30 75 and 150B Measure voltage between ULTRA Plus PDM terminals marked L1 and L2 N L1 L2 N and L3 for ULTRA Plus PDM 75 to ensure incoming power is OFE Also measure voltage between terminals marked L1 AUX and L2 N AUX if used to ensure power is OFE The green DC BU
71. 98 5 1 January 2000 3 20 Wire the ULTRA Plus Components Digital Inputs and Outputs Publication 1398 5 1 January 2000 Figure 3 15 Motor power EMC shield connection La shield conductive e cable jacket area F g Refer to Cables on page 3 49 for a selection of shielded motor power cables This section covers the control and interface connections between the PDM and the rest of the system This includes Digital I O Analog I O Relay Outputs Encoders Step and direction Inputs and Serial Ports Refer to PDM control connections on page 3 21 illustrating all control connections to the PDM See Figure 3 17 on page 3 22 showing the ULTRA Plus PDM which provides 16 optically isolated inputs and eight optically isolated outputs for machine control and interface General purpose I O uses 24VDC supply voltage The PDM has an internal 24VDC 500 mA power supply for this purpose isolated from the logic common The 24VDC Common must be tied to machine ground to provide a common ground reference The 1A fuse F1 on the PDM protects the internal 24 VDC supply Pin 1 of the interface connectors P1 P2 and P3 is located at the bottom of the connector and is marked on the front of the PDM IMPORTANT The user may supply external 24 VDC power by removing wire jumpers W3 and W4 on the PDM logic board and connecting the external supply to the 24 VDC and 24 volt common on
72. B 7 This table lists motor shaft seal kits available for the H F and N Series 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 Shaft seal kit H 4000 motor 0041 5058 47 mm x 20 mm x 7 mm Shaft seal kit H 6000 motor 0041 5059 80 mm x 38 mm x 8 mm Shaft seal kit H 8000 motor 0041 5053 005 85 mm x 45 mm x 8 mm W Shaft seal kit F 4000 motor 0041 5060 1 437 inch x 0 875 inch x 0 25 inch Shaft seal kit F 6000 motor 0041 5061 2 125 inch x 1 438 inch x 0 31 inch Shaft seal kit N 2300 motor mm in 0041 5068 0 035 x 0 001 x 0 005 0 875 x 0 250 x 0 125 Shaft seal kit N 3400 motor mm in 0041 5069 0 044 x 0 019 x 0 010 1 125 x 0 500 x 0 250 Shaft seal kit N 4200 motor mm in 0041 5070 0 044 x 0 025 x 0 010 1 125 x 0 625 x 0 250 Shaft seal kit N 5600 motor mm in 0041 5071 0 054 x 0 030 x 0 010 1 375 x 0 750 x 0 250 Note Shaft seals are manufactured to inch dimensions Millimeter dimensions are conversions from inches Shaft seals require a lubricant to reduce wear Lubricant is provided with kit Publication 1398 5 1 January 2000 B 8 Options and Accessories Publication 1398 5 1 January 2000 A Absolute positioning 3 5 3 7 AC 3 phase power 3 1 Coils suppressed with RC filters 2 45 Line filter Installation 2 40 2 41 Order B 3 Rasm
73. Block TB 1 and the Motor The last three digits indicate a standard cable length 010 10ft 3m 025 25ft 7m 050 50ft 15m and 075 75ft 23m PDM Motor Description Alternate Number 1398 PDM 10 H 2000 or H 3000 Motor 9101 1080 XXX 20 30 or 75 1398 PDM 10 H 4000 or F 4000 Motor 9101 1081 XXX 20 30 or 75 ULTRA Series F 2000 3000 or H 2000 3000 9101 1381 XXX ULTRA Series F 4000 or H 4000 9101 1382 XXX ULTRA Series F 6000 or H 6000 9101 1383 XXX ULTRA Series Programming Terminal Cable RS 232 P6 1 9101 2024 XXX ULTRA Series Operator Terminal Cable RS 232 9101 2025 XXX P7 ULTRA Series Motor Encoder Cable P5 9101 2027 XXX Connector ULTRA Series Control Station Cable 9101 2030 010 ULTRA Series Encoder Cable 9101 2031 XXX 1398 PDM 25 50 100 or 150 for 3000 Motor 9101 0250 XXX Power Cable with Motor Connector 1398 PDM 25 50 100 or 150 for H 4000 F 4000 9101 0251 XXX Motor Power Cable 1398 PDM 25 50 100 or 150 for H 6000 F 6000 9101 0252 XXX Motor Power Cable 1398 PDM 25 50 100 or 150 for H 8000 Motor 9101 0253 XXX Power Cable N Series Motor Power Cable 9101 1676 XXX ULTRA Series P4 to P4 Master Follower Cable 9101 2127 002 ULTRA Series Motor Encoder Cable P5 9101 2135 025 or Connector with right angle motor connector 9101 2135 050 N Series Encoder Cable P5 Connector with right 9101
74. D lt pe 6 lt Vs 7 NU CONN Publication 1398 5 1 January 2000 3 50 POSITIONING MODULE CONNECTOR P4 15 PIN MALE HIGH DENSITY Publication 1398 5 1 January 2000 Wire the ULTRA Plus PDM Components Figure 3 37 ULTRA Plus P4 or P5 to Auxiliary Encoder Unterminated P N 9101 2031 POSITIONING MODULE CONNECTOR P4 STEP STEP DIR d DIR 4 5V 4 COM i A 4 A INDEXER ENCODER CONNECTIONS INDEXER ENCODER CONNECTIONS P4 11 lt BLACK STEP P4 12 ORANGE LN STEP P4 8 BROWN DIR P4 13 ERES v DIR 4 14 WHILE 45V P4 7 Y COM P4 1 GREEN A P4 2 A P4 3 BLUE B BiA BLACK Y B E YELLOW A P4 10 BLACK y l P4 9 RER 5V P4 6 y COM P4 15 WA Wire the ULTRA Plus Components 3 51 Figure 3 38 ULTRA Plus P4 to P4 2 foot P N 9101 2127 MASTER AXIS SLAVE AXIS CONNECTOR LJ CONNECTOR P4 P4 15 PIN MALE 15 PIN MALE HIGH DENSITY HIGH DENSITY MASTER AXIS SLAVE AXIS CONNECTOR CONNECTOR P4 P4 At lt PAT P4 1 5 lt 4 2 v 4 2 gt A 4 P4 3 4 3 5 B B ___ 4 4 Y P4 4 xB 1 lt 4 5 4 5 gt 1 l 4 P4 10 Y P4 10 gt E SHIELD lt P4 15 e VS Figure 3 39 ULTRA Plus PDM P5 to or F Series Motor Encoder P N 9101 2027
75. DC Bus Power 1398 PDM 25 50 100 and 150 Above Terminal Block 1 is a DC BUS LED This LED indicates that the DC Bus is charged LED Label LED Color Description PHASE LOSS RED OFF OK Normal Operation ON Loss of one phase of incoming AC power The PSM will continue to run on two phases and the fault LED ON OVERTEMP RED OFF OK Normal Operation ON Excessive main heatsink temperature DISABLED RED OFF Not disabled Normal Operation ON DC bus disabled by external enable input PSM READY GREEN OFF No DC bus voltage ON DC bus charged Normal Operation If none of the LEDs are ON either red or green and incoming line voltages are found to be correct there may be a PSM failure Replace the PSM with another module Operator Terminal Status Screens Personality Module Default Initialization Check for Problems in the System 5 3 The ULTRA Plus PDM has 9 status screens that may be accessed by pressing the STATUS key Each time the STATUS key is pressed the next status screen is displayed The BACKSPACE key can be used to scroll backwards through the status screens The CLEAR Key will remove the status display or clear the peak values Variable Name Description Refer to the GML Programming Reference for detailed information about each flag and variable Status Flags ATHOME HSEQCPL INPOSN ERROR XFER READY ENABLED PAUSE Program Status Program Number
76. EQUIRED 6 32 STUD NUT AND WASHER SUPPLIED FOR CUSTOMER GROUNDING A LITTLEFUSE PART NUMBER CCMR 4 5 a Terminal gt i TERMINAL alleles e f INCHES T mm AIR INTAKE Publication 1398 5 1 January 2000 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 At terminal block remove jumper installed at factory for internal shunt clearance on all sides of shunt module EXTERNAL SHUNT WARNING High Voltage May Exist Up To Five Minutes 100 240 VAC 50 60 Hz There must be 155mm 6 1 in of clearance on all sides of B shunt module STATUS T Use twisted conductors 2 twists per foot minimum or a shielded twisted pair MGTORENCODER 9 8 AWG 8 4 mm 105 C 600V wire Max Length 3 05 m 10 ft for each wire JE Connect wires to terminal bloc Publication 1398 5 1 January 20
77. HKR DATE DATE DO NOT SCALE DRAW BREAK ALL EDGES 02 FILLETS AND ROUNDS DIMENSIONS ARE IN INCHES NG BC 8 5 88 JH 8 5 88 DIAG XFMR LOAD REG MAX 02 R MAX TOLERANCE ON ANGLES 1ANGLES FRACTIONS 1 64 DECIMALS XX 020 XXX 010 PART NO 9101 0132 SCALE DWG SIZE SHEET 1 1 1 of 1 Publication 1398 5 1 January 2000 2 8 Install the ULTRA Plus PDM Components Figure 2 3 Single PhaseTransformer Outline Diagram 1 4 20 GROUND STUD 6 35 DIA TRANSFORMER CHASSIS 3 32 0 06 84 1 5 w SECONDARY CONNECTIONS 2N 8 32 THD BOLTS 4 17 DIA 8 32 THD BOLTS 4 17 DIA 7 CONNECTION INSTRUCTIONS PRIMARY CONNECTIONS 123 NOTES 1 DIMENSIONS ARE IN INCHES mm 2 NRING OR SPADE LUG CONNECTORS NOT PROVIDED ARE REQUIRED FOR WIRING CONNECTIONS TO TRANSFORMER TERMINAL STRIPS MOUNTING HOLES 0 28 0 02 DIA 4 7 1 05 3kVA TRANSFORMER ELECTRO CRAFT P N 0020 5097 CLEARANCE RECOMMENDED FOR ACCESS TO WIRING BREAK ALL EDGES 02 FILLETS AND ROUNDS TOLERANCE ON 1 CHG DTEXT ET 19866 SJ UPDATED TITLE BLOCK 12 20 91 BC A 17320 BC RELEASED 2 23 89 JH REV REVISION DESCRIPTION DATE CHKR UNLESS OTHERWISE SPECIFIED PRAWN ey DATE DESIGN voi
78. If compiled with the debug option ON the instruction that is executing will also be displayed Position Status PCMD POSN FE Velocity Status VCMD FVEL1 VEL2 Input Status Inputs 1 through 16 Inputs 17 through 48 if an Expansion 1 0 or Memory and Expansion 1 0 card is installed Output Status Outputs 1 through 8 Outputs 9 through 24 if an Expansion 1 0 or Memory and Expansion 1 0 card is installed Current Status ICMD IAVE IN PEAK CURRENT Commanded PGEN PJOG PEXT Position Status Peak Status PFE PVEL1 PICMD All position values displayed on the Operator Terminal status screens are in user units velocity values are in user units per timebase and current torque variables are in amps An inoperable NVRAM may be recovered by initializing the PM to the factory default settings This command zeroes the NVRAM and performs a series of NVRAM integrity tests before installing factory default settings IMPORTANT This selection erases the existing Personality Module parameters and motion programs If the PM was programmed be prepared to restore the PM settings and motion programs from your backup files See section Apply Power for the First Time for instructions to initialize the PM with PDM and motor configuration data Publication 1398 5 1 January 2000 5 4 for Problems in the System Error Messages and Error Output Publication 1398 5 1 January 2000 To reinitialize a Persona
79. L CIRCUIT TRANSFORMER SECONDARY THEREFORE THE PSM INPUT POWER MUST BE ISOLATED FROM anD FROM THE 480V INPUT LINE THE THREE PHASE TRANSFORMER PROVIDES THE ISOLATION AND ALSO STEPS DOWN THE VOLTAGE 9N IN THIS EXAMPLE THE PSM INPUT POWER IS SUPPLIED DIRECTLY FROM THE 3 PHASE LINE DIAGRAM OUTLINE amp CONNECTION THEREFORE THE PSM AUX INPUT POWER MUST BE ISOLATED FROM FROM THE 240V INPUT LINE IN THIS EXAMPLE THE PSM AUX TRANSFORMER SECONDARY MUST NOTBEC NNECTEDTO PSM AUX 1398 PDM 25 50 100 and 150 AA SIZE TRANSFORMER FOR 400 VA PSM AUX CUSTOMER CONTROL CIRCUIT REQUIREMENTS 9101 0134 REV D1 Publication 1398 5 1 January 2000 PSM Interface Logic Wire the ULTRA Plus Components 3 9 The Status and Enable signals on the PSM are indicated in the following table that interface the PSM with the PDM or another control illustrates typical internal circuitry for the interface connections Figure 3 7 shows external connections of the PDMs PSM Connector Pin Signal Name P1 1 Status General 2 Status Purpose 3 PSM Enable Inputs Outputs 4 PSM Enable Figure 3 6 PSM interface internal circuit examples TBI POWER SUPPLY MODULE STATUS RFI EXTERNAL ENABLE INPUT ENABLE H NO 22 CONN ENABLE 4 1 5K OHM V 0 5 WATT BVA JUMPER W1 Figure 3 7 PSM interface external connection examples SAMPLE
80. L Ultra Software Description 1 3 Installation 4 1 Ground Ground bus bar 2 42 Safety ground 2 42 Single Point Ground Types 2 42 Torroid encoder shielding 2 45 Index 3 H Heat Heat Losses for sizing enclosures 2 3 Heat Sink Overtemperature error 5 6 High frequency energy 2 32 Home Home Command 3 26 Home Not Defined error 5 5 Home Sequence Complete output 3 27 Home Switch 3 26 Host PLC 3 28 I F Conversion Card 24VDC Sourcing 2 21 3 23 1 0 24VDC Sourcing 3 23 lavg Fault 5 6 In Position output Assignable function 3 27 Incremental encoder 3 31 3 35 Input Isolating input power 3 1 Step and direction 3 37 Installation EMC Motors and Cables 2 33 Installing for European Union Compliance 2 28 2 33 Emergency Stop Contactor 2 35 I F Conversion Card 2 34 Motor guidelines 2 16 Internal Internal logic power supply 3 5 3 7 Internal shunt 3 12 Invalid Opcode error 5 5 IP4X Enclosure 2 33 J Jog Forward 3 26 Reverse 3 26 Jumper PDM internal power supply 2 26 PDM Internal shunt connection 2 17 Publication 1398 5 1 January 2000 4 Index Publication 1398 5 1 January 2000 K KFF Out of Range error 5 5 Out of Range error 5 5 KP Out of Range error 5 5 KPZ Out of Range error 5 5 L Lead length EMC requirements 2 29 LED 5 1 Limit Forward 3 25 3 26 Reverse 3 25 3 26 Logic Supply Fault 5 6 LOOP Count Out of Range error 5 5 Variable Range error 5 5 Manuals 1 5 Math Overflow error 5 5
81. LED will light but the power supply is not disabled Extended operation of this product with an AC phase input missing will reduce the life of the product Refer to Power Wiring Diagram 1398 PDM 25 50 100 and 100 on page 3 5 for details This drawing shows an optional AC line filter and shielded motor cable These can be used in conjunction with the grounded metal enclosure to meet the Electromagnetic Compatibility requirements of the European Machinery Directive Refer to Electromagnetic Compatibility on page 2 36 for a discussion of EMC Wire the ULTRA Plus Components 3 7 DC Bus Power The DC bus from the PSM supplies power to the ULTRA Plus PDM 1398 PDM 25 50 100 and 150 The PSM DC bus must be connected as shown in Power Wiring Diagram Figure 3 4 on page 3 5 with the PSM in the center using the connection wires provided ATTENTION Do not substitute the DC bus wires provided with other wires Failure to observe this precaution may result in damage to the equipment Auxiliary Logic Supply An auxiliary power supply module PSM AUX is available to supply DC power to the internal logic supplies of up to four ULTRA Plus PDMs if the PSM is OFF The PSM AUX uses single phase 115 VAC power as the input The PSM AUX option is useful if ULTRA Plus PDM internal logic power must stay on even when the motor supply the PSM is off Absolute positioning is one example of when the PSM AUX would
82. LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND MAY REQUIRE DISCHARGE TIME UPON POWER REMOVAL DIMENSIONS ARE IN INCHES POWER WI RI NG THE AUX INPUT HAS AN INTERNAL FILTER WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE THE COMMON GROUND BUS BAR SHOULD BREAK ALL EDGES 02 MAX BE AS CLOSE TO THE DRIVE AS POSSIBLE FILLETS AND ROUNDS 02 R MAX 1398 PDM 150B TOLERANCE ON PART NO WIRE SIZES ARE MINIMUM RECOMMENDED VALUES THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED ANGLES 1 FRACTIONS 164 9101 2236 DECIMALS 020 SCALE DWGSIZE SHEET 010 N A C Ia 1 DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT OR A DRIVE FAULT WILL OCCUR MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE TERMINATE THE MOTOR POWER CABLE SHIELD BY CLAMPING IT TO THE DRIVE WITH THE BRACKET PROVIDED THIS BRACKET CAN BE USED FOR STRAIN RELIEF IF NON SHIELDED CABLES ARE USED SNUG BRACKET SCREWS DO NOT OVERTIGHTEN NEVER TORQUE OVER 10 LB IN The above drawings describe an optional AC line filter and shielded motor cable These can be used in conjunction with the grounded metal enclosure to meet the Electromagnetic Compatibility requirements of the European Machinery Directive Refer to Electromagnetic Compatibility on page 2 36 for a discussion of EMC A power cable with a
83. LKD 20 or KLM 20 PSM 125 with external shunt 30 Ampere KLKD 30 or KLM 30 DC Bus Terminals 4 Install the PSM cover Publication 1398 5 1 January 2000 3 16 Wire the ULTRA Plus Components Operator Terminals Publication 1398 5 1 January 2000 Power Connections 1398 HMI 002 Figure 3 11 illustrates the power connections to the Operator Terminal 115 220 230 240 VAC single phase 9101 2017 It must be properly grounded to prevent radiating radio frequency noise Figure 3 11 Operator Terminal power connections L1 Le N a GROUND EARTH 115 230 VAC NEUTRAL 115 230 VAC HOT Wire the ULTRA Plus Components 3 17 Power Connections 1398 HMI 003 The ULTRA Plus 1398 HMI 003 Operator Terminal requires a 24 volt power supply rated at 0 5 amps unless otherwise stated on the label Figure 3 12 Operator Terminal connections on back of unit 24 VDC DC COMMON gt 60 1 mglbEgEEG E Gg EB Essais not 1 sed 24VDC RS 232 connector The Operator Terminal requires a power supply capable of supplying a current of 500 mA at a regulated voltage of 24 volts Supplies providing between 18 volts and 30 volts are also suitable The terminal may take as little as 100 mA in certain circumstances so be sure that the chosen power supply can opera
84. MENSIONS ARE IN INCHES BREAK ALL EDGES 02 MAX FILLETS AND ROUNDS 02 R MAX DRAWN E JM DATE DESIGN ENGR 6 3 96 POWER WIRING CONNECTIONS TOLERANCE ON ANGLES 1ANGLES FRACTIONS 1 64 DECIMALS XX 020 00 010 1398 PDM 10 20 and 30 PART NO 9101 2195 SCALE N A SHEET of sinn ch 1 Publication 1398 5 1 January 2000 Wire the ULTRA Plus Components 3 3 Figure 3 2 Power Wiring for 1398 PDM 75 MOTOR POWER WIRES R S T GND MOTOR POWER CONNECTOR INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS MOTOR POWER MINIMUM sen RECOMMENDED AN BRU IQ TERMINALS CURRENT REQUIREMENT MAXIMUM AMPS AC RMS MATING CONNECTOR RECOMMENDED DRIVE TERMINAL S POWER WIRE L4N L1 AUX L2 N AUX 1 0 Amps AC at 115 Volts AC MOTOR CONTACT SIE POWER WIRE R mr eal 0 5 Amps AC at 230 Volts AC GAUGE mm GAUGE mm LiLZINi3 DM PDM 75 28 0 Amps at 100 240 Volts AC Three Phase 60 C COPPER MIN MOTOR ALL 16 AWG 1 5mm AC AUXILIARY 75_ 28 0 Amps at 100 240 Volts AC Single Phase POWER INPUT NOTE POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSH DM PDM 75 L1 L2 N OPTIONAL CURRENT OF 50A FOR THE MAIN INPUT AND 95A FOR THE 12 AWG 3 0mmE 14 AWG 2 5mmE AO AWG2 6rmne AUXILIARY INPUT DUAL ELEMENT TIME DELAY SLOW BLOW FUSES ARE RECOMMENDED FUSE SIZES MUST BE SELECTED ACCORDING LOCAL REGULATIONS
85. MIL STD 461 2 37 Monitor Output 3 29 Motor Compatibility with PDM Control 1 5 Description 1 5 Encoder 3 33 Mating Connectors 1 7 B 6 Mounting 2 14 Ordering Information B 5 Overtemperature error 5 6 Power leads 3 18 Shaft Seal Kits B 7 Shielded power cables 1 7 2 33 2 44 3 19 Thermostat 3 33 Mounting 2 1 Auxiliary PSM Transformer 2 14 Bonding 2 31 Environment 2 2 Motors 2 16 Positioning Drive Module 2 14 Requirements 2 10 Shunt Resistor 2 17 2 18 Ventilation 2 3 National Electrical Code Requirements 2 22 NEMA enclosure 2 2 Noise 2 36 Emission supression diagrams 2 46 Operator terminal suppression 3 48 Problems 2 36 See Bonding 2 31 0 Operating Environment 2 2 Operator Terminal Description 1 6 Installation 2 19 Mounting 2 19 Specifications A 3 Start up Procedure 4 11 Optically isolated inputs 3 25 Ordering Information Cable B 4 Motor Mating Connectors B 6 Motor Shaft Seal Kits B 7 Motors B 5 Transformers B 5 Output Analog Output 3 29 Connecting inputs and outputs 3 27 Enabled Relay output 3 31 Monitor output 3 29 Ready Relay output 3 30 Sinking signal of output 3 27 Pause input 3 25 PDM EMC mounting requirements 2 29 PDM with integral power supply 1 4 PDM with separate power supply 1 4 Peak Overcurrent error 5 7 Personal Computer PC 1 8 Personality Module Description 1 5 Factory Default Initialization 5 3 Initialization PDM 10 20 30 or 75 4 2 PDM 25 50 100 or 150 4 6 Installation
86. N P P disconnected from a load and the shaft key removed Improper wiring or undiscovered shipping damage could result in undesired motor motion Be prepared to remove 4 power if excessive motion occurs ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded during testing and in the final installation 4 9 Apply Power for the First Time 4 9 1 Disconnect motors from the load before applying power This prevents mechanical damage should a fault occur If this is not possible take adequate precautions in case of a fault Disconnect all interface cables from the ULTRA Plus PDM and remove the its cover 1398 PDM 25 50 100 or 150 only Connect the 4 motor wires R S T and ground to the proper ULTRA Plus PDM Install all ULTRA Plus PDM covers and connect all interface cables to the ULTRA Plus PDM Disable each ULTRA Plus PDM by performing one of the following Turn the Enable input OFF or Double click on the Feedback block to access the Feedback dialog Set State OFF and select Execute Select Cancel to exit the dialog Reapply input power and check for proper power up diagnostics as shown by the STATUS LED on each unit Limit the current to the motor as follows Double click the Equation block in the Online Manager command window to access user and system variables and the general purpose outputs Select System Variable Flags from the menu C
87. NECTING DEVICE IS REQUIRED FOR MAINTAINANCE amp SAFETY LOCAL REGULATIONS SHOULD BE OBSERVED IF A GROUNDED NEUTRAL IS USED INSTEAD OF L2 OR L2 AUX ONLY L1 MAY BE SWITCHED OR FUSED N 3 JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT SEE DRAWING 9101 1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS AN CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED BUT NOT TORQUE DRIVE RATED 35 75 AMPS FOR THREE PHASE INPUT 15 50 AMPS FOR SINGLE PHASE INPUT 5 DRIVE RATED 100 240 VAC RMS SINGLE OR THREE PHASE INPUT VOLTAGE 230 VAC STANDARD 6 DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY TN DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT OR A DRIVE FAULT WILL OCCUR 21871 JM RELEASED a 8 MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE REV ECO BY REVISION DESCRIPTION DATE A AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY AND ARE REQUIRED TO MEET THE ONSAS OTRERMOESPECRED TERANE DE DERN E EUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE CAUTION AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND REQUIRE DISCHARGE TIME UPON POWER REMOVAL DO NOT SCALE DRAWING JM 4 19 96 DIMENSIONS ARE IN INCHES e THE AUX INPUT HAS AN INTERNAL FILTER WIRING BE
88. NNECT USING LUG DESIGNED FOR 6 M4 MOUNTING SCREW CABLE ASSEMBLIES 9101 0122 006 ARE PROVIDED WITH EACH PSH AUK TO PROVIDE AUXILIARY POWER FOR UP TO 4 DRIVE MODULES EACH CABLE IS 6 FEET 1 8 METERS LONG DIAGRAM OUTLINE amp CONNECTION DRAWING DRIVE MODULE COVER MUST BE REMOVED FOR CONNECTION OF CABLE TO CONNECTOR P9 ON POWER BOARD A IMPORTANT AUXILIARY POWER SUPPLY MODULE INPUT POWER TO THE PSM AUX MUST BE ISOLATED FROM INPUT POWER TO THE PSM POWER SUPPLY MODULE A PSM AUX ISOLATION TRANSFORMER OR A 3 PHASE ISOLATION TRANSFORMER FOR THE PSM WILL PROVIDE THE REGUIRED ISOLATION SEE SHT 2 OF 2 DOCUMENT NO 9101 0134 REV D1 Publication 1398 5 1 January 2000 2 16 Install the ULTRA Plus PDM Components Publication 1398 5 1 January 2000 Motors The installation and operation of motors should adhere to the following guidelines Do motors that are not properly mounted Attach all motor cables after motor is mounted Mount motor with connectors pointing downward and use a drip loop to keep liquids flowing away from connectors Consider motor case temperature if necessary to safeguard operator and maintenance staff Maximum case temperature is approximately 100 C 212 F for a motor used at continuous rating in a 40 C ambient temperature ATTENTION Ensure all moving components are safe before energizing a system Equipment to be worked on should be appropriately identifi
89. O AWGIEX AND ALL 01213 mE RST MAZAWGDSAmm A 16 5 VONG y be 4 o RIS T Q R ANA T TI N SS fi 99 SUM 0 7 100 240 VAC RMS REDWIRE 7 BLACK WIRE LA GREEN WIRE PHASE INPRO RI IM UNE PHASING OF L1 L2 AND L3 DC BUS POS NEG AND GND WIRES 1 EACH INPUT POWER IS ARBITRARY ARE PROVIDED WITH EACH DRIVE MODULE FILTER A 2N FUSED DISCONNECT 3 PHASE ISOLATION OR AUTO TRANSFORMER 3 L3 OPTIONAL NOT REQUIRED WHEN DESIRED INPUT VOLTAGE IS AVAILABLE DIRECTLY FROM THE LINE 3 PHASE AC LINE 50 60 Hz TRANSFORMER CHASSIS pe MACHINE COMMON GROUNDING BUS BAR TO PROTECTIVE EARTH TERMINAL THE PSM MUST BE CENTERED BETWEEN THE DRIVE MODULES TO MINIMIZE THE DC BUS INDUCTANCE SO THAT AN EQUIVILENT NUMBER OF DRIVES ARE LOCATED ON EACH SIDE OF THE PSM FUSE SIZE PSM 125 UL CLASS RKS 90 5000 AIC A DISCONNECTING DEVICE IS REQUIRED FOR SAFETY AND MAINTENANCE PSM 50 UL CLASS 40 AMP 5000 AIC NOTES ON SIZING OF POWER TRANSFORMERS AND INPUT WIRES LEN 8 TRANSFORMER 3 PHASE KVA SECONDARY VOLTS RMS X PER PHASE SECONDARY CURRENT RMS X LINE TO LINE PRIMARY VOLTS RNS X PER PHASE PRIMARY CURRENT RMS b TRANSFORMER 3 PHASE SUMMATION OF EACH MOTOR
90. OMs on the ULTRA Plus PDM logic board in sockets U57 U66 U67 and U87 The end of the EPROM with the notch must be towatd the front of the ULTRA Plus PDM 4 Install the ULTRA Plus PDM cover if removed Jumpers W3 and W4 may be removed if an external 24 VDC power supply is used Removing these jumpers will disconnect the internal supply The jumpers do not need to be removed if only the 24V common P1 pin 1 is connected to machine common but must be removed if an external 24VDC supply is connected to P2 pin 12 Dip switch SW1 sets the address when multiple ULTRA Plus PDMs are connected in multi drop serial communications mode and sets the mode of operation for the Operator Terminal Serial 1 Auxilary P7 Refer to Networking on page 3 44 for more information Regulatory Requirements Install the ULTRA Plus PDM Components 2 27 Refer to Location of jumper and DIP switch on page 2 27 for the locations of jumpers W3 W4 and dip switch SW1 on the ULTRA Plus PDM logic board Figure 2 18 Location of jumper and DIP switch o F1 081 081 U10 U10 DIP SWITCH Sw1 w3 swi Sw1 2 JUMPERS Wi wa 1398 PDM 25 50 100 and 150 1398 1508 BOARD component side component side These guidelines discuss ways to minimize noise problems However equipment EMC performance must meet regulatory requirements in various parts of the world s
91. OP statement was out of range The valid range of a LOOP count is 0 to 65535 8 PRECISION Out of Range Decimal point precision is not within the range of 0 to 4 9 BCD Input Range A number larger than 9 was read in as a BCD number in a BCD statement in a program Check the inputs that are being used for the BCD input 12 LOOP Count Out of Range Loop constant value is not within the range of 0 to 65535 13 Profile Calculation The move cannot be made based on the parameters for the move distance velocity acceleration or time Possible causes are variable values used for the move parameters that result in an acceleration or time of 0 16 Invalid Opcode The GML tried to execute a program opcode that was not valid programs are compiled into opcodes that the GML executes Compile the program again to make sure it compiles correctly 17 Home Not Defined Home has not been defined when trying to execute a MOVP absolute move Run the Home program or Define Home and execute the MOVP command again 19 Delay Out of Range Time value for a Delay statement is greater than 65 535 seconds 20 KP Out of Range The parameter listed has exceeded the internal system 21 KFF Out of Range limit The limit is determined at run time based on the 22 Kl Out of Range Scale parameter Check the gain values under the 23 KPZ Out of Range Parameter menu 24 Gear Out Of Range The calculated value for the gear ratio denominator is greater than
92. OUNDING CHASSIS POINT FOR AMPLIFIER POINT FOR AMPLIFIER m J SYSTEM ONE PER AXIS SYSTEM ONE PER AXIS MACHINE COMMON TO PROTECTIVE Y GROUNDING BUS BAR NOTES EARTH TERMINAL AN MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1 L2 L3 TERMINALS EXAMPLE TO RETAIN DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1 L2 L3 POWER DOWN 2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE amp SAFETY LOCAL REGULATIONS SHOULD BE OBSERVED IF A GROUNDED NEUTRAL IS USED INSTEAD OF A LAIN AUX ONLY L1 AUX MAY BE SWITCHED OR FUSED JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT SEE DRAWING 9101 1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED BUT NOT TORQUE DRIVE RATED 65 150 AMPS PEAK FOR THREE PHASE INPUT DRIVE RATED 100 240 VAC RMS 230 VAC STANDARD DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY 22775 RELEASED REV ECO BY REVISION DESCRIPTION DATE UNLESS OTHERWISE SPECIFIED DRAWN BY DATE DESIGN ENGR 9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY AND ARE REQUIRED TO MEET THE DO NOT SCALE DRAWING JM 5 12 98 EUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE CAUTION AC
93. PDM 10 20 30 75 and 150B A 1 Operator Terminal A 3 Transformers A 4 Start Program 3 26 Start up Procedure 4 1 1398 PDM 10 20 30 75 and 150B 4 1 1398 PDM 25 50 100 or 150 4 6 Motors 4 8 Operator Terminal 4 11 Personality Module 4 11 Status outputs 3 10 Step and direction inputs 3 37 Storage P 4 Suitable filter types 2 39 Support Local product P 4 Technical product assistance P 4 SW1 dip switch Nework settings 3 44 Unique addresses in network 3 40 Symbols and Conventions P 4 System firmware Location 2 25 System Overview 1 2 Publication 1398 5 1 January 2000 6 Index Publication 1398 5 1 January 2000 T Terminal block Connections 3 1 3 6 TEXT Checksum error 5 7 Transformer Description 1 7 Isolation 3 6 Load Regulation 1398 PDM 10 20 30 75 and 150B Curve 2 6 Ordering B 5 Outline Diagram 1398 PDM 25 50 100 150 2 9 Sizing 2 4 Troubleshooting see Check for Problems in the System Typographical Conventions P 4 U Underwriter Laboratories Listing 2 22 Velocity calculation error 5 5 Ventilation 2 3 Watchdog Watchdog Reset error 5 7 Watchdog Test Fault error 5 7 Wording Conventions P 4 For more information refer to our web site w ww ab com motion For Rockwell Automation Technical Support information refer to www rockwellautomation com support or Tel 1 440 646 3434 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Ro
94. POWER WIRING CONNECTIONS 1398 PDN 25 50 9101 0411 100 and 150 EAE mum 20 010 NA D TIONS 168 tort Publication 1398 5 1 January 2000 3 6 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Power Supply Module PSM The Power Supply Module PSM can supply DC power to as many as six ULTRA Plus PDMs Three phase AC power 115 230 VAC is the only required input power for the PSM The input power may be optionally isolated through a transformer Field wiring must be copper with a minimum rating of 60 C The phasing of the input power L1 L2 and L3 is arbitrary The earth ground connection is required for safe and proper system operation Terminal block connections should be torqued to 11 Ib in 1 25 Nm on the 1398 PSM 50 and 24 Ib in 2 75 Nm on the 1398 PSM 125 IMPORTANT The 1398 PDM 25 50 100 and 150 does not contain supply fuses or disconnecting devices These must be supplied by the machine builder and connected externally for safety and maintenance purposes The Power Supply Modules will continue to operate with reduced capacity with the loss of one phase The red phase loss LED on the front of the PSM will turn ON to indicate the loss of the phase ATTENTION The power supply module allows for operation to continue even in the event of loss of one phase or during power disruption on the three phase AC inputs Under these conditions the Phase Loss
95. PUT 6 g HOME SWITCH INPUT 5 s START INPUT 4 9 a ENABLE INPUT 3 H REVERSE LIMIT INPUT 2 15 FORWARD LIMIT INPUT 1 24 VOLT COMMON E a INPUT SWITCHES RESISTANCE IS 3000 OHM MAXIMUM Publication 1398 5 1 January 2000 3 22 OUTPUT LOADS RESISTANCE IS 330 OHM MINIMUM Wire the ULTRA Plus PDM Components Figure 3 17 Typical Digital 1 0 wiring e o o INTERNAL J 24 VDC W3 ERROR OUTPUT 8 IN POSITION OUTPUT 7 HOME SEQUENCE COMPLETE OUTPUT 6 AT HOME OUTPUT 5 A PROGRAM RUNNING OUTPUT 4 g GENERAL PURPOSE OUTPUT OUTPUT 3 5 GENERAL PURPOSE OUTPUT OUTPUT 2 SWR 4 GENERAL PURPOSE OUTPUT OUTPUT 1 3 GENERAL PURPOSE INPUT INPUT 16 gt GENERAL PURPOSE INPUT INPUT 15 1 GENERAL PURPOSE INPUT INPUT 14 P1 14 GENERAL PURPOSE INPUT INPUT 13 T3 INTERRUPT 2 INPUT 12 32 INTERRUPT 1 INPUT 11 ERETURN INPUT 10 PAUSE NPUT 9 9 JOG FORWARD NPUT8 3 3K JOG REVERSE NPUT 7 TYPICAL INPUT HOME COMMAND NPUT6 HOME SWITCH NPUTS gh START NPUT 4 ENABLE NPUT3 REVERSE LIMIT NPUT 2 FORWARD LIMIT NPUT 1 INPUT SWITCHES RESISTANCE IS 3000 OHM MAXIMUM Publication 1398 5 1 January 2000 24 VOLT COMMON W4 INTERNAL 24 VDC SUPPLY INTERNAL 24 VDC SUPPLY 75mA MAX PER OUTPUT I F 24V Sourcing Wire the ULTRA Plu
96. R 220 INPUT 110 OUTPUT INPUT PRIMARY CONNECTIONS H1 H4 480 VAC INPUT JUMPER H3 to H2 240 VAC INPUT JUMPER H1 to H3 AND H2 to H4 OUTPUT SECONDARY CONNECTIONS X1 X2 120 VAC Publication 1398 5 1 January 2000 Install the ULTRA Plus PDM Components 2 15 Figure 2 10 PSM AUX Outline and Connection Diagram TRANSFORMER 0020 5093 3 50 69 soo va ZA fo SEE DRAWING 9101 0233 44 5 INPUT POWER DRIVE DRIVE 0 50 0 50 88 132 VAC MODULE MODULE 13 H 3 47 63 HZ 3 AMPS RMS 025 PSM AUX 6 5 9101 0120 0 50 TBI 13 AC INPUT OPTIONAL HEATSINK 900 8 38 POWER BOARD 228 213 Fi g i RED WIRE TO b PIN 3 4 BLACK WIRE TO PIN 1 FUSE 1 9101 0123 TB2 Hg DC OUTPUT 3 00 RED WIRE 77 TO BLACK WIRE TO i 2 00 i 2 410 5 MOUNTING SCREWS REQUIRED 3 NS MINIMUM RECOMMENDED PANEL SPACE DETAIL A NOTES 1 PSM AUX OUTPUT RATING 2 0 AMPS DC AT 165 VOLTS DC MAXIMUM LOAD 4 DRIVE MODULES DETAIL A DRAWN AT 1 4 SCALE 2 OUTPUT VOLTAGE VARIES WITH INPUT VOLTAGE NON REGULATED OUTPUT A SUGGESTED MOUNTING SCREW HEAD DIAMETER 0 37 9 4 MAXIMUM A PC BOARD MOUNTING SCREW IS AVAILABLE FOR OPTIONAL EARTH GROUND CONMNECTION CO
97. RA Plus PDM drive may be used as a distributed motion control element integrated with a host computer in a flexible automation system or as a stand alone programmable motion controller Optically isolated I O and power supplies are integrated into the products Publication 1398 5 1 January 2000 1 2 Overview of the ULTRA Plus System System Overview Publication 1398 5 1 January 2000 The electronic gearing feature allows the closed loop axis to follow a second master encoder at a programmable ratio A multi axis addressing scheme multi drop operation allows multiple ULTRA Plus PDM drives to be controlled from a host computer over a single serial communications link An ULTRA Plus PDM system consists basically of the following Positioning Drive Module which controls the position velocity and torque of the motor Personality Module that plugs into the ULTRA Plus PDM to match the controller with the motor used Brushless motor with feedback from an integral optical encodet Power Supply Module integral to the ULTRA Plus PDMs 1398 PDM 10 20 30 75 and 150B and separate for the ULTRA Plus PDMs 1398 PDM 25 50 100 and 150 and Operator Terminal Combinations of matched ULTRA Plus PDMs and motors are available providing continuous torques of 0 34 Nm to 88 14 Nm 3 inch pound to 750 inch pound and speeds up to 6000 RPM An ULTRA Plus Positioning Drive Module PDM motion control system consists
98. RNAL SHUNT OPTION TERMINALS A TRANSFORMER SIZES SHOWN ARE FOR MOST APPLICATIONS APPLICATIONS REQUIRING MAXIMUM PEAK TORQUE AT MAXIMUM MOTOR SPEED MAY REQUIRE A LARGER TRANSFORMER SECONDARY VOLTAGE MAY DROP BASED ON TRANSFORMER LOAD REGULATION PERFORMANCE WHEN THE MOTOR DELIVERS PEAK TORQUE THIS DROP IN TRANSFORMER VOLTAGE WILL LIMIT MAXIMUM MOTOR SPEED WHILE PEAK TORQUE IS REQUIRED SEE DRAWING 9101 1057 FOR TRANSFORMER LOAD REGULATION OF RELIANCE MOTION CONTROL TRANSFORMER N 5 DRIVE RATED 100 240 VAC RMS SINGLE PHASE INPUT VOLTAGE 230 VAC STANDARD 6 NOT DAISY CHAIN DRIVE MODULES MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT OR A DRIVE FAULT WILL OCCUR 8 MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE A d UN AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY THE AUX INPUT HAS AN INTERNAL FILTER WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE THE COMMON GROUND BUS BAR SHOULD BE AS CLOSE TO THE DRIVE AS POSSIBLE WIRE SIZES ARE MINIMUM RECOMMENDED VALUES THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED CONNECTOR MATING A 21936 RELEASED REV ECO BY REVISION DESCRIPTION DATE UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING DI
99. RxD 4 is 5 1 3 TxD lt oS 4 TxD E es 5 COMMON z az 22 15 6 SHIELD o 7 Not used 5 8 Not used 9 Not used Ji pa ULTRA Plus Operator Terminal x X NN lt m t m H xx xx vox reer COMMON COMMON IMPORTANT The 1k W 1 4 watt terminating resistor is used for noise suppression Cables POSITIONING MODULE CONNECTOR P7 9 PIN MALE POSITIONING MODULE CONNECTOR P6 9 PIN MALE CONNECTOR P7 co Wire the ULTRA Plus Components 3 49 Refer to Motor Connectors on page B 6 for ordering information about these and other cables Figure 3 35 ULTRA Plus PDM P7 to Operator Terminal P N 9101 2205 3 OPERATOR TERMINAL SERIAL PORT CONNECTOR 25 PIN FEMALE OPERATOR TERMINAL SERIAL PORT CONNECTOR RX w gt RED TX SHIELD 57 7 0 aH Vs P7 6 T Figure 3 36 ULTRA Plus PDM P6 to PC Serial Port 9 pin P N 9101 2024 o T PC SERIAL PORT CONNECTOR dow 9 PIN FEMALE POSITIONING MODULE CONNECTOR PC SERIAL PORT P6 CONNECTOR COM rats ye GREEN Ww 5 GND i BLACK Y TXD pics a RED v 5 RXD 6 BLACK Y RXD ieg y WHITE x r TXD i BLACK NU CONN SHIEL
100. S LED and the bicolor STATUS LED should be OFF Publication 1398 5 1 January 2000 2 24 Install the ULTRA Plus Components 1398 PDM 25 50 100 and 150 Measure voltages at Positive and Negative bus terminals to ensure incoming power is OFF If a PSM AUX is used measure the voltage at L1 and L2 of the PSM AUX to ensure that incoming power is OFF 2 Remove the ULTRA Plus cover 1398 PDM 25 50 100 and 150 only 3 Install Personality Module on ULTRA Plus logic board in socket at location U10 The end of the Personality Module PM with the colored label must be toward the front of the ULTRA Plus PDM If there is a colored label on the logic board the PM label will be next to it and the colors should match 4 Install the ULTRA Plus cover if removed IMPORTANT The Personality Module is programmed with standard factory default settings If replacing a previously installed Personality Module user programs and user selected parameters must be re entered into the new Personality Module memory using GML Ultra Software Publication 1398 5 1 January 2000 Install the ULTRA Plus PDM Components 2 25 System Firmware All ULTRA Plus PDMs come with the system firmware installed Therefore Installation unless you are upgrading your ULTRA Plus PDM to a newer version of firmware you will not need to install system firmware Refer to Figure 2 17 for system firmware location Figure 2 17 Location
101. S ACTUAL AVERAGE OUTPUT POWER X 1 2 1 2 FACTOR ADDS 20 AS ROUGH ESTIMATE OF DRIVE MODULE amp MOTOR LOSSES SEE DRAWING 9101 0132 TRANSFORMER LOAD REGULATION TO DETERMINE EFFECT OF PEAK LOADS ON SYSTEM DC BUS VOLTAGE FOR WIRE GAUGES NOTED STRIPPED ENDS OF STRANDED WIRES MUST BE FULLY TINNED SO WIRE DIA STAYS LARGE ENOUGH FOR PROPER CLAMPING IN POWER SUPPLY MODULE OR DRIVE MODULE TERMINAL FOR 16 GAUGE MOTOR POWER WIRE STRIPPED ENDS OF STRANDED WIRES MUST BE DOUBLED OVER AND FULLY TINNED FOR PROPER CLAMPING IN DRIVE MODULE TERMINAL ESERIES MOTORS ARE USED WITH BRU 500 DRIVES ONLY HN TERMINAL POST HARDWARE DETAILS _ SPRING DISK WASHERS FLAT WASHER 6 TERMINAL POST M6 NUT CONNECTING LUGS CAUTION DO NOT OVERTIGHTEN USE NUT DRIVER ONLY 36 LB IN 4 0 Nm ABSOLUTE MAXIMUM TIGHTENING TORQUE SS TERMINAL POST BASE 7 Sa DRIVE OR POWER SUPPLY BUS BAR POSITIVE NEGATIVE TERMINAL POSTS M6 TERMINAL POST M6 NUT CONNECTING LUGS GROUND TERMINAL POSTS COMMON GROUNDING POINT FOR RS AND T MOTOR BE CORRECTLY PHASED POWER SUPPLY DRIVE MODULE SYSTEM MOTOR POWER MATING CONNECTOR MOTOR POWER CONNECTOR RELIANCE MOTION CONTROL 3 PHASE TRANSFORMERS 208 230 240 380 460 480 VAC PRIMARY 115 230 VAC SECONDARY 50 60 Hz RELIANCE PART NUMBER 0020 5091 001 0020 509700 0020 5091 0037 0020 5091 007 TORQUE TO 24 LB IN TORQUE TO 11 5
102. TRA Plus PDM The GML Ultra Software manuals contain all the information to quickly configure the ULTRA Plus PDM and develop application programs Publication 1398 5 1 January 2000 1 6 Overview of the ULTRA Plus System Accessories Publication 1398 5 1 January 2000 Operator Terminal The optional 1398 Operator Terminal allows the machine operator convenient access to status information program variables control functions and message display capabilities The Operator Terminal has a bright 4 line by 20 character vacuum fluorescent display and a sealed membrane keyboard with tactile feedback The two available Operator Terminals display multiple status screens for monitoring and diagnostics Four programmable function keys are available to perform up to twenty four 24 predefined functions some of which are selecting and running a program jogging the system and stopping a program The GML Ultra Software may display messages and prompts on the screen and receive input from the keypad Four additional user programmable keys identified as X keys provide extra flexibility within a user s program Figure 1 3 ULTRA Plus 1398 HMI 002 Operator Terminal front numeric keypad function keys programmable keys 2 4 1 Figure 1 4 ULTRA Plus 1398 HMI 003 Operator Terminal front function keys
103. TWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE THE COMMON GROUND BUS BAR SHOULD BE AS CLOSE TO THE DRIVE AS POSSIBLE BREAK ALL EDGES 02 MAX POWER WIRING CONNECTIONS FILLETS AND ROUNDS 02 R MAX AN 0 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED TOLERANCE ON PART NO A ANGLES 1ANGLES 9101 1453 A N TERMINATE THE MOTOR POWER CABLE SHIELD BY CLAMPING IT TO THE DRIVE WITH THE BRACKET PROVIDED THIS BRACKET CAN BE USED FOR STRAIN RELIEF IF FRACTIONS s1 64 e NON SHIELDED CABLES ARE USED SNUG BRACKET SCREWS DO NOT OVERTIGHTEN NEVER TORQUE OVER 10 LB IN THE SHIELDS ON SHIELDED POWER CABLES MUST DECIMALS XX 020 BE GROUNDED AT A MINIMUM OF ONE POINT FOR SAFETY DWGSIZE SHEET XXX 010 C 1o 1 Publication 1398 5 1 January 2000 3 4 Wire the ULTRA Plus Components Figure 3 3 Power Wiring for 1398 PDM 150B MOTOR POWER WIRES R S T GND MOTOR POWER CONNECTOR INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS GaGa BoE ai sama RECOMMENDED IQ TERMINALS CURRENT REQUIREMENT MAXIMUM AMPS AC RMS RECOMMENDED DRIVE TERMINAL S POWER WIRE LI AULIN AUK 1 0 Amps AC at 115 Volts AC MOTOR MATING CONNECTOR RECOMMENDE A R S SAUGEIn d 1 0 5 Amps AC at 230 Volts AC CONTACT SIZE GAUGE D crag 1 09 COPPER MIN jc AUXILIARY 011213 PDM 150B 46 0 Amps at 100 240 Volts AC Three Phase GAUGE mm
104. XD RS 422 transmit 16 RXD RS 422 receive 17 RXD RS 422 receive 7 Signal ground Publication 1398 5 1 January 2000 3 42 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Figure 3 25 Operator Terminal RS 232 connections ULTRA Plus PDM Figure 3 26 Operator Terminal RS 422 connections ULTRA Plus PDM Operator P7 Terminal Connector COM1 Connector RXD P7 2 2 TXD COM P7 5 Shield P7 6 Operator P7 Terminal Connector COM1 Connector Peet RXD P7 2 15 TXD TXD P7 4 16 RXD COM P7 5 7 COM Shield P7 6 1398 HMI 003 ULTRA Plus PDM P7 Serial 1 Auxiliary The ULTRA Plus PDM connects to the Operator Terminal The connection can be wired using RS 232 for distances up to 15 meters 50 feet Pin Signal names RS 232 RS 422 1 No connection RxD4 2 RxD RxD 3 TxD TxD 4 No Connection TxD 5 Common Common 6 Shield Shield 7 No connection 8 No connection 9 No connection Operator Terminal screw terminal on back Pin and Signal names Wire the ULTRA Plus Components 3 43 Pin RS 232 Pin RS 422 1 Tx 6 TxA 2 RxD 7 TxB 3 RTS 8 RxA 4 CTS 9 RxB 5 Common 10 Common Figure 3 27 ULTRA Plus PDM connects to the Operator Terminal ULTRA Plus Positioning Drive Module 1398 PDM 9101
105. all entry points in one of two ways A mating bulkhead connector can be mounted on the enclosure or the cable jacket may be removed so that the shield can be clamped to the enclosure The motor power cable shield may be terminated to the PDM chassis on those drives that have the motor power cable bracket supplied with them In this case the motor power cable shield does not have to be terminated to the enclosure The lead length between the and filter does not need to be shielded but it should be as short as possible All other cables must be shielded with the shields terminated at both ends If ground loops are an issue the shield can be capacitively terminated at one end The should be mounted in a grounded metal enclosure an enclosure is not required Route the encoder feedback serial communications and digital I O cables separately from AC and motor power cabling One of the most important factors is the motor cable shield termination at the motor end The shield must be terminated to the case of the motor through the connector backshell or through a metal gland in the case of a motor with flying leads If there are any intermediate connectors in any of the screened cables the screen must connect through the backshells and not by routing a drain wire through a pin inside the connector Use of a drain wire virtually guarantees failure to meet the EMC requirements The 1398 PDM 10 20 30 75 and 150B
106. am by placing function blocks representing the specific actions on the computer then connect them in the proper order of operations Then you enter the motion and process specifications using a fill in the form approach Each block has its own form Publication 1398 5 1 January 2000 1 4 Overview of the ULTRA Plus System Publication 1398 5 1 January 2000 After a diagram is downloaded to the ULTRA Plus PDM it is translated into a program or script in the native language of the motion controller Positioning Drive Modules The ULTRA Plus PDM is a self contained single axis programmable motion controller The ULTRA Plus PDM provides control and power for the brushless servo motor Motion programs are stored in onboard nonvolatile memory Two RS 232 RS 422 serial ports provide communications with the personal computer and the optional Operator Terminal Optically isolated digital I O allows simple machine interfacing and control ULTRA Plus PDMs are manufactured in different packages which cover a wide range of power capability The 1398 PDM 10 20 30 75 and 150B incorporate an integral power supply in each and supply continuous torques of 3 to 450 inch pounds in combination with standard motors The 1398 PDM 25 50 100 and 150 use a separate power supply module which can be shared among multiple drives and provide continuous torques of 20 to 750 inch pounds with the standard motors Integral Power Supply Modules Th
107. ation Allen Bradley Roxburgh Schaffner PDM Power Supply Part Number Part Number Suitable AC Line Filter Types Single phase PDMs MIF or MDF FN 350 xx XX Three phase PDMs MIF3xx or MDF FN 351 xx 3xx Rockwell Automation stocks some Roxburgh filters but does not offer low current single phase filters Most applications are multiple axis such that multiple PDMs may be connected to a filter e g MDF xx with higher current rating Manufacturer phone numbers Roxburgh 01724 281770 011 44 1724 281770 from USA and Schaffner 1 800 367 5566 Publication 1398 5 1 January 2000 2 40 Install the ULTRA Plus Components Publication 1398 5 1 January 2000 AC Line Filter Selection Selection of the proper filter is only the first step in reducing conducted emissions Correct filter installation is crucial to achieving both EMI attenuation and to ensure safety All of the following guidelines should be met for effective filter use 1 The filter must be mounted close to the input terminals This is particularly important for higher frequency emissions 5 30 MHz If the distance exceeds 600 mm 2 ft then a strap should be used to connect the ground between the PDM and filter rather than a wire 2 The wires connecting the AC source to the filter should be shielded from ot at least separated from other high power cables i e connection between the PDM and the filter motor power cable etc If the
108. be useful since position information is maintained as long as logic power is on Another example would be maintaining ULTRA Plus PDM logic power so the serial interface could be used for troubleshooting and diagnostics Refer to PSM AUX Outline and Connection Diagram page 2 15 for wiring information on the PSM AUX and optional PSM AUX isolation transformer Publication 1398 5 1 January 2000 3 8 Wire the ULTRA Plus Components Figure 3 5 Auxiliary Power Supply Connections SAMPLE INPUT POWER WIRING CONFIGURATIONS PSM AUX WITH 1398 PDM 25 50 100 and 150 A Pl SAZ F d EXAMPLE d oN V POWER SUPPLY DRIVE EXAMPLE 240V LINE 9 MODULE PSM MODULE 480V LINE 8N POWER SUPPLY MODULE PSM 240VAC lale PHASE RST 8 9 215 2 12 480VAC 3 PHASE PRIMARY 240VAC 3 PHASE SECONDARY 0020 5091 XXX 480VAC 3 PHASE PSM AUX TRANSFORMER N 0020 5093 AA CONTROL CIRCUIT TRANSFORMER 240VAC 120VAC IN PSM AUX LA 480VAC E 120VAC PSM AUX Q CONTROL CIRCUIT TRANSFORMER 1 Hs 240VAC 120VAC nmmn L 5 CUSTOMERS 2 NOTES F4 420VAC CUSTOMER S L gt CONTROL CONTROL GIRGHITS CIRCUITS Z N IN THIS EXAMPLE PSM AUX INPUT POWER IS CONNECTEDTO AT THE CONTRO
109. between other circuit cables and the motor or power cable should be minimized A rule of thumb is 300 mm 1 ft of separation for each 10 m 30 ft of parallel run The 300 mm 1 ft separation can be reduced if the parallel run is less than 1 m 3 ft Cable intersections should always occur at right angles to minimize magnetic coupling Do not route any cables connected to the PDM directly over the PDM vent openings Otherwise the cables will pick up the emissions leaked through the vent slots If you construct your own motor cable a 4 conductor cable should be used with the 4 conductors twisted The ground conductor must be attached to the motor and PDM earth terminals The shield must be separately terminated according to the guidelines for the specific PDM The encoder mounted on the brushless servo motor should be connected to the PDM with a cable using multiple twisted wire pairs and an overall cable shield Standard Rockwell Automation Allen Bradley encoder cables are offered that are terminated in various lengths If building your own cable be sure to connect the cable shield to the motor case and to the PDM chassis through the connectors for a complete 360 connection per the cable assembly diagram otherwise noise on the encoder signals can cause faults in the PDM PDM SHIELD Install the ULTRA Plus PDM Components 2 45 If EMI problems persist additional counter measures can be attempted Several suggestions for syste
110. ckwell 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 Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels 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 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
111. e DO NOT SCALE DRAWING BC 1 10 89 BB 2 22 89 DIMENSIONS ARE IN INCHES MAX 02 R MAX DIAGRAM OUTLINE TRANSFORMER PART NO ANGLES 1ANGLES 8 00 0 06 FRACTIONS 1 64 9101 1056 203 11 5 DECIMALS XX4 010 SCALE DWGSZE SHEET 005 1 1 C 101 Publication 1398 5 1 January 2000 Figure 2 4 Three Phase Transformer Outline Diagram CONNECTION INSTRUCTIONS PRIMARY CONNECTIONS N Annaan Aaaama SECONDARY i CONNECTIONS N 0 25 20 GROUND STUD TRANSFORMER CHASSIS F 8 0 MIN CLEARANCE RECOMMENDED FOR ACCESS TO WIRING 4 NOTES SIZES ARE LISTED IN THE DIMENSION CHART 2N USELUGS DESIGNED FOR 6 SCREW MOUNTING Install the ULTRA Plus Components 2 9 one rant io 9101 0131 GREF r E3006 0 56 40 03 DIA THRU 4 4 RELIANCE MOTION CONTROL KVA OVERALL DIMENSIONS MOUNTING HOLES LOCATION SCREW SIZES TRANSFORMER PART NO RATING PRIMARY SECONDARY A B c D F G SECONDAR O020 508 001 s 1257 80 950 880 420 asp 15 5 Sa 00200091002 1825 ws 32 Ms A E poppe amp 2 SB gm pm am z 130 sm im 0020 5091 004 18 2250 900 1825 1600 538 298 Hen i be C1 Hw REDRAWN 19866 20625 16383 RELEASED 8 88 JH REV ECO BY REVISION DESCRIPTION DATE CHKR UNLESS OTHERWISE SPECIFIED
112. e 1398 PDM 10 20 30 75 and 150B are rated for 10 20 30 75 and 150 amp peak currents respectively These modules are packaged with an integral power supply to achieve a small size Input power to a 1398 PDM 10 20 or 30 is single phase 115 or 230VAC Input power to a 1398 PDM 75 or 1398 PDM 150B is three phase 115 or 230VAC The input power may be optionally isolated through a transformer These ULTRA Plus PDMs have a built in solid state soft charge of the internal DC bus capacitor They also include a built in dissipative shunt regulator that provides synchronous motor dynamic braking The ULTRA Plus PDMs allow use of an optional external shunt resistor for applications requiring higher shunt power capability than provided by the internal shunt resistor Separate Power Supply Modules The 1398 PDM 25 50 100 and 150 are rated for 25 50 100 and 150 amp peak currents respectively These ULTRA Plus PDM modules use a separate power supply module 1398 PSM 50 or 1398 PSM 125 which may be shared among multiple ULTRA Plus PDMs to achieve the most economical system package Other than the packaging and power ranges all the ULTRA Plus PDMs are all identical in setup and programming Overview of the ULTRA Plus System 1 5 Power Supply Module PSM The power supply module is only required for 1398 PDM 25 50 100 and 150 systems The Power Supply Module PSM can supply DC power to as many as six ULTRA Plus modules
113. e the motor shaft counterclockwise and verify that the Count value decreases e Select Cancel to exit the Encoder dialog 15 Select Close to exit the Axis Setups window 16 Enable the ULTRA Plus PDM by performing one of the following Turn the Enable input ON or Double click on the Feedback block set State ON and select Execute Publication 1398 5 1 January 2000 4 8 Apply Power for the First Time Motors Publication 1398 5 1 January 2000 Select Cancel to exit the dialog 17 Verify the motor is stationary and has holding torque 18 Command motion and verify the motor rotates in the proper direction by performing one of the following steps Enable the jog inputs or Double click on the Jog Axis block in the Online Manager window to access the Jog Axis dialog Select Execute from the Jog Axis dialog to rotate the motor The direction and speed of rotation may be changed in the Jog Axis block Select Cancel to exit the Jog Axis dialog 19 Select ESTOP in the Online Manager command window to halt motion stop program execution and set Feedback OFF 20 Remove input power The LEDs should turn off within ten seconds 21 Repeat Step 6 through Step 20 for each additional ULTRA Plus PDM ATTENTION Motor power connectors are for assembly purposes only They should not be connected or disconnected while power is applied to the drive 4 Perform the initial power up with the motor shaft ATTENTIO
114. ed and access to power restricted according to required lockout tagout procedures Motors and linkages must be securely attached before a system is made operational Failure to observe these safety procedures could result in personal injury and damage to equipment External Shunt Install the ULTRA Plus PDM Components 2 17 The following procedure outlines the installation of External Shunt 200W 9101 1183 and External Shunt 900W 9101 1697 units 1 Remove jumper between terminals 1 and 2 at the internal shunt connection The jumper is supplied with the amplifier 2 Wire an external shunt resistor between terminals 1 and 3 at the external shunt connections Use wire of the recommended wire size 8 60 218 4 EXTERNAL SHUNT RESISTOR gt 2 m EXHAUST Figure 2 11 External Shunt 200W mounting and connection diagram 3 05 77 5 2 00 0 50 10 M5 50 8 12 7 MTG HOLES 3 B 189 r7 928 Jd EXTERNAL SHUNT n RESISTOR A 45 5 20 4 75 132 120 6 I y 9 49 MIN 72 CONNECTION DIAGRAM NOTES N FOR INTERNAL SHUNT RESISTOR JUMPER INSTALLED BETWEEN PINS 1 amp 2 OF TERMINAL FOR EXTERNAL SHUNT RESISTOR REMOVE JUMPER INSTALLED BETWEEN PINS 1 amp 2 OF TERMINAL INSTALL WIRING AS SHOWN AA 36 OF 14 AWG WIRE IS SUPPLIED WITH EXTERNAL SHUNT RESISTOR CUT TO LENGTH AS R
115. el Stud mounting a ground bus to the enclosure back wall or chassis to the Sub panel Sub panel Back wall of enclosure Mounting bracket or Sub panel ground bus Welded stud Star washer S Scrape paint Flat washer pep Flat washer Use aly brush remove If the mounting bracket is coated with paint trom threa a Dres Y a non conductive material anodized maxmuze grong connecuon i painted etc scrape the material around the mounting hole Use plated panels or scrape paint on front of panel Ground bus or mounting bracket my EN Star washer Scrape paint on both sides of panel and use star washers Star washer ES Flat washer b if me mounting bracket is coated with a non conductive materia Star wasiier anodized painted etc scrape the material around each mounting hole Publication 1398 5 1 January 2000 2 32 Install the ULTRA Plus Components Publication 1398 5 1 January 2000 Multiple Sub Panels Bonding multiple sub panels creates a common low impedance exit path for the high frequency energy inside the cabinet Sub panels that are not bonded together may not share a common low impedance path This difference in impedance may affect networks and other devices that span multiple panels Refer to the illustration below for recommended bonding practices Figure 2 21 Multiple sub panels and cabinet Recommended Bond the top and bottom of each sub panel to the cabinet usi
116. ernal shunt jumper and installation of a larger external shunt between terminals 1 and 3 allow more power to be dissipated Publication 1398 5 1 January 2000 Terminal Identifier Description 1 Internal or Positive DC BUS External 2 Internal Internal shunt regulator resistor 3 3 External Shunt regulator transistor collector ATTENTION High voltage is present on the terminals of ULTRA Plus PDMs After removing power check for remaining voltage before making or removing any connection Failure to observe this safety procedure could result in personal injury or damage to equipment ATTENTION ATTENTION Restrict casual contact to equipment The ULTRA Plus PDMs and external shunt devices should be installed in an industrially rated cabinet to provide safe containment and restricted access Failure to observe this safety procedure could result in exposure to electrical hazards and damage to equipment Loose high voltage wires can cause a fire Do not tin solder exposed leads on cables going to high voltage terminals Soldered contracts may loosen over time Failure to observe this safety practice could result in intermittent service and damage to equipment Wire the ULTRA Plus Components 3 13 The external shunt is enabled when the DC BUS increases to a specific value 420 VDC An increase in DC BUS voltage may occur when the amplifier decelerates the
117. es is four times the motor s FLA Therefore the largest fuses permissible for use are four times the motor s FLA marked on the motor converted to a RMS value The ULTRA Plus PDMs have been evaluated and listed by Underwriter Laboratories Inc according to UL 508C with fuses sized as four times the continuous output current FLA of the PDM In almost all cases fuses selected to match the PDM input current rating will meet the National Electrical Code requirements and provide the full PDM capabilities Dual element time delay fuses should be used to avoid nuisance trips during power initialization due to inrush current Solid state motor overload protection operates within 8 minutes at 200 overload and within 20 seconds at 600 overload 1398 PDM 10 20 30 75 and 150B A short circuit current rating without fuse restrictions must be suitable for use on a circuit capable of delivering not more than 5000 RMS symmetrical Amperes 240 Volts maximum A short circuit current rating with fuse restrictions must be suitable for use on a circuit capable of delivering not more than 200 000 RMS symmetrical Amperes 240 Volts maximum when protected by high interrupting capacity current limiting fuses Class CC G J L R T 1398 PDM 25 50 100 and 150 A short circuit current rating suitable for use on a circuit capable of delivering not more than 5 000 RMS symmetrical Amperes 240 Volts maximum when protected by e 139
118. esponding to the PDM Operator Terminal address which must be set up in GML Ultra Software Figure 3 33 Operator Terminal RS 422 multi drop connections AXIS Port 1 TXD P7 4 Port 1 TXD P7 4 TXD P7 3 RXD P7 1 RXD P7 2 RXD P7 1 COM P7 5 Publication 1398 5 1 January 2000 3 48 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Operator Terminal 1398 HMI 003 One Operator can connect to multiple ULTRA 100 Series Drives This method requires customer supplied RS 422 cable connections A particular ULTRA Plus PDM may be selected from the terminal by using the NO key followed by the numeric key corresponding to the ULTRA Plus PDM address Refer to the GML Ultra Software manual for further details Figure 3 34 ULTRA Plus PDM RS 422 multiple drop connections ULTRA Plus Positioning Drive Modules RS 422 Multiple Drop Connections customer supplied cabling G Pi1 P7 2 RxD ae 5 1 3 TxD 4 5 4 TxD ER 8 5 COMMON a2 5 6 SHIELD 7 Notused 8 Not used 9 Not used 1 RxD gt 7 2 RxD te 5 1 3 TxD 2 2 4 TxD ER 59 5 COMMON az 5 6 SHIELD 7 Not used 8 Not used 9 Not used O Pin 1 RxD P7 2
119. fore returning to a zero 0 volt condition With the jumper in the enable input deactivated position standard Position B the enable input has no effect on the PSM operation and the PSM activates itself when three phase voltage in the proper voltage range is connected to the input Wire the ULTRA Plus Components 3 11 Figure 3 8 Power Supply Module jumper location D B 2 lt DIAGNOSTIC INDICATOR LIGHTS POWER SUPPLY MODULE CIRCUIT BOARD COMPONENT SIDE TB1 1 I INTERFACE WT 4 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 REFER TO INSTRUCTION MANUAL FOR SIGNAL SPECIFICATION AND DETAILS OF OPERATION BEFORE USING POSITION A SHORTING JUMPER ACROSS EXTERNAL ENABLE INPUT IS DE ACTIVATED BOTTOM 2 PINS POSITION B POWER SUPPLY MODULE IS ENABLED WHENEVER STANDARD SETTING INPUT POWER IS APPLIED AND NO POWER SUPPLY MODULE FAULT CONDITIONS ARE DETECTED Publication 1398 5 1 January 2000 3 12 Wire the ULTRA Plus Components External Shunt Connections The ULTRA Plus PDM 1398 PDM 10 20 75 and 150B has a built in shunt regulator The following table depicts the internal shunt selection with a factory installed jumper between terminals 1 and 2 Removal of the int
120. heck Current Limit in the scroll list and enter a current limit value that is low 25 of peak current is a low value Select Execute to make the selection Select Cancel to exit the Equation dialog Select Close to exit the Axis Setups window Command motion and verify each motor rotates in the proper direction by performing one of the following steps Enable the jog inputs or Double click on the Jog Axis block in the Online Manager window to access the Jog Axis dialog Select Execute from the Jog Axis dialog to rotate the motor Select Cancel to exit the Jog Axis dialog Select ESTOP in the Online Manager command window to halt motion stop program execution and set Feedback OFF If the motor does not turn clockwise the power wires and encoder wires should be inspected to ensure proper connection to the ULTRA Plus PDM Disable all ULTRA Plus PDMs and turn OFF input power Measure the DC bus voltage to be sure that it is below 15 VDC Publication 1398 5 1 January 2000 4 10 Apply Power for the First Time 10 Now that the system installation is verified return the I limit parameter to a value appropriate for the application Publication 1398 5 1 January 2000 Operator Terminal Personality Module Apply Power for the First Time 4 11 The Operator Terminal requires no special start up procedure Refer to Operator Terminals on page 3 16 for wiring instructions The operator terminal display LED should be
121. i 2 39 Roxburgh 2 39 Schaffner 2 39 Power transformer 2 38 Power wiring 2 38 Accel calculation error 5 5 Analog to Digital converter Resolution 3 28 ANSI C62 and C63 2 37 Assignable function Home Sequence Complete output 3 27 Assignable functions Digital Outputs 3 27 At Home output Assignable function 3 27 Auxiliary power supply Description 1 7 Logic power 3 5 3 7 BCD Input Range error 5 5 Bonding Mounting 2 31 Sub panels 2 32 Bus DC Power Supply 3 7 Overvoltage error 5 7 Undervoltage error 5 6 Cable Description 1 7 Order B 4 Shielding 2 29 Cam Profile Overflow error 5 6 connector 3 41 Connections Motor power 3 18 Index Operator Terminal power supply 3 16 PDM terminal block 3 1 3 6 Contents of manual P 2 Conventions Conventions used in this manual P 3 Conversion Card 24V Sourcing 2 21 D DC Coils suppressed with diode 2 45 Multiple power installations 3 6 DC Bus Power supply 3 7 Delay Qut of Range error 5 5 Diagnostics DC Bus Power LED 5 2 Error Messages 5 4 LED 5 1 Personality Module Default Initialization 5 3 Diagram Auxiliary Power Supply Connections 3 8 External Shunt Mounting and Connection Diagram 2 17 2 18 Power Wiring Diagram 1398 PDM 25 50 100 and 100 3 5 Power Wiring Diagram for 1398 PDM 10 20 and 30 3 2 Power Wiring for 1398 PDM 150B 3 4 Power Wiring for 1398 PDM 75 3 3 PSM AUX Outline and Connection Diagram 2 15 Transformer Load Regulation 1398
122. impedance noise coupling The ground bus bar GBB should be connected to the AC ground and if necessary to the enclosure All circuits or subsystems should be connected to the GBB by separate connections These connections should be as short as possible and straps should be used when possible The motor ground conductor must return to the ground terminal on the PDM not the GBB Install the ULTRA Plus PDM Components 2 43 Shielding and Segregation The EMI radiating from the PDM enclosure drops off very quickly over distance Mounting the PDM in a conductive enclosure such as an industrial cabinet further reduces the radiated emissions The cabinet should be set up to act as a Faraday cage The cabinet should have a high frequency ground and the size of openings should be minimized All ULTRA Plus PDMs must be mounted in an industrial cabinet to meet safety requirements The primary propagation route for EMI emissions from a PDM is through cabling The cables conduct the EMI to other devices and can also reradiate the EMI For this reason cable segregation and shielding are important factors in reducing emissions Cable shielding can also increase the level of immunity for a PDM Where shielded cables are unterminated as the cable connection passes through the wall of the cabinet the shield must be bonded to the cabinet wall to prevent noise picked up by the shielding inside the cabinet from being radiated outside the cabinet by the cab
123. le Where shielded cables are terminated using connectors the shield must not be grounded inside the connector through a drain wire or noise on the shield will couple onto the signal conductors inside the connector Connectors should have conductive backshells and the shield should be terminated to ground only through the Publication 1398 5 1 January 2000 2 44 Install the ULTRA Plus Components Publication 1398 5 1 January 2000 backshell The following suggestions are recommended for all installations especially since they are inexpensive Use a shielded motor cable that is terminated at both ends The shield should be connected to the GBB or chassis at the PDM end and the motor frame at the motor end The coaxial configuration provides magnetic shielding and the shield provides a return path for HF currents which are capacitively coupled from the motor windings to the frame If power frequency circulating currents are an issue a 250 VAC capacitor should be used at one of the connections to block to 50 60 Hz currents while passing HF currents Signal cables encoder serial analog should be routed away from the motor cable and power wiring Separate steel conduit can be used to provide shielding between the signal and power wiring Do not route signal and power wiring through common junctions or raceways Signal cables from other circuits should not pass within 300 mm 1 ft of the PDM The length or parallel runs
124. lit No message will appear on the screen unless the operator terminal is connected to the ULTRA Plus PDM serial port and the ULTRA Plus PDM sends a message to the operator terminal When the Operator Terminal is connected to a ULTRA Plus PDM press the Status key to verify the Operator Terminal is communicating properly Refer to the GML Ultra User Manuals for saving the Personality data in a computer file and loading it into the ULTRA Plus controller using the upload options in the GML Online Manager Publication 1398 5 1 January 2000 4 12 Apply Power for the First Time Publication 1398 5 1 January 2000 Chapter 5 Light Emitting Diodes LED Check for Problems in the System The ULTRA Plus PDM system is designed to provide diagnostic aids that help isolate any problems to a module in the system A module may be a ULTRA Plus PDM Power Supply 1398 PDM 25 50 100 and 150 Personality Module motor and encoder cables or the mechanical system The ULTRA Plus PDM circuitry is designed to prevent problems in any one module from damaging any other module The modular package allows very simple field replacement If a GML is replaced the personality module is transferred to the replacement module and all programs parameters and other information are moved to the PDM The Personality Module system firmware and fuses the only field replaceable items in the system Maintenance of the ULTRA Plus PDM system is
125. lity Module to the factory default settings perform the following 1 Select Initialize ULTRA Plus PDM from the File menu The Initialize Personality Module window will appear 2 Click the Factory Default Initialization tab 3 Click the Factory Initialize PM button to initialize the PM The Percent Complete indicator displays the status of the initialization If there is a fault GML Ultra Software can provide specific error messages If a personal computer running GML software is connected to the P6 connector the error message can be displayed in the Monitor menu Status dialog box The error messages are also displayed on the optional Operator Terminal The Error output may be disabled and used as a general purpose output Therefore this output may not be available for diagnostic purposes The remainder of the discussion about the Error output assumes that output 8 is assigned as the Error output The output can be assigned in the Parameter menu The Error output becomes active whenever the ULTRA Plus PDM detects a fault The ULTRA Plus PDM will not begin to execute motion programs while a fault is present After removing the cause of the fault toggling the ENABLE input OFF and back ON or issuing a RESET command will clear the fault and allow execution of motion programs Some faults however can only be cleared by an HRESET command These faults include numbers 42 45 54 68 69 73 and 74 Refer to Error Messages on page 5
126. ms modifications follow 1 A ferrite doughnut or torroid around a signal cable may help The ferrite will attenuate common mode noise but will do nothing for differential mode noise Specifically this should help RS232 communication problems Figure 2 26 Torroid encoder shielding method for brushless servo motors ENCODER CABLE BRUSHLESS MOTOR e Recommended raw cable for building your own cable Belden Part number Carol Part number 8337 C0625 ENCODER MOTOR CASE Suppress each switched inductive device that is near the servo amplifier This includes solenoids relay coils starter coils and AC motors such as in motor driven mechanical timers 3 DC coils should be suppressed with a free wheeling diode connected across the coil 4 AC coils should be suppressed with RC filters a 200 ohm 1 2 Watt resistor in series with a 1 2 microFarad 600 Volt capacitor is commonly used 5 Motor power windings can be grounded shielded and choked to minimize noise emissions Publication 1398 5 1 January 2000 2 46 Install the ULTRA Plus PDM Components TWISTED TOGETHER Figure 2 27 Motor power winding methods to minimize noise emissions PDM BRUSHLESS MOTOR TWISTED TOGETHER R R T T MOTOR CASE CHASSIS sh TO SINGLE POINT EARTH GROUND PDM BRUSHLESS MOTOR TWISTED TOGETHER N R t 1
127. n 1398 5 1 January 2000 3 14 Wire the ULTRA Plus 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 4 _ TB2 1 R1 i lu etm TB2 3 R1 s R2 pure NOTES TB2 3 R7 2 R8 R9 Configuration good for all ULTRA Plus HERE TB2 3 900 Watts 1800 Watts 1 900W Unit Configuration 2 900W Unit Configuration TB2 1 m 2 1 R1 E Ip R1 R2 2 2 3 NOTES Uses 900W units p n 9101 1674 Configuration good for 1398 PDM 075 150 and 150B units Configuration good for 1398 PDM 150 and 150B units only Publication 1398 5 1 January 2000 Wire the ULTRA Plus Components 3 15 Replacing the PSM Shunt Fuse The DC Bus shunt fuse is located in the Power Supply Module To check and ot replace this fuse 1 Measure voltages at L1 L2 and L3 phase to phase to ensure incoming power is OFF Make sure that the green PSM READY LED is OFF Remove the PSM cover 2 Remove the shunt fuse and test with an ohmmeter shunt fuse a DC rated fuse must be used 3 Replace the shunt fuse Figure 3 10 Shunt Fuse location Shunt Resistor Power Supply Module 1398 PDM 25 50 100 and 150 Shunt Fuse PSM 50 8 Ampere KLKD 8 or KLM 8 PSM 125 20 Ampere K
128. n could result in damage to the equipment or severe bodily injury Connector Pin Signal Name Assignable Function Analog 1 0 and status 12 24 VDC 24 VDC 11 Output 8 Error 10 Output 7 In Position 9 Output 6 Home Sequence Complete 8 Output 5 At Home 7 Output 4 Program Running 6 Output 3 5 Output 2 4 Output 1 P2 Connecting Inputs and Outputs Together A digital output from a may be connected to an input on the same or another PDM A single wire connection between the output pin and the input pin is all that is required If connecting I O between controllers the 24 VDC common P1 pin 1 also needs to be connected between each controller Multiple digital outputs may be wired together to form a wire OR connection If any one of the outputs turns on the line is pulled low on This is useful for Publication 1398 5 1 January 2000 3 28 Wire the ULTRA Plus PDM Components Publication 1398 5 1 January 2000 connecting the Error outputs from each axis of a system to a host PLC or machine controller to indicate an error in any of the axes Multiple digital inputs may be wired together If the line is pulled low all connected inputs will turn on This is useful for connecting an input on each axis of a system to an output from a host PLC or machine controller to synchronize events Analog Input Figure 3 18 illustrates the Analog to Digital converter ADC input ADC1 L
129. n ungrounded shield can result in ATTENTION P 8 high voltages on the shield and anything connected to it Shielded power cables must be grounded at a minimum of one point for safety Failure to observe this precaution could result in damage to the equipment or severe bodily injury Publication 1398 5 1 January 2000 Auxiliary Logic Power Wire the ULTRA lus Components 3 5 Single phase AC power 100 240 VAC may be supplied to the internal logic supply through L1 AUX and L2 N AUX Auxiliary supply power to the internal logic supply is useful if the ULTRA Plus PDM logic must stay ON when the motor power must be turned OFF Absolute positioning is one example of when this would be useful since position information is maintained as long as logic power is on Another example would be maintaining the ULTRA Plus PDM logic power so the ULTRA Plus PDM serial interface could be used for diagnostics 1398 PDM 25 50 100 and 150 Figure 3 4 Power Wiring Diagram 1398 25 50 100 and 100 N N N V V LN DRIVE MODULE A DRIVE MODULE POWER SUPPLY MODULE POS NEG GND POS NEG DRIVE MODULE A N DRIVE MODULE AN PART No 9101 0411 POWER SUPPLY MODULE AND DRIVE MODULE TERMINALS th ACCEPTABLE WIRE RANGE TGAUGEImmE ERODUGT 60 C COPPER ONLY TERMINALS UZLS AWG t0mme POS WEG oxo DRIVE MODULES POME T
130. ng 1 in by 1 4 in minimum wire braid Bonded cabinet ground bus to sub panel Scrape the paint around each fastener to maximize metal to metal contact Install the ULTRA Plus PDM Components 2 33 Motors and Cables The system tests were made using Rockwell Automation Allen Bradley motors and both shielded and unshielded power cables The shielded cables have a 0 5 portion of the cable jacket stripped off exposing the shield approximately 12 from the PDM end of the cable This stripped area is to be clamped onto the chassis for shield termination when used with the ULTRA Plus PDMs Refer to Motor power EMC shield connection on page 3 20 Low Voltage Directive The PDMs must be mounted in an enclosure that provides a minimum of IP4X protection such that only authorized individuals have access to them ATTENTION High voltage is present on the DC Bus and terminal block connections for several minutes after electrical power is removed Motor connectors are for assembly and disassembly only These connections should never be made or broken while the PDM is energized Measure remaining voltage on terminal block prior to removing the protective cover or touching any connections Failure to observe this safety procedure could result in personal injury or damage to equipment Publication 1398 5 1 January 2000 2 34 Install the ULTRA Plus PDM Components Publication 1398 5 1 January 2000 I F
131. ny electromagnetic device that is adversely affected by the EMI coupled to it Install the ULTRA Plus PDM Components 2 37 Figure 2 23 EMI Source Victim Model CONDUCTED EMI EMI EMI SOURCE VICTIM RADIATED EMI EMI VICTIM Immunity to EMI is primarily determined by equipment design but how you wire and ground the device is also critical to achieving EMI immunity Therefore it is important to select equipment that has been designed and tested for industrial environments The EMI standards for industrial equipment include EN 61000 4 X series 1000 4 X and IEC 801 X series ANSI C62 and C63 and MIL STD 461 Also in industrial environments you should use encoders with line driver outputs rather than single ended outputs and digital inputs outputs with electrical isolation such as those provided with optocouplers The EMI model provides only three options for eliminating the EMC problem reduce the EMI at the source increase the victim s immunity to EMI harden the victim reduce the EMI at the victim eliminate the coupling mechanism In the case of servo drives reducing the EMI source requires slowing power semiconductor switching speeds However this adversely affects PDM performance with respect to heat dissipation and speed torque regulation Hardening the victim equipment may not be possible or practical The final and often the most realistic solution is to reduce
132. oblem in the GML internal power supply Continued 43 Error Messages Peak Overcurrent Check for Problems in the System 5 7 Description The GML current sensors detected a short circuit in the motor leads Check motor power cables for shorts 44 Bus Overvoltage The DC bus voltage exceeded safe levels This error usually indicates that the power supply shunt is not operating properly Check the shunt fuse on the Power Supply Module 1398 PDM 25 50 100 and 100 See Figure 3 10 on page 3 15 45 46 Encoder 1 Fault Encoder 2 Fault Incorrect encoder signals were detected by the PDM circuitry The encoder signals may be out of quadrature or an encoder signal is missing broken wire 4 Watchdog Test Fault The Watchdog circuitry test performed at power up failed The GML should be replaced 48 Personality Fault A checksum error was detected in the personality data for the GML Reload the Personality Module from a previously saved file or replace the Personality Module 49 Watchdog Reset The watchdog timer is pulsed by the microprocessor every millisecond to ensure that the microprocessor is running properly If the microprocessor fails to pulse the watchdog a Watchdog Reset fault occurs 50 RAM R W Fault The static RAM failed a test The GML should be replaced EPROM Checksum One of the EPROMs failed the checksum test at power up All three EPROMs U66 U6
133. ocated on P3 5 it may be used to read any analog signal with a range of 10V Analog inputs and signal names The analog signal ground must be connected to the Analog Common on connector P3 4 The Analog Common is tied to earth ground internally The 10 bit ADC has a resolution of approximately 20 mV This analog input may be used as a general purpose analog input or as the feed rate input Refer to the GML Ultra Software manuals for information about the use of this input Connector Analog 1 0 and status Analog Common 5 Analog Input ADC1 Figure 3 18 Analog input and output typical internal circuits 15 VDC fh E b 15 VDC 15 VDC gj 15 vc P MONITOR ANALOG OUTPUT 1 ANALOG OUTPUT ADC1ANALOG INPUT 15VDC 15vDc Pa ANALOG COMMON P34 RELAY COMMON x 2 ENABLED RELAY gt i i READY RELAY G 45VDC 15 VDC Wire the ULTRA Plus PDM Components 3 29 Analog Output The Digital to Analog Converter DAC output DAC1 on pin P3 6 outputs an analog signal with a range of 10 volt Analog output and signal names The analog signal ground must be connected to the Analog Common on pin P3 4 The 12 bit DAC has a resolution of approximately 5 mV Refer to the GML Ultra Software for information about the use of this output Connector Pin Signal Name P3 Analog I O and status 4 Analog Common 6 Analog Output DAC Monitor Output The Programmable Monitor output
134. of Rockwell Automation is prohibited Throughout this manual we use notes to make you aware of safety considerations Identifies information about practices or ATTENTION fe P a circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid a hazard and recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley is a trademark of Rockwell Automation GML Ultra Software is a trademark of Rockwell Automation UL and cUL are registered trademarks of Underwriters Laboratories Windows is a trademark of Microsoft Corporation Overview of the ULTRA Plus PDM System Install the ULTRA Plus PDM Components Table of Contents Preface IntrOQUuCtlOD Peds BRR SHE d P 1 Who Should Use this Manual P 1 Purpose of this Manual cio wae eee eee BR IURE EE EH I P 1 Contents of this p 2 Related P 3 Conventions Used in this P 3 Product Receiving and Storage Responsibility P 4 Adler Btadley SuppoEkts ooo au o ea e t ar et Xon etes P 4 Local Product Support ii 500s rx adu Fea estados 4 Technical Prod
135. of a number of components connected to accomplish a specific function This section provides a brief overview of the various components of the ULTRA Plus Positioning Drive Module PDM motion control system Overview of the ULTRA Plus System 1 3 Figure 1 2 ULTRA Plus PDM Control System Cc ei IWS ULTRA PLUS ULTRA PLUS PERSONALITY POWER SUPPLY POSITIONING DRIVE MODULE MODULE MODULE PSM PDM PSM USED L ONLY WITH 1398 PDM 025 1398 PDM 050 1398 PDM 100 OR 1398 PDM 150 C18 Ce n9 MOTOR SERIES F SERIES H SERIES N SERIES iT MANUALS r1 ULTRA PLUS OPERATOR TERMINAL Optional M ei P FT f PERSONAL COMPUTER Windows compatible user supplied AUXILIARY ENCODER User supplied option SOFTWARE GML Ultra for Windows GML is an exclusive Graphical Motion Control Language from Allen Bradley GML integrates software programming and debugging to solve your motion control problems It offers a Microsoft Windows interface to the ULTRA Plus PDM series of controllers GML Ultra Software uses a flow chart approach to motion control programming You produce a diagram motion progr
136. ontinuous 50 amps 100 amps Output Current Continuous 600 W 1200 W Shunt Dissipation Peak Shunt 20 kW 40 kw Power Terminal Block 11 0 Ib in 24 0 Ib in Torque 1 25 Nm 2 75 Nm The two optional operator terminal specifications are compared in the following table Operator Terminals Terminal 1398 HMI 002 1398 HMI 003 Input voltage 110 240 VAC 15 24 VDC 20 Nominal Supply 25 Watts 0 5 Amps Temperature Operating 32 to 131 F 0 to 55 C ambient 32 to 104 F 0 to 40 C ambient Storage 40 to 158 F 40 to 70 C 4 to 176 F 20 to 80 C ambient ambient Humidity 5 to 95 non condensing 80 maximum non condensing Weight 7 Ib 3 kg 2 3 Ib 0 1 kg Display Vacuum Fluorescent Display 4 Vacuum Fluorescent Display 4 lines by 20 characters Characters 5 mm high lines by 20 characters Characters 5 mm high Front panel seal NEMA 4 IP64 NEMA 4 IP65 NEMA 12 IP66 RS 232 cable 9101 2205 9101 2205 Publication 1398 5 1 January 2000 A 4 Specifications Transformers Publication 1398 5 1 January 2000 Multi tap isolation transformers are available for line voltage matching Single Phase Transformer specifications The 1398 PDM 10 20 30 and 75 use a single phase transformer Specification Value Rating 3 0 kVA Input 220 230 240 440 460 480 VAC RMS Output 115 230 VAC RMS Ambient temperature 32 to122 F 0 to 50 C
137. or Problems in the System Specifications Options and Accessories Chapter 4 1398 PDM 10 20 30 75 and 150 4 1 1398 PDM 25 50 100 and 150 4 4 Power Supply Module ss so ucoi i e ur Hecht sees ve a ES 4 5 Start up Procedure for 4 6 2 eile oe he PE ee ee 48 Operator Terminal vH e ua es ed oa dts 4 11 Personality Module s ood deoa ats oa ced x aca od UNO 4 11 Chapter 5 Light Emitting Diodes 5 1 Positioning Drive Module STATUS 5 1 DC Bus Power 1398 PDM 25 50 100 and 150 5 2 Operator Terminal Status 5 5 3 Personality Module Default 5 3 Error Messages and Error 5 4 Appendix A 1398 PDM 10 20 30 75 150 1 1398 PDM 25 50 100 150 2 Operator Vetmidale uie deca 3 Transformers ra c vecino exe EDI nr ERR A 4 Single Phase Transformer specifications A 4 Three Phase Transformer specifications A 4 Appendix B Optional 1 I F Conversion B 2 Power Supply Modules aude ced
138. or compliance with the European Union Low Voltage Directive LVD It must be mounted the same enclosure as ULTRA Plus PDM This table lists three phase power supplies and their fuses Item Number Description Alternate Number 1398 PSM 50 Power Supply Module 9101 3056 1398 PSM 125 Power Supply Module 9101 3057 Auxiliary PSM 9101 0439 Connector TB1 PSM Screw Terminal 9101 0111 1398 PSM 50 Fuse 9101 0225 Bussman KLM 8 or Littelfuse KLK D 8 1398 PSM 125 Fuse 9101 1076 Bussman KLM 20 or Littelfuse KLK D 20 Fuse F1 PSM AUX 9101 0123 Bussman 7 or Littelfuse 313 007 Options and Accessories B 3 AC Line Filters This table lists AC Line Filters required for CE EMC compliance 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 Multiple drives 1 9101 1388 50 Amps continuous single phase 1398 PDM 75 9101 1389 36 Amps continuous three phase 1398 PDM 150B 9101 1575 50 Amps continuous three phase Multiple drives 9101 1390 80 Amps continuous three phase 7 For multiple PDMs using one filter the combined PDMs input current must not exceed filter ratings Publication 1398 5 1 January 2000 B 4 Options and Accessories Cables This table lists power cables between the PDM Terminal
139. osure offering protection as defined in standard EN 60529 529 to at least IP54 such that they are not accessible to an operator or unskilled person NEMA 12 enclosure exceeds these requirements providing protection to IP65 The environment in the enclosure must be clean and free of oil mist coolant mist conductive particles water and corrosive chemicals The enclosure must also be properly sized and ventilated if required to ensure that the required operating temperature of the ULTRA Plus PDM is not exceeded Refer to Specifications on page A 1 Ventilation Install the ULTRA Plus Components 2 3 The maximum power losses are shown below to help in sizing an enclosure and any required ventilation Typical heat losses can run approximately one half maximum power losses Maximum power losses for help in sizing enclosures Model Maximum Loss Watts 1398 PDM 10 50 dissipative shunt 1398 PDM 20 100 dissipative shunt 1398 PDM 25 200 1398 PDM 30 150 dissipative shunt 1398 PDM 50 180 1398 PDM 75 300 dissipative shunt 1398 PDM 100 275 1398 PDM 150 300 1398 PDM 150B 500 dissipative shunt 1398 PSM 50 110 dissipative shunt 1398 PSM 125 240 dissipative shunt Operator Terminal 25 3 0 kVA Transformer 350 TF 03 3 kW transformer 350 TF 06 6 kW transformer 600 TF 18 18 kW transformer 1200 As an additional aid in sizing an
140. ow ULTRA Plus PDM Phasing of Phasing Connections Power Source 1398 PDM 10 20 and 30 Single Arbitrary between L1 and L2 N 1398 PDM 075 Single Arbitrary between L1 and L2 N 1398 PDM 075 and 150 Three Arbitrary between L1 L2 N and L3 If auxiliaty power is used ensure proper connections are made to terminals L1 AUX and L2 N AUX 3 With input power still off disconnect motor leads from ULTRA Plus PDM terminals R S and T Verify with an ohmmeter that the resistance between ULTRA Plus PDM terminals R to GND S to GND and T to GND is above 500k ohms If the resistance is acceptable reconnect the motor leads to the ULTRA Plus terminals marked S and Connect all interface cables P1 P7 to the ATTENTION Perform the initial power up with the motor shaft disconnected from a load and the shaft key removed Improper wiring ot undiscovered shipping damage could result in undesired motor motion Be prepared to remove power if excessive motion occurs S Make sure that the motor is disconnected from the load before applying power This prevents mechanical damage should a fault occur Apply input power and check the LEDs The green DC BUS LED should turn on to indicate power is applied The bicolor STATUS LED should turn green 7 8 IMPORTANT The PDM is in a fault condition if the STATUS LED is red Continue with the following instructions and perform Step 9 to clear any faults
141. pecifically the European Union Ultimately it is the responsibility of the machine builder to ensure that the machine meets the appropriate requirements as stated The following installation requirements are for compliance to the Low Voltage Directive LVD and the Electromagnetic Compatibility EMC Directive for ULTRA Plus PDMs The information below is based on successful testing using the specified installation methods Publication 1398 5 1 January 2000 2 28 Install the ULTRA Plus Components Electromagnetic Compatibility Directive It is impossible to guarantee a specific ULTRA Plus PDM installation will meet the EMC requirements without testing The 1398 PDM 10 20 30 75 and 150B installed as described below should be compliant with European EMC requirements The 1398 PDM 25 50 100 and 150 are not CE compliant Figure 2 19 Recommended installation for EMC Encoder Leads Bulkhead Connectors F or Clamps R 5 Bracket EN No Shield ENCLOSURE Connection Required MOTOR POWER CABLE Ground Bus Bar ALTERNATIVE MOTOR POWER CABLE SHIELD TERMINATION FILTER Bulkhead Connector or Clamp MOTOR LEADS Publication 1398 5 1 January 2000 Install the ULTRA Plus PDM Components 2 29 Important points are Cable shields must be bonded to the enclosure at
142. presentative for sales and order support product technical training warranty support support service agreements Technical Product Assistance If you need to contact Allen Bradley for technical assistance please review the information in the Check for Problems in the System chapter first Then call your local Allen Bradley representative For the quickest possible response please have the catalog numbers of your products available when you call Chapter 1 Functional Description Overview of the ULTRA Plus PDM System The ULTRA Plus PDM motion control system is a positioning drive system which integrates a high performance sinusoidal brushless motor velocity controller and a programmable position controller into a single package Traditional motion controller architecture uses separate drive and position control modules with an analog interface between individual components The ULTRA Plus PDM motion controllers use advanced microprocessor technology to control both position and velocity with a single processor eliminating the need for any analog interface The single processor architecture eliminates the problems associated with analog circuitry such as offset and thermal drift Both the velocity and position control loops are closed digitally so gain parameters are stored as numbers which give repeatable results over time and from controller to controller Figure 1 1 ULTRA Plus PDM Product Family The ULT
143. rent address on DIP switch SW1 for each PDM on the RS 422 network The cable used for these connections should be 22 AWG twisted pair with an overall shield grounded at one point Figure 3 31 RS 422 Multi drop connections AXIS n Port 2 Port 2 TXD P6 TXD P6 TXD P6 4 TXD P6 3 RXD P6 1 SW1 7 OFF SW1 7 OFF RS 232 Daisy Chain The two serial ports can also operate as one port with the transmit and receive lines fed through for multiple connections Switch 7 on DIP switch SW1 selects the independent or daisy chain operation of the two serial ports Remember to set a different address for each PDM in the chain The cable used for these connections should be 22 AWG twisted pair with an overall shield grounded at one point Figure 3 32 RS 232C Daisy chain connections XD RXD GND TXD RXD GND 3 2 5 3 2 5 P6 Port 2 P7 Port 1 SW1 7 OFF AXIS n XD GND TXD RXD GND 3 2 5 3 2 5 P6 Port 2 P7 Port 1 SW1 7 ON AXIS 2 Operator Terminal COM1 Connector TXD 14 TXD 15 RXD 16 RXD 17 COM 7 Wire the ULTRA Plus Components 3 47 Operator Terminal 1398 HMI 002 Figure 3 33 illustrates an additional option which is to connect one Operator Terminal to multiple PDMs This method requires RS 422 connections as shown in the following drawing A PDM may be selected from the terminal by using the NO key followed by the numeric key corr
144. s Components 3 23 The ULTRA Plus PDM has sinking active low I O which is common in the US but sourcing active high I O is preferred in Europe Rockwell Automation Allen Bradley offers a DIN rail mounted interface card which converts the I O from sinking to sourcing active high This interface card must be mounted in the same enclosure as the drive PDM pin connection with the IF 24V Conversion Card The interface card is a DIN rail mounting unit that has a terminal strip 1 5mm_2 screw clamp type down each side The PDM side of the card connects to P1 and P2 connectors on the PDM Connector P1 General purpose inputs PDM Pin Wire IF Card Pin Cable Number Color Number Pair 1 24 volt common GREEN 1 Pair 1 2 Input RED 2 Pair 1 3 Input ORANGE 3 Pair 2 4 Input BLACK 4 Pair 2 5 Input RED 5 Pair 3 6 Input WHITE 6 Pair 3 7 Input RED 7 Pair 4 8 Input BLACK 8 Pair 4 9 Input BLUE 9 Pair 5 10 Input RED 10 Pair 5 11 Input BLACK 11 Pair 6 12 Input YELLOW 12 Pair 6 13 Input RED 13 Pair 7 14 Input YELLOW 14 Pair 7 Publication 1398 5 1 January 2000 3 244 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Continued Number Color Number Pair P2 General purpose inputs 1 Input WHITE 1 and outputs 2 Input BLACK
145. s The ports operate at baud rates of 1200 2400 4800 9600 or 19200 Refer to the GML Ultra Software manuals for detailed information The default setup for the serial ports is e 9600 baud e No parity 8 data bits stop bit Handshaking ON e RS 232C protocol Host Computer Serial 2 Computer P6 provides the communication interface between the PDM and the personal computer used for programming and configuration This is also the serial port that must be used for Host communications Host computer and signal names One or more ULTRA Plus PDMs may be installed on an RS 422 multi drop network or an RS 232 daisy chain network If more than one ULTRA Plus Publication 1398 5 1 January 2000 3 40 Wire the ULTRA Plus Components PDM is in the network each must have a unique address selected on the 5 1 dip switch Refer to Networking on page 3 44 for more information Connector Pin Signal Name RS 232 RS 422 P6 Serial Port 2 1 No connection RXD 2 RXD RXD 3 TXD TXD 4 No connection TXD 5 Common Common 6 Shield Shield Figure 3 24 shows typical RS 232 connections between a personal computer PC and the Serial port P6 on the PDM These diagrams illustrates the connections required for programming a single PDM Figure 3 24 Personal Computer RS 232 connections ULTRA Plus Personal Computer Serial Port P6 9 pin Serial Connector Connector RXD P6 2 TXD P6 3 COM
146. s so misunderstood as electrical noise The subject is complex and the theory easily fills a book This section provides guidelines that can minimize noise problems The majority of installations do not exhibit noise problems However the filtering and shielding guidelines are provided as counter measures The grounding guidelines provided below are simply good grounding practices They should be followed in all installations Electrical noise has two characteristics the generation or emission of electromagnetic interference EMI and response or immunity to EMI The degree to which a device does not emit EMI and is immune to EMI is called the device s ElectroMagnetic Compatibility EMC Equipment for use in the European Union legally requires a specific level of Since this applies when the equipment is brought into use it is of considerable importance that a PDM system as a component of a machine be correctly installed Installation guidelines for specific products can be found in the product manuals or as separate documents available from Rockwell Automation Figure 2 23 shows the commonly used EMI model The model consists of an EMI source a coupling mechanism and an EMI victim Devices such as servo drives and computers which contain switching power supplies and microprocessors are EMI sources The mechanisms for the coupling of energy between the source and victim are conduction and radiation Victim equipment can be a
147. se inputs Pin Signal Name Assignable Function 14 Input 13 Program Select 13 Input 12 Int2 Program Select 12 Input 11 Int1 Program Select 11 Input 10 Emergency Return 10 Input 9 Pause 9 Input 8 Jog Forward 8 Input 7 Jog Reverse 7 Input 6 Home Command 6 Input 5 Home Switch 5 Input 4 Start Program 4 Input 3 Enable 3 Input 2 Reverse Limit 2 Input 1 Forward Limit 1 24 VDC Common Even if an input is assigned a function it may be used as a general purpose input Wire the ULTRA Plus Components 3 27 Digital Outputs The general purpose outputs are referred to as O1 through O8 in program statements The outputs are optically isolated and operate on the same 24 volt supply used by the general purpose inputs Digital outputs and assignable functions These outputs are all capable of sinking 75 mA continuously driven to less than 1 volt Outputs O7 and O8 are defined respectively as Home Sequence Complete In Position and Error Outputs however functions may be disabled and the outputs used as general purpose outputs Optionally Output O4 may be enabled as a Program Running output and output O5 may be enabled as an At Home output ATTENTION ULTRA Plus will not automatically turn outputs External circuitry must be used to ensure the state of digital outputs in an emergency stop situation Failure to observe this precautio
148. t common closing a switch will allow current to flow through the opto isolator turning it on In general inputs are considered ON in this state and OFF when there is no connection from the input to 24 volt common The Forward and Reverse Limit switches are exceptions with the switch open indicating that a limit has been hit The Home Switch input parameter defines the Home switch input to be open or closed to indicate the home position and the PAUSE parameter can select the Pause input as active open or active closed The general purpose inputs on PDM are referred to as I1 through 116 in program statements Inputs I1 through 110 can be assigned the predefined functions shown in the table below Inputs I11 and 112 may be used as Interrupt inputs Inputs 112 to 116 may be used as program select inputs of these input functions may be disabled and the inputs used as general purpose inputs In addition to the input functions defined below other functions may be assigned to any available input Optional input functions are Hardware Reset Stop Program Define Home Connector Pin Signal Name Assignable Function P2 General purpose 12 24 VDC inputs ANd Outputs 3 Input 16 Program Select MSB 2 Input 15 Program Select 1 Input 14 Program Select Publication 1398 5 1 January 2000 3 26 Wire the ULTRA Plus Components Publication 1398 5 1 January 2000 Continued Connector P1 General purpo
149. te correctly with this load Large switch mode supplies tend to need a certain minimum load before they will operate correctly It is very important how the power supply is mounted in relation to the Operating Terminal Observe the following points The power supply must be mounted close to the unit with usually not more than 6 feet of cable between the supply and the Operator Terminal Ideally as short a length as is possible should be use In particular the power supply should not be mounted on the back of the panel when the Operator Terminal is installed in the panel door unless a short cable run can be achieved The wire used to connect the Operator Terminal to its power supply should be at least 22 gauge wire If a longer cable run is used you will need to increase the cable gauge The routing of the cable should be kept away from contactors inverters and other devices that generate significant electrical noise Publication 1398 5 1 January 2000 3 18 Wire the ULTRA Plus Components Motors Publication 1398 5 1 January 2000 Power Connections Phasing of the three phase drive module outputs R S and T must conform to the motor R S and T leads for proper operation Connect the earth ground to ensure a safe installation and proper operation See Figure 3 13 for connector pin and signal identification of H and F Series motors Figure 3 13 Motor power connections for H and F Series mo
150. th an ULTRA Plus PDM system Prior to installation of the ULTRA Plus PDM system verify that all the necessary components are available Each axis of motion requires an ULTRA Plus PDM and a motor If 1398 PDM 25 50 100 and 150 is used there must be at least one power supply module for the system ATTENTION Observe all applicable local national and international safety codes when using this equipment Wiring practices grounding disconnects and over current 5 g 9 gt protection are of particular importance Failure to observe safety codes could result in personal injury or damage to equipment Before mounting the PDM you should install any option cards Personality Modules and system firmware Other operations such as removing jumpers on the logic board should also be performed before mounting the system ATTENTION During installation protect equipment from metal chips weld splatters and other debris Complete all drilling cutting welding etc before mounting the equipment Failure to observe this precaution could result in damage to or destruction of the equipment Publication 1398 5 1 January 2000 2 2 Install the ULTRA Plus PDM Components Publication 1398 5 1 January 2000 Environment The ULTRA Plus PDM and power supply modules are designed for simple installation on a flat surface such as the back wall or plate of an enclosure They must be enclosed in a grounded metal encl
151. the PDM is enabled and opens when the PDM is disabled Enabled relay output and signal names Relay Common P3 3 is the common of this contact This contact is rated 0 3 at 24 VDC ATTENTION pe ULTRA Plus PDM will not automatically turn outputs External circuitry must be used to ensure the state of digital outputs in an emergency stop situation Failure to observe this precaution could result in damage to the equipment or severe bodily injury Connector Pin Signal Name Analog 1 0 and status 2 Enabled Relay output 3 Relay Common The PDM provides interfaces for two separate encoder feedback connections The PDM will accept encoder inputs at a maximum frequency of 750 kHz on a single channel A or B for encoders with phase error of less than or equal to 45 degrees There is a four times multiplier on the encoder input to the PDM on both the encoder 1 and encoder 2 inputs so four encoder counts is equivalent to one encoder line With a standard 2000 line encoder the PDM will count 8000 encoder pulses per revolution The PDM will accept differential line driver quadrature signals from a 5 volt incremental encoder As illustrated in Figure 3 20 the PDM accepts A B and I Index signals from the encoder with A leading B for clockwise rotation facing the motor drive shaft Connections are provided for A B B I I 5 VDC and common signals Publication 1398 5 1 January 2000 3 32 Wire the
152. tors DRIVE MODULE MOTOR POWER MOTOR POWER TERMINALS CABLE MATING CONNECTOR CONNECTOR R R AA A R WHITE S S B S BLACK T T C lt T DRIVE MODULE GND 77 CHASSIS GREEN D MOTOR CASE REN 1 Do not interchange any connection in the cable 2 Ground connections 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 See Figure 3 14 on page 3 18 for connector pin and signal identification of N Series motors Figure 3 14 Motor power connections N Series motors E0723 1 Do not interchange any connection in the cable 2 Ground connections 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 ATTENTION High voltage may be present on terminals of the ULTRA Plus PDM Remove power and disconnect the power cable before making or removing any connection Failure to observe this precaution could result in damage to the equipment or severe bodily injury Wire the ULTRA Plus Components 3 19 Cable sizes are indicated in the appropriate drawings Refer to Power Wiring Diagram for 1398 PDM 10 20 and 30 on page 3 2 Refer to Power Wiring for 1398 PDM 75 on page 3 3 Refer to Power Wiring for 1398 PDM 150B on page
153. ts in italics Publication 1398 5 1 January 2000 Preface 4 Product Receiving and Storage Responsibility Allen Bradley Support Publication 1398 5 1 January 2000 You the customer are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company Check the item s you receive against your purchase order If any items are obviously damaged it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill Should you discover any concealed damage during unpacking you are responsible for notifying the freight agent Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment Leave the product in its shipping container prior to installation If you are not going to use the equipment for a period of time store it ina clean dry location within an ambient temperature range of 0 to 65 C 32 to 149 F within a relative humidity range of 5 to 95 non condensing in an area where it cannot be exposed to a corrosive atmosphere ina non construction area Allen Bradley offers support services worldwide with over 75 Sales Support Offices 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone plus Allen Bradley representatives in every major country in the world Local Product Support Contact your local Allen Bradley re
154. uct 1 P 4 Chapter 1 Functional Description su Mies ove ete cae eee in 1 1 Systen C VeL VAC We ane eect GN cs aepo S a Selene ae Ms 1 2 GML Ultra for Windows 1 3 Positioning Drive Modules ess sen ease e rx adem 1 4 Power Supply Module 5 1 5 Motots LEN apes tua a bh 1 5 Personality Module 1 5 Manuals e een s S DIEN RIES A 1 5 ACCESSOS EEE E eiut 1 6 sso cu eeu tote th eror Gare siis 1 6 Transformer S e reais ne fone qur ere wile Vete ar Sdn 1 7 Auxiliary Power Supply Module 5 1 7 Cables itus eos atit ats head a osuere WE anton d 1 7 Shunt Le s Qe 1 8 Personal Computer 1 8 Chapter 2 obs aee ite pute Meee sape gud a eee 2 1 Environment cese xml eek eee eee ye 2 2 Ventilationen ol TIEREN REO REN See S g es 2 3 Transformer Sing eee OR v COR Rn 2 4 Mounting Requirements cuoc och Ra teda xen sen 2 10 1398 PDM 25 50 100 and 150 Power Supply Module 2 14 PSM Auxiliary 2 14 Motots Se else aa a i ELO lls 2 16 External Shunti o bis d uet a a bx T a 2 17 Operator Terminal eot to o dede ep uu 2 19 I F Conversion Card 24VDC Sourcing

1398-5.1 JAN00 ULTRA Plus Series Positioning

Contents

Download Pdf Manuals

Related Search

Related Contents