1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding,...
Transcript of 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding,...
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1398ULTRA Plus SeriesPositioning Drive Module(Catalog Nos. 1398-PDM-10, -20, -30, -50, -75, -100, -150, and -150B)
Installation Manual
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Important User Information
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ATTENTION
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Table of Contents
Preface$ * %+,- * %* - * %.- * /&0 * 1.,- * 1* & & * 2 * 2
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Chapter 1Overview of the ULTRA Plus PDM System
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Chapter 2Install the ULTRA Plus PDM Components
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Chapter 3Wire the ULTRA Plus PDM Components
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iii
Chapter 4Apply Power for the First Time %1?; *0- %>/>1>97%7> 2 %
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Chapter 5Check for Problems in the System 3<0!3<0" 7 %
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Appendix ASpecifications %1?; *0- %>/>1>97%7> %
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Appendix BOptions and Accessories *0-5 %
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iv
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Preface
Introduction & ( '
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Who Should Use this Manual
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Preface 2
Contents of this 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 PDM product series.
2 Install ULTRA Plus PDM Components
Provides mounting information for the ULTRA Plus PDM system.
3 Wire the ULTRA Plus PDM Components
Provides connection information for the ULTRA Plus PDM system.
4 Apply Power for the First Time
Outline steps when applying power to equipment for the first time.
5 Check for Problems in the System
Diagnostic aids that help isolate problems to a system module.
Appendix A Specifications Provides physical, electrical, environmental, and functional specifications for the
Appendix B Options and Accessories Provides identification numbers and descriptions of the ULTRA Plus PDM and related products
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Preface 3
Related Documentation
Conventions Used in this Manual
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For this information Read This Document Document Number
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 Manual
1398-5.10
Step oriented information that will help you use GML Ultra to program your ULTRA Plus system.
GML Ultra User Manual 1398-5.11
Reference material that explains the theory behind how you program your ULTRA Plus for your application needs.
GML Ultra Reference Manual 1398-5.12
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 ordering instructions. Also indicates whether the documents are available on CD-ROM or in multi-languages.
Allen-Bradley Publication Index SD499
A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary
AG-7.1
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Preface 4
Product Receiving and Storage Responsibility
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Chapter 1
Overview of the ULTRA Plus PDM System
Functional Description ,3&**0- ,3&**0-
Figure 1.1 ULTRA Plus PDM Product Family
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1-2 Overview of the ULTRA Plus PDM System
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Overview of the ULTRA Plus PDM System 1-3
Figure 1.2 ULTRA Plus PDM Control System
GML Ultra™ for Windows™
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OR1398-PDM-150
ULTRA PLUS OPERATOR TERMINAL(Optional)
MANUALS
PERSONAL COMPUTER(Windows™ compatible
user supplied)
GML ULTRA™SOFTWARE
AUXILIARY ENCODER(User supplied option)MOTOR SERIES
F-SERIESH-SERIESN-SERIES
ULTRA PLUSPOWER SUPPLY
MODULE
ULTRA PLUSPOSITIONING DRIVE
MODULE
PERSONALITYMODULE
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1-4 Overview of the ULTRA Plus PDM System
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Overview of the ULTRA Plus PDM System 1-5
Power Supply Module (PSM)
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Personality Module (PM)
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1-6 Overview of the ULTRA Plus PDM System
Accessories Operator Terminal
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Figure 1.3 ULTRA Plus 1398-HMI-002 Operator Terminal (front)
Figure 1.4 ULTRA Plus 1398-HMI-003 Operator Terminal (front)
function keys
programmable keys
numeric keypad
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X3
X2
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STATUS
MODE
CLEAR
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NO
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YES
ENTER
function keys
numeric keypad
programmable keys
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Overview of the ULTRA Plus PDM System 1-7
Transformers
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Auxiliary Power Supply Module (PSM)
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Motor Connectors
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1-8 Overview of the ULTRA Plus PDM System
Shunt Kits
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Chapter 2
Install the ULTRA Plus PDM Components
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2-2 Install the ULTRA Plus PDM Components
Environment
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Install the ULTRA Plus PDM Components 2-3
Ventilation
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Maximum power losses for help in sizing enclosures
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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
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A2dw + 2dh + 2wh( )
144-----------------------------------------------=
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2-4 Install the ULTRA Plus PDM Components
Transformer Sizing
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63 025,-------------------------------------------------------------------------------- 746Watts
HP------------------------× KVA
1000Watts---------------------------× 2.0×=
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Install the ULTRA Plus PDM Components 2-5
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2-6 Install the ULTRA Plus PDM Components
Figure 2.1 Single PhaseTransformer Load Regulation Curve
DIAG, XFMR LOAD REG
20625 JL __ __C UPDATE TITLE BLOCK
PDM UPDATE 19960 BC 2-19-92 BCB
1
1
1
.XXX±.010DECIMALS.XX±.020FRACTIONS:±1/64"
DO NOT SCALE DRAWING
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
A
PART NO.
DWG SIZE SHEETSCALE
1:1 of
REV ECO CHKRDATEREVISION DESCRIPTIONBYDESIGN ENGRDRAWN BY
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9101-1057
11-22-91
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19866A RELEASED
210
220
230
240
250
2. CURVE SHOWS REDUCTION IN TRANSFORMER SECONDARY VOLTAGE
AND DRIVE MODULE INTERNAL DC BUS VOLTAGE, DUE TO TRANSFORMER
INTERNAL LOSSES, AS BUS CURRENT LOAD INCREASES.
(NOT ACCESSIBLE TO THE USER).
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.
DC BUS VOLTAGE AND CURRENT IS MEASURED AT MOTOR POWER
CIRCUITS INTERNAL TO THE DRIVE MODULE
1 PHASE TRANSFORMER SECONDARY VOLTAGE
VERSUS DC BUS CURRENT
AND CORRESPONDING DC BUS VOLTAGE,
3 kVA TRANSFORMER
BUS CURRENT (ADC)
BU
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VD
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260
270
280
290
300
310
320
233
226
219
212
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184
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170
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0020-5097 3
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RELIANCE MOTION CONTROL1 PHASE TRANSFORMER
NOTES:
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Install the ULTRA Plus PDM Components 2-7
Figure 2.2 Three PhaseTransformer Load Regulation Curves
DIAG, XFMR LOAD REG
B-C B-19866,C-19960
20625 JL __ __D UPDATE TITLE BLOCK
1
1
1
.XXX±.010DECIMALS.XX±.020FRACTIONS:±1/64"
DO NOT SCALE DRAWING
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
A
PART NO.
DWG SIZE SHEETSCALE
1:1
REV ECO CHKRDATEREVISION DESCRIPTIONBY
DESIGN ENGRDRAWN BY
8-5-88
8-5-88BC JH
UNLESS OTHERWISE SPECIFIED
9101-0132
8-5-88
of1 1
JHBC
16383A RELEASED
2. CURVES SHOW REDUCTION IN TRANSFORMER SECONDARY VOLTAGE
AND THE DRIVE MODULE DC BUS VOLTAGE, DUE TO TRANSFORMER
INTERNAL LOSSES, AS BUS CURRENT LOAD INCREASES.
3. ALL DATA TAKEN WITH TRANSFORMER PRIMARY VOLTAGE HELD
TO 480 VAC 3 PHASE LINE TO LINE 60 Hz AND WITH SECONDARY
WIRED FOR 230 VAC LINE TO LINE NO LOAD.
DC BUS VOLTAGE AND CURRENT IS MEASURED AT POS & NEG
OUTPUT TERMINALS OF THE POWER SUPPLY MODULE.
3 PHASE TRANSFORMER SECONDARY VOLTAGE
VERSUS DC BUS CURRENT
AND CORRESPONDING DC BUS VOLTAGE,
FOR 3, 6, 12, AND 18 kVA TRANSFORMERS
BUS CURRENT (ADC)
BU
S V
OLT
AG
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VD
C)
330
3 kVA
6 kVA
12/18 kVA
0 10 20 30 40 50 60 70 80 90100250
260
270
280
290
300
310
320
233
226
219
212
205
198
191
184
177(V
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0020-5091-0010020-5091-0020020-5091-0030020-5091-004
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kVAPART NUMBER
RELIANCE MOTION CONTROL3 PHASE TRANSFORMERS
NOTES:
Publication 1398-5.1 — January 2000
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2-8 Install the ULTRA Plus PDM Components
Figure 2.3 Single PhaseTransformer Outline Diagram
9.20 MAX.
8.00 MIN.
SECONDARY CONNECTIONS
PRIMARY CONNECTIONS
8-32 THD BOLTS
8-32 THD BOLTS
(4.17 DIA)
(4.17 DIA)
2
2
CONNECTION INSTRUCTIONS
1/4-20 GROUND STUD(6.35 DIA)
(TRANSFORMER CHASSIS)
8.20 MAX. CLEARANCE RECOMMENDEDFOR ACCESS TO WIRING
NOTES:
1. DIMENSIONS ARE IN INCHES (mm)
2 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING CONNECTIONS TO
TRANSFORMER TERMINAL STRIPS.
(210)
(235)
(200)9.10 MAX.
.XXX±.005DECIMALS.XX±.010FRACTIONS:±1/64"
DO NOT SCALE DRAWINGUNLESS OTHERWISE SPECIFIED
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
9101-1056
DATE DATE
1-10-89
C
PART NO.
DWG SIZE SHEETSCALE
1:1
REV ECO CHKRDATEREVISION DESCRIPTION
DIAGRAM,OUTLINE,TRANSFORMER
BYDESIGN ENGRDRAWN BY
BBBC 2-22-89
17320 2-23-89A BC JH
A00759 TM __ __B1 CHG'D TEXT19866 SJ 12-20-91 BCB UPDATED TITLE BLOCK
RELEASED
(230)
3.32 ±0.06(84 ±1.5)
8.00 ±0.06(203 ±1.5)
MOUNTING HOLES: 0.28 ±0.02 DIA (4)(7.1 ±0.5)
3kVA TRANSFORMERELECTRO-CRAFT P/N 0020-5097
1 1of
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-9
Figure 2.4 Three Phase Transformer Outline Diagram
A MAX
1
1
B MAX
.012 REF
F REF
C MAX
D ±0.06
G REF
E ±0.06
B-C 19866,20625
A00761 TM __ __C1 REDRAWN
2
1
SECONDARYCONNECTIONS
PRIMARYCONNECTIONS
CONNECTION INSTRUCTIONS
0.25-20 GROUND STUD(TRANSFORMER CHASSIS)
8.0 MIN CLEARANCERECOMMENDED FORACCESS TO WIRING
0.56 ±0.03 DIA THRU (4)
OVERALL DIMENSIONS
F G PRIMARY SECONDARY
3.502.382.383.25
1.151.361.301.81
5-406-326-328-32
6-328-32
10-3210-32
36
1218
12.5015.2515.2522.50
6.506.508.509.00
9.5012.5013.2518.25
5.5010.5010.5016.00
4.203.785.905.38
A B C D E
RELIANCE MOTION CONTROLTRANSFORMER PART NO.
KVARATING
0020-5091-0010020-5091-0020020-5091-0030020-5091-004
MOUNTING HOLES LOCATION SCREW SIZES
9101-0131
.XXX±.005DECIMALS.XX±.010FRACTIONS:±1/64"
DO NOT SCALE DRAWING
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
D
PART NO.
DWG SIZE SHEETSCALE1:1 of
REV ECO CHKRDATEREVISION DESCRIPTIONBYDESIGN ENGRDRAWN BY
8-5-88
8-88BC JH
PART NO.
UNLESS OTHERWISE SPECIFIED
9101-0131
2-5-87
1 1
DIAG,OUTLINE,XFMR,BRU-500/IQ5000
JHBCB
16383A RELEASED
2
1 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRINGCONNECTIONS TO TRANSFORMER TERMINAL STRIPS.TERMINAL STRIP SCREWSIZES ARE LISTED IN THE DIMENSION CHART.
USE LUGS DESIGNED FOR #6 SCREW MOUNTING.
NOTES:
Publication 1398-5.1 — January 2000
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2-10 Install the ULTRA Plus PDM Components
Mounting Requirements
*,3&**0-
Figure 2.5 1398-PDM-10, 20 and 30 Mounting
P1
14.20360.6
13.75349.2
1.0025.4
1.0526.6
1.0025.4
4.10104.1
0.277.0
CLEARANCE HOLES FOR #10(M5) MOUNTING SCREWS
8.93226.8
SW1
U10
EXHAUSTAIR
AIR INTAKE
Digital InputsTB1
1
1
10
5
L1 Aux
L2/N Aux
L1
L2/N
DC Bus+
DC Bus-
100-
240
Vac
50/
60 H
z
5
Digital
AndInputs
P2
10
Outputs
I/OAnalog
P35
Status/
1
P4Encoder 2Auxiliary
P5Encoder 1
Motor
T
R
S
Mot
or
DC Bus
After Removing PowerMay Exist Up To Five Minutes
High VoltageWARNING:
P6Serial 2
Computer
P7
AuxiliarySerial 1
Status
Ultra Plus Series
Allen-Bradley
TB2
1
3
2
Inte
rnal
Ext
erna
l Shu
nt
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Install the ULTRA Plus PDM Components 2-11
Figure 2.6 1398-PDM-75 Mounting
226.8
0.277.0
151.7
25.4 25.4
SW1
U10
AIR INTAKEAIR INTAKE
AIR EXHAUST
FIN
AL
INS
PE
CT
ION
5
1
10
P1Digital Inputs
1
5
And OutputsDigital Inputs
P2
10
TB1
L2/N Aux
L1 Aux
L2/N
L3
L1
DC Bus-
DC Bus+
100-
240
Vac
50/
60 H
z
DC Bus
Mot
or
T
S
R
Auxiliary
P3Status/Analog
I/O
5
1
Encoder 1P5
Motor
P4Encoder 2
ComputerSerial 2
P6
After Removing PowerMay Exist Up To Five Minutes
High VoltageWARNING:
Status
TB2
P7Serial 1
Auxiliary
Ext
erna
l Shu
nt
Inte
rnal 1
3
2
Ultra Plus Series
Allen-Bradley
5.97
1.9950.5
1.00 1.00
8.93
14.20360.7
13.75349.2
Publication 1398-5.1 — January 2000
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2-12 Install the ULTRA Plus PDM Components
Figure 2.7 1398-PDM-25, 50, 100, and 150 Mounting
P1General Purpose
Inputs
Inputs And OutputsGeneral Purpose
P2
StatusI/O AndAnalog
P3
Input 2Encoder
P4
Input 1Encoder
P5
Port 2Serial
P6
Port 1Serial
P7
16.87
428.6
0.25
6.4
0.45
11.4
4.50
114.3
34.9
34.9
246.4
252.1
16.15
410.2
AIR INTAKE
EXHAUSTAIR
Allen-Bradley
Ultra Plus Series
Dangerous Voltages May Exist Up To 5 Minutes AfterDo Not Remove Cover With Power Applied.
Removing Power.
Do Not Apply Power With Cover Removed.WARNING:
1.38
1.38
9.93
9.70
17.50
444.5
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-13
Figure 2.8 1398-PDM-150B Mounting
POT1 POT2 POT3
P10
111
P9P8
U87
U67U66
U57
U57
U66
U87
U67
U10
U10
Ultra Plus SeriesAllen-Bradley
S
R
T
DC Bus+
L2
L3
L1 Aux
L2/N Aux
DC Bus-
L1
100-
240
Vac
50/
60 H
z
Au
xilia
ryA
C M
ain
s (3
0 O
nly
)M
oto
r
Inte
rnal
Ext
ern
al S
hu
nt
1
3
2
TB2
DC BUS
Status
P7Serial 1
Auxiliary
P6Serial 2
Computer
P5Encoder 1
Motor
P4Encoder 2
Auxiliary
P3Status/Analog
I/O
P2Digital InputsAnd Outputs
P1Digital Inputs
WARNING:High Voltage MayExist Up To Fifteen MinutesAfter Removing Power.
TB1
FIN
AL
INS
PE
CT
ION
226.8
AIR INTAKE AIR INTAKEAIR INTAKE
AIR EXHAUST
8.93
14.20360.7
151.75.97
2.7569.9
2.7569.931.8
1.250.277.0
13.75349.2
[31.8] [139.7]1.25 5.50
Publication 1398-5.1 — January 2000
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2-14 Install the ULTRA Plus PDM Components
1398-PDM-25, 50, 100, and 150 Power Supply Module
(*0- *0-
PSM Auxiliary Transformers
4 /? *-
Figure 2.9 PSM Auxiliary Transformer mounting
9101-0233
1.
5.00 MAX
4.38
5.50 MAX.
4.256.25
1.
8.0 MIN. CLEARANCE RECOMMENDED FOR ACCESS TO WIRING
RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED
FOR WIRING CONNECTIONS TO THE TRANSFORMER.
INPUT (PRIMARY) CONNECTIONS: H1,H4480 VAC INPUT: JUMPER H3 to H2240 VAC INPUT: JUMPER H1 to H3 AND H2 to H4
OUTPUT (SECONDARY) CONNECTIONS: X1,X2120 VAC
H1 H3 H2 H4
X1X2
OUTPUT POWER @ 50/60Hz110 VAC OUTPUT VOLTAGE50˚C MAX. TEMPERATURE RISE 500 VA MIN.
NOMINAL OPERATING VOLTAGES 480 OR 240 INPUT, 120 OUTPUT460 OR 230 INPUT, 115 OUTPUT440 OR 220 INPUT, 110 OUTPUT
CONNECTION INSTRUCTIONS
X2 X1
H1 H2H3 H4
MAX.
0.69
0.318-32 TERMINAL SCREWS (6)
NOTES:
SCHEMATIC SYMBOL
SPECIFICATIONS:
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-15
Figure 2.10 PSM-AUX Outline and Connection Diagram
1.75(44.5)
3.50(89)
0.50(13)
8.38(213)
0.50(13)
3.00(77)
2.00(50)
9.00(229)
0.25(6.5)
0.50(13)
AUXILIARY POWER SUPPLY MODULE
DIAGRAM, OUTLINE & CONNECTION DRAWING
DOCUMENT NO. 9101-0134 REV D1
Publication 1398-5.1 — January 2000
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2-16 Install the ULTRA Plus PDM Components
Motors
'
• 0
• -
• . - %>>E.!/%/E4" 2>E.
ATTENTION
!< (
< @ -
4 )
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-17
External Shunt
< />>+!?%>% %%;1"< ?>>+!?%>% %8?9"'
&) %/ )
+ %1 , (
Figure 2.11 External Shunt (200W) mounting and connection diagram
1
3
8.60
4.00
3.40 MIN
TB1
TERMINAL
3
1
2
EXHAUSTAIR
AIR INTAKE(mm)
(86.3)
(101.6)
(218.4)
INCHES
2
1.00
0.502.00
3.05
0.25
5.20 4.75
#10 (M5)MTG HOLES (3)
(77.5)
(50.8) (12.7)
(6.3)(25.4)
(132) (120.6)
4
3
2
1
4
4.5 A
600V
EXTERNAL SHUNTRESISTOR
1
CONNECTION DIAGRAM
1 2 3
Terminal
NOTES:
LITTLEFUSE PART NUMBER : CCMR-4.5
#6-32 STUD (NUT AND WASHER SUPPLIED) FOR CUSTOMER GROUNDING.
36" OF #14 AWG WIRE IS SUPPLIED WITH EXTERNAL SHUNT RESISTOR.CUT TO LENGTH AS REQUIRED.
REMOVE JUMPER INSTALLED BETWEEN PINS 1 & 2 OF TERMINAL.
JUMPER INSTALLED BETWEEN PINS 1 & 2 OF TERMINAL.
INSTALL WIRING AS SHOWN.
FOR INTERNAL SHUNT RESISTOR:
FOR EXTERNAL SHUNT RESISTOR:
EXTERNAL SHUNT RESISTOR
Publication 1398-5.1 — January 2000
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2-18 Install the ULTRA Plus PDM Components
Figure 2.12 External Shunt (900W) mounting and connection diagram
0
2
1
3456
78
9
ABCD
E
F
WARNING: High VoltageMay Exist Up To Five MinutesAfter Removing Power
DC Bus
DC Bus +
DC Bus -
L1
L3
L2/N
L1 AUX
L2/N AUX
T 1B
EX
TE
RN
AL
SH
UN
T
INT
ER
NA
L
SE
RIA
L 2
AU
XIL
IAR
YM
OTO
R E
NC
OD
ER
CO
NT
RO
LLE
RS
ER
IAL
1
J4
J3
J2
J1
J5
TB2
1
2
3
STATUS
COM
A2
A1
Mot
or
R
T
S
100-
240
VA
C 5
0/60
Hz
Use twisted conductors
(2 twists per foot)
minimum or a shielded
twisted pair
8 AWG (8.4 mm)
105 °C, 600V wire
Max. Length 3.05 m
(10 ft) for each wire
There must be 155mm (6.1 in.) Of
clearance on all sides of
shunt module
There must be
155mm (6.1 in.)
of clearance on
all sides of
shunt module
Cabinet
Connect wires
to terminal block
inside front cover
At terminal block,
remove jumper
installed at factory
for internal shunt
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-19
Operator Terminal
4 /%14 /%2/ /> 5 !" !" 5 %>> ! "
& GH %
Figure 2.13 Operator Terminal (1398-HMI-002) Dimensions
10.50(266.7)
5.05(128.3)
3.50(88.9)
0.65(16.5)
6.00(152.4)
GASKET
Publication 1398-5.1 — January 2000
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2-20 Install the ULTRA Plus PDM Components
Figure 2.14 Operator Terminal (1398-HMI-003) Dimensions
RS-232 connector24 VDCNot used
1 2 3 4 5 6 7 8 9 10
8.11[206.0]
6.89[175.0]
6.26[159.0]
7.40[188.0]
3.28[83.25]
3.28[83.25]
3.28[83.25]
2.22[56.5]
0.17[4.25]
6.13 MAX.[155.7]
7.27 MAX.[184.7]
3.13[79.5]
Ø 0.14 (8)[3.5]Ø 3.86
[98.0]
3.70[94.0]
3.86[98.0]
3.86[98.0] 0.20
[5.0]
GASKET SUPPLIEDWITH UNIT
RECOMMENDED PANEL CUTOUT DIMENSIONS
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-21
I/F Conversion Card, 24VDC Sourcing
4 /%7 $@4/2=. . 0$D ! " ,3&**0-<,3=0
Figure 2.15 I/F 24 Volt Sourcing Conversion Card Mounting Dimensions
P1
P2 1
USER
26
261
77.0(1.9)
77.0(1.9)
169.0 (6.7)
42.5(1.7)
85.0(3.4)
47.0(1.9)
7.5(0.3)
25(1.0)
170.0 (6.7)
17.5(0.7)
35.0(1.4)
Publication 1398-5.1 — January 2000
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2-22 Install the ULTRA Plus PDM Components
PDM Fusing Requirements 4 ,3&**0-
Short Circuit Protection
$,D< . K43 !43"*0- K43 K43! " &-,3&**0-
, 3 $ ,37>;.( !43"*0-
$*0- D< . *0-0 (
'
• ;/>>F
• />8>>F
1398-PDM-10, 20, 30, 75, and 150B
7>>>&- /2> =
/>>>>>&- /2>= !...#A3&"
1398-PDM-25, 50, 100, and 150
7>>>&- /2>= '
• %1?; *- 7>'& 2>
• %1?; *- %/7'& ?>
& G* -H /
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-23
Personality Module Installation
* - ,3&**0- * - & 4 /%8 * -,3&**0-
Figure 2.16 Location of Personality Module
Installing the Personality Module (PM)
. ,3&**0-544
- ,3&**0- 3%3/@D!3%3/@D31 ,3&**0- 97" 544 3%,J3/@D,J 544 0.,3<0 ,3<0544
ATTENTION
!
5 * -
4
F1
U10
DS1F1
DS1
U10
SW1SW1
11
PersonalityModule
1398 PDM-10, 20, 30, 75, and 150BLOGIC BOARD
(component side)
1398 PDM-25, 50, 100, and 150LOGIC BOARD
(component side)
Publication 1398-5.1 — January 2000
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2-24 Install the ULTRA Plus PDM Components
- *D 544$*- ,J 3%3/*- ,J 544
&,3&**0- !%1?; *0- /77>%>>%7>"
$* -,3&**0- ,%>* -!*-" ,3&**0-$ *-
$,3&**0- ! "
IMPORTANT * - $ * - * - #-3,
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-25
System Firmware Installation
,3&**0- ,3&**0- & 4 /%9
Figure 2.17 Location of system firmware
U57U57
U67U67
U66U66
U87 U87
SYSTEMFIRMWARE
1398 PDM-10, 20, 30, 75, and 150BLOGIC BOARD
(component side)
1398 PDM-25, 50, 100, and 150LOGIC BOARD
(component side)
Publication 1398-5.1 — January 2000
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2-26 Install the ULTRA Plus PDM Components
Installing the Firmware EPROMs
. ,3&**0-544
- ,3&**0- 3%3/@D!31%1?;*0- 97%7>" 544 3%,J3/@D,J 544 0.,3<0 ,3<0544
- *D 544$*- ,J 3%3/*- ,J 544
&,3&**0- !%1?; *0- /77>%>>%7>"
$ <*&5-,3&**0- ,79,88,89,;9<*&5- ,3&**0-
$,3&**0- ! "
Jumper and DIP Switches A +1+2 /2=0. &) ) /2=!*%%" O/2=0.*/%/
0+% ,3&**0- 5 % !*9"& GD H 1 22
ATTENTION
! 4 <*&5-
5 * -
4
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-27
& G3) 0$*H / /9 ) +1+2+%,3&**0-
Figure 2.18 Location of jumper and DIP switch
Regulatory Requirements ( C <-. < ,,
3=0 !3=0"< .!<-."0 ,3&**0-
F1
U10
DS1F1
DS1
U10
SW1SW1
11
W4
W4W3
W3
1398 PDM-10, 20, 30, 75, and 150BLOGIC PC BOARD(component side)
1398 PDM-25, 50, 100, and 150LOGIC PC BOARD(component side)
DIP SWITCH Sw1
JUMPERS
Publication 1398-5.1 — January 2000
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2-28 Install the ULTRA Plus PDM Components
Electromagnetic Compatibility Directive
$ ,3&**0-<-. %1?; *0- %>/>1>97%7> < <-. %1?; *0- /77>%>>%7> .<
Figure 2.19 Recommended installation for EMC
Ground Bus Bar
FILTER
Bulkhead Connectorsor Clamps
EncoderLeads
Bulkhead Connectoror Clamp
S
T
R
MOTOR LEADS
MOTOR POWER CABLE
Bracket
No ShieldConnectionRequired
ENCLOSURE
ALTERNATIVE MOTOR POWERCABLE SHIELD TERMINATION
S
T
R
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-29
$ '
• . ) *0- $
• *0- $
• *0- G<-$H
• & $@5 .
5 $ , <-. P
%1?; *0- %>/>1>97%7><-. !%>=@" . *0- 0 *0-
Publication 1398-5.1 — January 2000
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2-30 Install the ULTRA Plus PDM Components
*0- ! *0-"
PDM current ratings and suitable supply filters
& &, < *
Roxburgh filters available directly from Rockwell Automation
%1?; *0- %>/>1>97%7>
PDM Current Rating Schaffner Roxburgh
1398-PDM-10 1φ 10 A FN350-12-29 MDF16 or MIF10
1398-PDM-20 1φ 19 A FN350-20-29 MDF18 or MIF23
1398-PDM-30 1φ 28 A FN350-30-33 MDF36 or MIF32
1398-PDM-75 3φ 28 A FN351-36-33 MDF336 or MIF330
1398-PDM-150B 3φ 50 A --- MDF 350
Roxburgh Current Rating Rockwell - USA Rockwell - Crewe
MDF18 1φ 18A NONE 48-0428
MDF36 1φ 36A 9101-1387 48-0429
MDF336 3φ 36A 9101-1389 48-0430
MDF501 1φ 50A 9101-1388 NONE
MDF350 3φ 50A 9101-1575 NONE
MDF3701 3φ 70A 9101-1390 NONE
MIF10 1φ 10A 9101-1517 NONE
MIF23 1φ 23A 9101-1518 NONE
1.MDF50 & MDF370 can be used for multiple PDMs
ATTENTION
!
4 )
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-31
Bonding Your System
!<-$"
,
4 //> $ <
Figure 2.20 Recommended bonding practices
Publication 1398-5.1 — January 2000
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2-32 Install the ULTRA Plus PDM Components
Multiple Sub Panels
&
Figure 2.21 Multiple sub-panels and cabinet
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-33
Motors and Cables
&@ >7H ) %/H *0- ,3&**0-& G- <-.H 1 />
Low Voltage Directive
*0- $*2J (
ATTENTION
!C 0.
- *0- (-
4 )
Publication 1398-5.1 — January 2000
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2-34 Install the ULTRA Plus PDM Components
I/F 24V Sourcing Conversion Card
,3&**0-!"$@5, !"$@5 < & 0$D $@5 *0-
ULTRA Plus PDM I/F Conversion Card
IMPORTANT /2=0.
Description Alternate Number
I/F Conversion Card, 24V Sourcing(1)
(1) Required for compliance with the European Union Low Voltage Directive (LVD). It must be mounted in the same enclosure as ULTRA Plus PDM.
9103-0152
Cable, I/F Conversion Card 3ft (1m) 44-0141-003
Cable I/F Conversion Card 10ft (3m) 44-0141-010
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-35
Emergency Stop Contactor
*0- ( $ 1 ( 0.
<-. *0- .(
Figure 2.22 Emergency Stop Contactor Wiring
!#D0"
IMPORTANT <-.
R
S
T
Drive
R
S
T
Motor
GNDGND
Isolated terminal
Grounded terminal or stud
Unbraided shield
Enclosure wall
Resistor
Resistor
Resistor
Publication 1398-5.1 — January 2000
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2-36 Install the ULTRA Plus PDM Components
Electromagnetic Compatibility
* ) ) (
) C
< ' !<-$" <-$ <-$<-$K< -.!<-."
< < , <-. *0- $ &
4 //1<-$<-$ <-$0 <-$ = <-$
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-37
Figure 2.23 EMI Source-Victim Model
$<-$ <-$ <-$ <D8%>>> 2 J !$<.%>>> 2 J$<.;>% J "D$.8/.81-$3 0 28% @
<-$ <-. '
• <-$
• K<-$! "
• <-$!"
$ <-$ C *0- @ C
EMIVICTIM
EMISOURCE
EMIVICTIM
CONDUCTED EMI
RADIATEDEMI
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2-38 Install the ULTRA Plus PDM Components
Filtering
. .*0- *0- $ *0-
5 <-. *0-. ( $ ,4 )! " ! "
. <-$ *0- $. . ( !."!*0-"
4 &@ *0- < 0 *0- *0-
IMPORTANT G.H G0 H
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-39
&@ & 4 & <, . 5 4
Rockwell Automation/Allen-Bradley PDM/ Power SupplySuitable AC Line Filter Types
Roxburgh Part Number
Schaffner Part Number
Single phase PDMs MIF xx or MDF xx
FN 350-xx
Three phase PDMs MIF3xx or MDF 3xx
FN 351-xx
Rockwell Automation stocks some Roxburgh filters, but does not offer low current single phase filters. Most applications are multiple axis such that multiple PDMs may be connected to a filter (e.g. MDF xx) with higher current rating. Manufacturer phone numbers: Roxburgh 01724-281770 (011-44-1724-281770 from USA), and Schaffner (1-800-367-5566).
Publication 1398-5.1 — January 2000
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2-40 Install the ULTRA Plus PDM Components
AC Line Filter Selection
. <-$ '
*0- !7 1>-C("$8>>!/" *0-
. !*0- "$ <-$*0- . 4 //2/ 2%
+
$ *0- ! " !C4" C4
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-41
Figure 2.24 AC Line Filter installation
*0- . *0- *0- *0-.C C4 $ . . 4 .
ACLINE
RADIATEDEMI
PDM
RADIATEDEMI
FILTER
CONDUCTED EMI
CONDUCTED EMI
POOR
ACLINE
PDM
RADIATEDEMI
FILTER CONDUCTED EMI
GOOD
ATTENTION
!C.
4
4 )
Publication 1398-5.1 — January 2000
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2-42 Install the ULTRA Plus PDM Components
Grounding
C !C4" C4 ;C@!/>C@" C 7'% 1'%
K $ $
) C4 ( C4 $ C4 4 //7 !" ! "-*0-.
Figure 2.25 Single point ground types
GH (! " !#". # *0-#
CIRCUIT1
SERIES CONNECTION PARALLEL CONNECTION
CIRCUIT2
CIRCUIT3
CIRCUIT1
CIRCUIT2
CIRCUIT3
GROUND BUS BAR
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-43
Shielding and Segregation
<-$ *0- -*0- 4 ((,3&**0-
<-$ *0- <-$ <-$4 . *0-
+ + .
Publication 1398-5.1 — January 2000
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2-44 Install the ULTRA Plus PDM Components
'
, # *0- C4 $ /7>=. 7>@8>C( C4
! " 0 )
1>>!%"*0-
( 1>>!%" %>!1>" 1>>!%" %!1"
. (
0 *0- *0-5
$ 2 2 *0- *0-
*0- &@ $ *0- 18>E! " *0-
Publication 1398-5.1 — January 2000
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Install the ULTRA Plus PDM Components 2-45
$<-$ '
GH &/1/
Figure 2.26 Torroid encoder shielding method for brushless servo motors
. ! "
0. Q K
. &. !/>>%@/+ %@/ 4 8>>= "
- (
SHIELD
ENCODER CABLE
Recommended raw cable forbuilding your own cable
Belden Part number
8337
Carol Part number
C0625
ENCODER
PDM
BRUSHLESSMOTOR
MOTOR CASE
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2-46 Install the ULTRA Plus PDM Components
Figure 2.27 Motor power winding methods to minimize noise emissions
TWISTED TOGETHER
TWISTED TOGETHER
TWISTED TOGETHER
COMMON MODE CHOKE(10-20 TURNS ON COMMONFERRITE TORROID CORE)
SHIELD
TO SINGLE POINTEARTH GROUND
TO SINGLE POINTEARTH GROUND
TO SINGLE POINTEARTH GROUND
CHASSIS
R
S
T
PDM
CHASSIS
R
S
T
PDM
CHASSIS
R
S
T
PDM
BRUSHLESSMOTOR
MOTOR CASE
RS T
BRUSHLESSMOTOR
MOTOR CASE
RS T
BRUSHLESSMOTOR
MOTOR CASE
RS T
Publication 1398-5.1 — January 2000
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Chapter 3
Wire the ULTRA Plus PDM Components
,3&**0-
System Power Connections
1398-PDM-10, 20, 75, and 150B
%1?; *0- %>/>1> . %>>/2>=.%1?; *0- 97%7> . %>>/2>=. 4 8>E.3%3/@D%1?; *0- %>/>1> %1?; *0- 97%7>3%3/@D31 %% !%/7D"%1?; *0- %>/>97%7>
ATTENTION
! D< .
4 )
1 Publication 1398-5.1 — January 2000
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3-2 Wire the ULTRA Plus PDM Components
Figure 3.1Power Wiring Diagram for 1398-PDM-10, 20, and 30
5
10
9
97
9
9
1
3
7
5
4
3
2
1
10
4
ABCD
PIN SIGNALRST
MOTOR CASE
2
9
1
7
3
UL CLASS J,CLASS R OR EQUIVALENT FUSES AREACCEPTABLE, LOCAL REGULATIONS MUST BE OBSERVED.
FUSEBLOCK
COMMON GROUNDINGPOINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS)
MACHINE COMMONGROUNDING BUS BAR
AC LINEFILTERAC LINE
FILTER
TO PROTECTIVEEARTH TERMINAL
H-SERIESF-SERIESN-SERIES
MOTORS
DC BUSTB1
L2/N AUX
L1 AUX
L2/N
L1
DC-DC+
R
ST
TERMBLOCK
DRIVE
ALL
PDM-10
PDM-20
L1,L2/N,
L1,L2/N,
L1,L2/N,
PDM-30
INPUT (OPTIONAL)
0020-5097.
OF L2 OR L2/AUX, ONLY L1 MAY BE SWITCHED OR FUSED.
NOTE: SLOW BLOW FUSES ARE REQUIRED TO ALLOW FOR INRUSH CURRENT DURING POWER INITIALIZATION AT THE MAIN AND AUXILIARY TERMINALS. TIME DELAY VERSIONS OF
21936 __ __
____
H-SERIESF-SERIESN-SERIES
MOTORS
DC BUSTB1
FUSEBLOCK
COMMON GROUNDINGPOINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS)
L2/N AUX
L1 AUX
L2/N
L1
DC-DC+
R
ST
WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED.
AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL. TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY. THE AUX INPUT HAS ANINTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD BE AS CLOSETO THE DRIVE AS POSSIBLE.
14 AWG/2.5mmÉ
MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE.8.
MOTOR POWERCONNECTOR MATING
CONNECTORMOTOR POWER
DRIVEMODULE
TERMINAL(S)
L2/N AUXL1 AUX,
RECOMMENDEDPOWER WIRE(GAUGE/mmÉ)
˚16 AWG/1.5mmÉ
10 AWG/4mmÉ
14 AWG/2.5mmÉ
AC AUXILIARY POWER
INPUT POWER WIRES
DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
DO NOT DAISY CHAIN DRIVE MODULES. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
DRIVE RATED 100-240 VAC RMS,SINGLE PHASE INPUT VOLTAGE (230 VAC STANDARD).
6.
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
A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IN EUROPE,IF A GROUNDED NEUTRAL IS USED INSTEAD
MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2 TERMINALS
JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
(EXAMPLE: TO RETAIN DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2 POWER DOWN). WHEN USING A THREE PHASE SUPPLY CONNECT THE MAINAND AUXILIARY INPUTS TO THE SAME PHASE.
L1,L2/N,
0020-5097
RELIANCEPART NUMBER
˚
H-2005
1.0 Amps AC at 115 Volts AC0.5 Amps AC at 230 Volts AC
10.0 AMPS AC19.0 AMPS AC28.0 AMPS AC
DRIVE MODULE INPUT CURRENT REQUIREMENTSIQ TERMINALS
L1 AUX, L2/N AUX
PDM-10PDM-20PDM-30
PDM-30 3.0kVATRANSFORMER SIZES
SUGGESTED
MOTOR POWER CONNECTORMOTOR POWER WIRES R,S,T,GNDMINIMUM
RECOMMENDEDPOWER WIRE(GAUGE/mmÉ)
MOTOR
16 AWG/1.5mmÉ
12 AWG/3.0mmÉ
H-3007H-3016H-4030F-4030H-4050F-4050H-4075F-4075
MOTOR POWERMATING CONNECTOR
16 AWG/1.5mmÉ
14 AWG/2.5mmÉ
CONTACT SIZE(GAUGE/mmÉ)
L1
L2
(OPTIONAL, NOT REQUIRED WHENDESIRED INPUT VOLTAGE ISAVAILABLE DIRECTLY FROM THELINE)
TRANSFORMERCHASSIS
ISOLATION OR AUTO TRANSFORMER
OR CIRCUIT BREAKER
AC LINESINGLE PHASE
50/60Hz
FUSED DISCONNECT
TORQUE ALL TERMINALSTO 11 LB-IN.
TERMINAL STRIPACCEPTABLE WIRE RANGE
(GAUGE/mmÉ)
22-10 AWG/0.5-6mmÉ
DRIVEMODULE
„XCON…„XCON…
(60˚C COPPER ONLY)
(60˚C COPPER ONLY)
NOTES
POWER WIRING CONNECTIONS
.XXX±.010DECIMALS.XX±.020FRACTIONS:±1/64"
DO NOT SCALE DRAWING
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
C
PART NO.
DWG SIZE SHEETSCALE
N/A of
REV ECO CHKRDATEREVISION DESCRIPTIONBYDESIGN ENGRDRAWN BY
JM
UNLESS OTHERWISE SPECIFIED
9101-2195
6-3-96
1398-PDM-10,20, and 30
1 1
JM
A RELEASED
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Wire the ULTRA Plus PDM Components 3-3
Figure 3.2 Power Wiring for 1398-PDM-75
2
77
1111
4
5
5
10
11
9
99
9
1
3
7
5
4
3
2
1
10
ABCD
PIN SIGNAL
RST
MOTOR CASE
9
1
3
10
FUSES ARE RECOMMENDED. FUSE SIZES MUST BE SELECTEDACCORDING TO LOCAL REGULATIONS.
FUSEBLOCK
COMMON GROUNDINGPOINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS)
MACHINE COMMONGROUNDING BUS BAR
AC LINEFILTER
AC LINEFILTER
TO PROTECTIVEEARTH TERMINAL
DC BUSTB2
L2/N AUX
L1 AUX
L2/N
L3
L1
DC-DC+
R
ST
TERMBLOCK
DRIVE
ALL
DM/PDM-75 L1,L2/N,L3
L2 OR L2/AUX, ONLY L1 MAY BE SWITCHED OR FUSED.
NOTE: POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSHCURRENT OF 50A FOR THE MAIN INPUT AND 95A FOR THEAUXILIARY INPUT. DUAL ELEMENT TIME DELAY (SLOW BLOW)
21871 __ __
____
H-SERIES H-SERIESF-SERIES F-SERIESN-SERIES N-SERIES
MOTORS MOTORS
DC BUSTB2
TB1 TB1
FUSEBLOCK
COMMON GROUNDINGPOINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS)
L2/N AUX
L1 AUX
L2/N
L3
L1
DC-DC+
R
ST
WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED.
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
AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY, AND ARE REQUIRED TO MEET THEEUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE. CAUTION: AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND REQUIRE DISCHARGE TIME UPON POWER REMOVAL.
NON-SHIELDED CABLES ARE USED. SNUG BRACKET SCREWS, DO NOT OVERTIGHTEN. NEVER TORQUE OVER 10 LB-IN. THE SHIELDS ON SHIELDED POWER CABLES MUSTBE GROUNDED AT A MINIMUM OF ONE POINT FOR SAFETY.
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 SHOULDBE AS CLOSE TO THE DRIVE AS POSSIBLE.
10 AWG/2.5mmÉ
MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE.8.
MOTOR POWERCONNECTOR MATING
CONNECTORMOTOR POWER
DRIVE MODULE
TERMINAL(S)
L2/N AUXL1 AUX,
RECOMMENDEDPOWER WIRE(GAUGE/mmÉ)
(60˚C COPPER MIN)
16 AWG/1.5mmÉ AC AUXILIARY
(OPTIONAL)POWER INPUT
INPUT POWER WIRES
DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
DRIVE RATED 100-240 VAC RMS, SINGLE OR THREE PHASE INPUT VOLTAGE (230 VAC STANDARD).
6.
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 FORTHREE PHASE INPUT, 15/50 AMPS FOR SINGLE PHASE INPUT.
A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IF A GROUNDED NEUTRAL IS USED INSTEAD OF
MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2/N, L3 TERMINALS (EXAMPLE: TO RETAIN
JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2/N, L3 POWER DOWN).
(60˚C COPPER MIN)
H-6100
H-4050
H-4075
28.0 Amps at 100-240 Volts AC Single Phase28.0 Amps at 100-240 Volts AC Three Phase
1.0 Amps AC at 115 Volts AC 0.5 Amps AC at 230 Volts AC
DRIVE MODULE INPUT CURRENT REQUIREMENTSCURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS)BRU/IQ TERMINALS
L1,L2/N,L3
L1 AUX,L2/N AUX
DM/PDM-75DM/PDM-75L1,L2/N
MOTOR POWER CONNECTORMOTOR POWER WIRES R,S,T,GNDMINIMUM
RECOMMENDEDPOWER WIRE(GAUGE/mmÉ)
MOTOR
12 AWG/3.0mmÉ
8 AWG/10.0mmÉF-6100
F-4050
F-4075
H-6200F-6200
MOTOR POWERMATING CONNECTOR
10 AWG/6.0mmÉ
14 AWG/2.5mmÉ
CONTACT SIZE(GAUGE/mmÉ)
L1
L2/N
L3
(OPTIONAL, NOT REQUIRED WHENDESIRED INPUT VOLTAGE ISAVAILABLE DIRECTLY FROM THELINE)
TRANSFORMERCHASSIS
ISOLATION OR AUTO TRANSFORMER
OR CIRCUIT BREAKER
AC LINETHREE PHASE
50/60Hz
FUSED DISCONNECT
TORQUE ALL TERMINALSTO 11 LB-IN.
TERMINAL STRIPACCEPTABLE WIRE RANGE
(GAUGE/mmÉ)
22-10 AWG/0.5-6mmÉ
DRIVE MODULE
„XCON…„XCON…
NOTES
POWER WIRING CONNECTIONS75A
.XXX±.010DECIMALS.XX±.020FRACTIONS:±1/64"
DO NOT SCALE DRAWING
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
C
PART NO.
DWG SIZE SHEETSCALE
N/A of
REV ECO CHKRDATEREVISION DESCRIPTIONBY
DESIGN ENGRDRAWN BY
JM
UNLESS OTHERWISE SPECIFIED
9101-1453
4-19-96
1 1
JM
A RELEASED
Publication 1398-5.1 — January 2000
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3-4 Wire the ULTRA Plus PDM Components
Figure 3.3 Power Wiring for 1398-PDM-150B
. ) < . < - 0 & G< .H / 18 <-.
BLOW) FUSES ARE RECOMMENDED. FUSE SIZES MUST BE SELECTEDACCORDING TO LOCAL REGULATIONS.
FUSEBLOCK
COMMON GROUNDINGPOINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS)
MACHINE COMMONGROUNDING BUS BAR
AC LINEFILTER
XCON
AC LINEFILTER
TO PROTECTIVEEARTH TERMINAL
DC BUS
TB2
L2/N AUX
L1 AUX
L2
L3
L1
DC-DC+
R
ST
TERMBLOCK
DRIVE
ALL
PDM-150BL1,L2,
L3
L2/N AUX, ONLY L1 AUX MAY BE SWITCHED OR FUSED.
NOTE: POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSHCURRENT OF 70A (PEAK) FOR THE MAIN INPUT AND 105A (PEAK)FOR THE AUXILIARY INPUT. DUAL ELEMENT TIME DELAY (SLOW
22775 __ __
____
H-SERIES H-SERIESF-SERIES F-SERIESN-SERIES N-SERIES
MOTORS MOTORS
DC BUS
TB2
TB1 TB1
FUSEBLOCK XCON
COMMON GROUNDINGPOINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS)
L2/N AUX
L1 AUX
L2
L3
L1
DC-DC+
R
ST
ABCD
PIN SIGNALRST
MOTOR CASE
WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED.
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
AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY, AND ARE REQUIRED TO MEET THEEUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE. CAUTION: AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND MAY REQUIRE DISCHARGE TIME UPON POWER REMOVAL.
NON-SHIELDED CABLES ARE USED. SNUG BRACKET SCREWS, DO NOT OVERTIGHTEN. NEVER TORQUE OVER 10 LB-IN.
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 SHOULDBE AS CLOSE TO THE DRIVE AS POSSIBLE.
8 AWG/10.0mm
MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE. 8.
MOTOR POWER CONNECTOR MATING
CONNECTORMOTOR POWER
DRIVE MODULE
TERMINAL(S)
L2/N AUXL1 AUX,
RECOMMENDEDPOWER WIRE(GAUGE/mm )
(75 C COPPER MIN)
16 AWG/1.5mmAC AUXILIARY
(OPTIONAL)POWER INPUT
INPUT POWER WIRES
DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
DRIVE RATED 100-240 VAC RMS (230 VAC STANDARD).
6.
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.
A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IF A GROUNDED NEUTRAL IS USED INSTEAD OF
NOTES
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
JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2, L3 POWER DOWN).
(75 C COPPER MIN)
H-6300
46.0 Amps at 100-240 Volts AC Three Phase
1.0 Amps AC at 115 Volts AC 0.5 Amps AC at 230 Volts AC
DRIVE MODULE INPUT CURRENT REQUIREMENTSCURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS)IQ TERMINALS
L1,L2,L3
L1 AUX,L2/N AUX
PDM-150B
MOTOR POWER CONNECTORMOTOR POWER WIRES R,S,T,GNDMINIMUM
RECOMMENDEDPOWER WIRE(GAUGE/mm )
MOTOR
8 AWG/10.0mm
4 AWG/25.0mm4 AWG/25.0mm
8 AWG/10.0mm
F-6300H-8350
H-6200
H-8500
F-6200
MOTOR POWERMATING CONNECTOR
8 AWG/10.0mm
6 AWG/16.0mm8 AWG/10.0mm
10 AWG/6.0mm
CONTACT SIZE(GAUGE/mm )
L1
L2
L3
(OPTIONAL, NOT REQUIRED WHENDESIRED INPUT VOLTAGE ISAVAILABLE DIRECTLY FROM THELINE)
TRANSFORMERCHASSIS
ISOLATION OR AUTO TRANSFORMER
OR CIRCUIT BREAKER
AC LINETHREE PHASE
50/60Hz
FUSED DISCONNECT
TORQUE ALL TERMINALS
TORQUE ALL TERMINALS
TO 11 LB-IN.
TO 12 LB-IN.
TERMINAL STRIPACCEPTABLE WIRE RANGE
(GAUGE/mm )
22-10 AWG/0.5-6mm
12-6 AWG/8.0-14mm
DRIVE MODULE
5
10
3
1
9
10
1
2
3
4
7
3
1
9
9 9
9
11
10
5
5
4
11 11
7 7
2
POWER WIRING1398-PDM-150B
.XXX +/- .010
DECIMALS: .XX +/- .020
FRACTIONS: +/- 1/64"
DO NOT SCALE DRAWINGUNLESS OTHERWISE SPECIFIED
ANGLES :+/- 1TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
5-12-98
C
PART NO.
DWG SIZE SHEETSCALE
N/A 1 1of
REV ECO CHKRDATEREVISION DESCRIPTIONBYDESIGN ENGRDRAWN BY
JM
A JM RELEASED
9101-2236
2
2
2
2
2
2
2
2
22
2
2
2
2
2
2
ATTENTION
!
4 )
Publication 1398-5.1 — January 2000
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Wire the ULTRA Plus PDM Components 3-5
Auxiliary Logic Power
. %>> /2>=. 3%,J3/@D,J
,3&**0-5D 544 ,3&**0- ,3&**0-
1398-PDM-25, 50, 100, and 150
Figure 3.4 Power Wiring Diagram (1398-PDM-25, 50, 100, and 100)
11
10
1010
5
4
4
9
8
9
8
6
4
4
5
7 7
1
2
3
11
AB
C
D
PIN SIGNAL
RS
TMOTOR CASE
0020-5091-001
0020-5091-0020020-5091-0030020-5091-004
RELIANCEKVA
36
1218
UV
W
E
TERMINAL SIGNAL
SR
TMOTOR CASE
11
5
7
6
6
4
1
A00787 TM 5-30-95 RBA1 CHG'D NOTE 1
2
3
11
21871 JM __ __B ADDED H-SERIES MTR OPTION
WIRE SIZES ARE RECOMMENDATIONS. THE REQUIREMENTSOF LOCAL REGULATIONS MUST BE OBSERVED.
AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL.TO BE USED FOR IMPROVING THE SYSTEM'S ELECTROMAGNETICCOMPATABILITY. WIRING BETWEEN THE POWER SUPPLY ANDFILTER SHOULD BE AS SHORT AS POSSIBLE. THE COMMONGROUND SHOULD BE AS CLOSE TO THE MODULE AS POSSIBLE.
COMMON GROUNDING POINT FORPOWER SUPPLY-DRIVE MODULE
SYSTEM
TO PROTECTIVEEARTH TERMINALMACHINE COMMON
GROUNDING BUS BAR
ACLINE
FILTER
9101-0411
POWER WIRING CONNECTIONS
.XXX±.010DECIMALS.XX±.020FRACTIONS:±1/64"
DO NOT SCALE DRAWING
ANGLES ±1ANGLES ˚TOLERANCE ON:FILLETS AND ROUNDS .02 R MAXBREAK ALL EDGES .02 MAXDIMENSIONS ARE IN INCHES
DATE DATE
D
PART NO.
DWG SIZE SHEETSCALE
N/A of
REV ECO CHKRDATEREVISION DESCRIPTIONBY
DESIGN ENGRDRAWN BY
5-30-95
2-2-95TM BCB
PART NO.
UNLESS OTHERWISE SPECIFIED
9101-0411
1-24-95
1 1
COTM
1398-PDM-25, 50,100, and 150
21244A RELEASED
TORQUE TO 11.5 LB-IN.
TORQUE TO 24 LB-IN.
POWER WIRES MUSTBE CORRECTLYPHASED
R,S AND T MOTOR
(GAUGE/mmÉ)60˚C COPPER ONLY
TERMINALSPRODUCT
PSM-125
PSM-50AND ALL
DRIVE MODULES
L1,L2,L3
L1,L2,L3R,S,T
POWER SUPPLY MODULE ANDDRIVE MODULE TERMINALS
6-0 AWG/16-55mmÉ
8 AWG/10mmÉ
10-4 AWG/6-25mmÉ
14-12 AWG/2.5-4mmÉ
16 AWG/1.5mmÉ
ACCEPTABLE WIRE RANGE
MOTOR POWER WIRES R,S,T,GND
MINIMUMRECOMMENDED
POWER WIRE(GAUGE/mmÉ)
MOTOR
16 AWG/1.2mmÉ
12 AWG/3.0mmÉ
8 AWG/8.6mmÉ
4 AWG/21.6mmÉ
TERMINAL BLOCK
S-3007S-3016S-4030F-4030S-4050F-4050S-4075F-4075S-6100F-6100S-6200F-6200S-6300F-6300S-8350S-8500I-5300I-6600
MOTOR POWERMATING CONNECTOR
16 AWG/1.5mmÉ
14 AWG/2.5mmÉ
12 AWG/4mmÉ
8 AWG/10mmÉ
6 AWG/16mmÉ
8 AWG/10mmÉ
6 AWG/16mmÉ
CONTACT SIZE(GAUGE/mmÉ)
208/230/240/380/460/480 VAC PRIMARY, 115/230VAC SECONDARY, 50/60 Hz
PART NUMBER
H-SERIES, S-SERIES,F-SERIES AND W-SERIESMOTORS
I-5300 AND I-6600MOTORS
100 TO 240 VAC RMS3 PHASE INPUT POWER
PHASING OF L1,L2 AND L3INPUT POWER IS ARBITRARY
RED WIRE
BLACK WIREGREEN WIRE
DC BUS POS, NEG, AND GND WIRES (1 EACH)ARE PROVIDED WITH EACH DRIVE MODULE
L1
L2
L3
FUSED DISCONNECTFUSED DISCONNECT
3 PHASE AC LINE50/60 Hz
TRANSFORMERCHASSIS
3 PHASE ISOLATION OR AUTOTRANSFORMER.
(OPTIONAL, NOT REQUIREDWHEN DESIRED INPUT VOLTAGE
IS AVAILABLE DIRECTLYFROM THE LINE).
POS NEG GND
DRIVE MODULE
POS NEG GND
DRIVE MODULE
POS NEG GND
MOTOR TERMINAL BOXMOTOR POWER TERMINAL STRIP
MOTOR POWER TERMINAL STRIP
MOTOR POWER CONNECTOR
MOTOR POWER CONNECTOR
MOTOR POWER MATING CONNECTOR
POWER SUPPLY MODULE
POS NEG GND
DRIVE MODULE
POS NEG GND
DRIVE MODULE
M6 TERMINAL POST
M6 NUT
CONNECTING LUGS
M6 TERMINAL POSTM6 NUT
SPRING DISK WASHERS
FLAT WASHER
CONNECTING LUGS
DRIVE OR POWER SUPPLYBUS BAR
TERMINAL POST BASE
c) 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 FORPROPER 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 FORPROPER CLAMPING IN DRIVE MODULE TERMINAL.
TERMINAL POST HARDWARE DETAILS:
I-SERIES MOTORS ARE USED WITH BRU-500 DRIVES ONLY.
1000 1000
DO NOT OVERTIGHTENUSE NUT DRIVER ONLY
36 LB-IN (4.0 Nm) ABSOLUTEMAXIMUM TIGHTENING TORQUE.
NOTES:
THE PSM MUST BE CENTERED BETWEEN THE DRIVE MODULES TO MINIMIZE THE DC BUS INDUCTANCE, SO THAT ANEQUIVILENT NUMBER OF DRIVES ARE LOCATED ON EACH SIDE OF THE PSM.
FUSE SIZE: PSM-125-UL CLASS RK5 90 AMP (5000 AIC) A DISCONNECTING DEVICE IS REQUIRED FOR SAFETY AND MAINTENANCE. PSM-50-UL CLASS RK5 40 AMP (5000 AIC)
NOTES ON SIZING OF POWER TRANSFORMERS AND INPUT WIRES:
a) TRANSFORMER 3 PHASE KVA = X (LINE-TO-LINE SECONDARY VOLTS RMS) X (PER PHASE SECONDARY CURRENT RMS) =
X (LINE-TO-LINE PRIMARY VOLTS RMS) X (PER PHASE PRIMARY CURRENT RMS).
b) TRANSFORMER 3 PHASE KVA = (SUMMATION OF EACH MOTORS ACTUAL AVERAGE OUTPUT POWER) X (1.2) 1.2 FACTOR ADDS 20%AS ROUGH ESTIMATE OF DRIVE MODULE & MOTOR LOSSES.
RELIANCE MOTION CONTROL3 PHASE TRANSFORMERS
R S TR S TL1 L2 L3R S TR S T
GROUND TERMINAL POSTSPOSITIVE,NEGATIVE TERMINAL POSTS
3 3
CAUTION
Publication 1398-5.1 — January 2000
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3-6 Wire the ULTRA Plus PDM Components
Power Supply Module (PSM)
* -!*-"0. ,3&**0- . %%7@/1>=. *- 4 8>E. 3%3/31 %% !%/7D"%1?; *- 7>/2 !/97D"%1?; *- %/7
* - 3<0 *- 5D
& G* + 0 !%1?; *0- /77>%>>%>>"H 1 7 . ) < . < - 0 & G< .H / 18 <-.
IMPORTANT %1?; *0- /77>%>>%7>
ATTENTION
! .
, *33<0
< .
Publication 1398-5.1 — January 2000
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Wire the ULTRA Plus PDM Components 3-7
DC Bus Power
0. *- ,3&**0-!%1?; *0- /77>%>>%7>"*-0.* + 0 4 121 7*-
Auxiliary Logic Supply
!*- ,J"0. ,3&**0-*-544*- ,J%%7=.
*- ,J,3&**0- !*-"*- ,J ,3&**0- & G*- ,J5.0 H / %7 *- ,J*- ,J
ATTENTION
!00.
4
Publication 1398-5.1 — January 2000
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3-8 Wire the ULTRA Plus PDM Components
Figure 3.5 Auxiliary Power Supply Connections
9
9
8
10
8
8
10
9
F3
F2
F1
240VAC,3 PHASE
CONTROL CIRCUITTRANSFORMER
PSM-AUXTRANSFORMER0020-5093
240VAC 120VAC
F4
GNDL3L2L1
L1 L2 L3
240VAC 120VAC
PSM-AUX
POWER SUPPLYMODULE (PSM)
DRIVEMODULE
EXAMPLE:240V LINE
CUSTOMER'S120VACCONTROLCIRCUITS
12
L3L2L1
PO
S
NE
G
GNDTSR
PO
S
NE
G
GND
DIAGRAM, OUTLINE & CONNECTION
PSM-AUX, 1398-PDM-25, 50, 100, and 150
9101-0134 REV D1
480VAC, 3 PHASE PRIMARY240VAC, 3 PHASE SECONDARY
480VAC,3 PHASE
GNDL3L2L1
F4
0020-5091-XXX
L1 L2 L3
480VAC 120VAC PSM-AUX
CONTROL CIRCUITTRANSFORMER
POWER SUPPLYMODULE (PSM)
DRIVEMODULE
EXAMPLE:480V LINE
F3
F2
F1
CUSTOMER'S120VACCONTROLCIRCUITS
IN THIS EXAMPLE, THE PSM INPUT POWER IS SUPPLIED DIRECTLY FROM THE 3 PHASE LINE.
THEREFORE, THE PSM-AUX INPUT POWER MUST BE ISOLATED FROM AND FROM THE 240V INPUT LINE.
IN THIS EXAMPLE THE PSM-AUX TRANSFORMER SECONDARY MUST NOT BE CONNECTED TO .
SIZE TRANSFORMER FOR 400 VA (PSM-AUX)+ CUSTOMER CONTROL CIRCUIT REQUIREMENTS.
IN THIS EXAMPLE, PSM-AUX INPUT POWER IS CONNECTED TO AT THE CONTROL CIRCUIT
TRANSFORMER SECONDARY. THEREFORE THE PSM INPUT POWER MUST BE ISOLATED
FROM AND FROM THE 480V INPUT LINE. THE THREE PHASE TRANSFORMER PROVIDES
THE ISOLATION AND ALSO STEPS DOWN THE VOLTAGE.
12
L3L2L1P
OS
NE
GGND
TSR
PO
S
NE
G
GND
NOTES:
SAMPLE INPUT POWER WIRING CONFIGURATIONS, PSM-AUX WITH 1398-PDM-25, 50, 100, and 150
Publication 1398-5.1 — January 2000
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Wire the ULTRA Plus PDM Components 3-9
PSM Interface Logic
<*- *-*0- 4 19 *0-
Figure 3.6 PSM interface - internal circuit examples
Figure 3.7 PSM interface - external connection examples
PSM Connector Pin # Signal Name
P1 1 Status-
General 2 Status +
Purpose 3 PSM Enable-
Inputs/Outputs 4 PSM Enable +
Publication 1398-5.1 — January 2000
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3-10 Wire the ULTRA Plus PDM Components
Status Outputs
*- . *- *- &
Enable Input
*-< *-< & G*- H 1 ? ) +%& G* -) H 1 %%
+) !*"*-5D+544*-0. 544 5D 0. *0- *-*- 5D
+) ! *"*- *-
ATTENTION
!$*- 0. !/" ( !>"
Publication 1398-5.1 — January 2000
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Wire the ULTRA Plus PDM Components 3-11
Figure 3.8 Power Supply Module jumper location
INTERFACECONNECTOR
AB
TB1
1
4
DIAGNOSTICINDICATORLIGHTS
W1D
S1
POWER SUPPLY MODULECIRCUIT BOARD(COMPONENT SIDE)
W1 JUMPER SETTING
SHORTING JUMPER ACROSSTOP 2 PINS (POSITION A)
SHORTING JUMPER ACROSSBOTTOM 2 PINS (POSITION B)
(STANDARD SETTING)
SELECTS:
EXTERNAL ENABLE INPUT IS SELECTED.EXTERNAL CONNECTION IS REQUIRED
TO CONNECTOR TB1 SIGNALS ENABLE+AND ENABLE-. REFER TO INSTRUCTION
MANUAL FOR SIGNAL SPECIFICATIONAND DETAILS OF OPERATION BEFORE
USING POSITION A.
EXTERNAL ENABLE INPUT IS DE-ACTIVATED.POWER SUPPLY MODULE IS ENABLED WHENEVERINPUT POWER IS APPLIED AND NO POWER SUPPLY
MODULE FAULT CONDITIONS ARE DETECTED.
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3-12 Wire the ULTRA Plus PDM Components
External Shunt Connections ,3&**0-!%1?; *0- %>/>97%7>" ) %/& ) %1
Terminal Identifier Description
1 Internal orExternal
Positive DC BUS
2 Internal Internal shunt regulator resistor
3 External Shunt regulator transistor collector
ATTENTION
!C ,3&**0-
4 )
ATTENTION
!&
,3&**0-
4 (
ATTENTION
!3
0! "
4
TB2
Ext
erna
l Shu
nt
Inte
rnal 1
3
2
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Wire the ULTRA Plus PDM Components 3-13
0., !2/>=0." 0., 0.,+ 0.,2/>=0.
$ ,3&**0- $ ) ! %/" 4 < :!/>>+" < :!?>>+" & G< + <H 1 %2
Internal Shunt Dissipation Ratings
Shunt Rating 1398PDM10
1398PDM20
1398PDM30
1398PDM75
1398PDM150b
Continuous (W) 50.0 180.0
Peak (kW) 4.5 10.0 19.0
External Shunt Dissipation Power Ratings
Shunt Rating 1398PDM10
1398PDM20
1398PDM30
1398PDM75
1398PDM150b
Minimum Resistance(Ohms ±10%) (1)
(1) For sizing purposes, approximately 420 Vpeak will drop across any given resistor assembly.
30.0 18.0 9.0
Continuous Power (kW)2
0.8 1.8 2.4 4.0 8.0
Peak Power (kW) (2)
(2) Continuous and Peak Power Ratings are given measured with a minimum resistance shunt. Higher Resistances will decrease Power Rating.
6.0 10.0 19.0
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3-14 Wire the ULTRA Plus PDM Components
Figure 3.9 External Shunt Wiring Examples
TB2-1
R1 R2
TB2-1
TB2-3
1 - 200W Unit Configuration*200 Watts
TB2-1
TB2-3
4 - 200W Unit Configuration*800 Watts
9 - 200W Unit Configuration*1800 Watts
R1
R1 R2
R3 R4
TB2-1
TB2-3
R1 R3
R4 R6
R7 R9
R2
R5
R8NOTES:Uses 200W units p/n 9101-1079 *Configuration good for all ULTRA Plus PDMs
TB2-1
TB2-3
R1
TB2-3NOTES:
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
1 - 900W Unit Configuration*900 Watts
2 - 900W Unit Configuration**1800 Watts
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Wire the ULTRA Plus PDM Components 3-15
Replacing the PSM Shunt Fuse
0.* -@ '
- 3%3/31 544- *-&<0B3<0544&*-
&
&Figure 3.10 Shunt Fuse location
$*-
IMPORTANT + %1?; *- 7>%1?; *- %/70.
Shunt Resistor
Shunt Fuse
DC Bus Terminals
Power Supply Module(1398 PDM-25, 50, 100, and 150)
PSM - 50 8 Ampere KLKD-8 or KLM-8
PSM - 125 20 Ampere KLKD-20 or KLM-20
PSM - 125 (with external shunt) 30 Ampere KLKD-30 or KLM-30
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3-16 Wire the ULTRA Plus PDM Components
Operator Terminals Power Connections (1398-HMI-002)
4 1%% 5 %%7@//>@/1>@/2>=.!?%>% />%9"$
Figure 3.11 Operator Terminal power connections
GROUND (EARTH)
115/230 VAC (NEUTRAL)
115/230 VAC (HOT)
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Wire the ULTRA Plus PDM Components 3-17
Power Connections (1398-HMI-003)
,3&*%1?; C-$ >>15 /2 >7
Figure 3.12 Operator Terminal connections (on back of unit)
• 5 7>> /2 %;1>
• %>> 3
$ 5 5 '
• 85 $ $ 5
• 5 // $
RS-232 connector24 VDCnotused
1 2 3 4 5 6 7 8 9 10
1 2
SUPPLY
COMMON
+24v
24 VDC (DC+)
COMMON
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3-18 Wire the ULTRA Plus PDM Components
Motors Power Connections
* & & . 4 1%1 C4
Figure 3.13 Motor power connections for H, and F-Series motors
4 1%2 1 %; D
Figure 3.14 Motor power connections N-Series motors
ATTENTION
!C ,3&**0-
&
4 )
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
E N/CD
BC
ABROWN
BLACK
BLUE
GRN/YEL
SHIELD
ST
R
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
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Wire the ULTRA Plus PDM Components 3-19
.( '
• & G* + 0 %1?; *0- %>/>1>H 1 /
• & G* + %1?; *0- 97H 1 1
• & G* + %1?; *0- %7>H 1 2
• & G* + 0 !%1?; *0- /77>%>>%>>"H 1 7
&@
Shield Termination
&@ ) $ <-.
ATTENTION
!-
4 )
ATTENTION
!0! "
4 )
ATTENTION
!
4 )
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3-20 Wire the ULTRA Plus PDM Components
Figure 3.15 Motor power EMC shield connection
& G.H 1 2?
Digital Inputs and Outputs *0- '0$@5$@5&5< $ * & G*0- H 1 /% *0-
4 1%9 1 //,3&**0- %8 # $@5/2=0.*0- /2=0.R7>> /2=0.. %4%*0- /2=0.*% *%*/*1 *0-
cable jacket shieldconductivearea
IMPORTANT /2=0. ) +1+2*0- O/2=0./2 *%*/
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Wire the ULTRA Plus PDM Components 3-21
Figure 3.16 PDM control connections
R
TG
SP5-15
P5-14
P5-13P5-12
P5-11
P5-10
P5-9
P5-8P5-7
P5-6
P5-5
P5-4
P5-3
P5-2
P5-1
SHIELD
+5 VDC
ANALOGTS+
TS-
I-
+5 VDC
NC
COMMON
COMMON
I+
B-
B+
A-
A+
P4-15P4-14P4-13P4-12P4-11P4-10P4-9P4-8P4-7P4-6P4-5P4-4
P4-2P4-3
P4-1
SHIELD+5 VDCDIR-
STEP+I-
DIR+COMMONCOMMONI+
B-B+A-A+
+5 VDC
STEP-
P2
P1
12
11
10
9
8
7
6
5
4
3
2
1
12
13
14
11
10
9
8
7
6
5
4
3
2
1
OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM
INPUT SWITCHES: RESISTANCE IS 3000 OHM MAXIMUM
24 VOLT COMMON
FORWARD LIMIT
REVERSE LIMIT
ENABLE
START
HOME SWITCH
HOME COMMAND
JOG REVERSE
JOG FORWARD
PAUSE
ERETURN
INTERRUPT #1
INTERRUPT #2
GENERAL PURPOSE INPUT INPUT 13
INPUT 12
INPUT 11
INPUT 10
INPUT 9
INPUT 8
INPUT 7
INPUT 6
INPUT 5
INPUT 4
INPUT 3
INPUT 2
INPUT 1
GENERAL PURPOSE INPUT
GENERAL PURPOSE INPUT
GENERAL PURPOSE INPUT
GENERAL PURPOSE OUTPUT
GENERAL PURPOSE OUTPUT
GENERAL PURPOSE OUTPUT
PROGRAM RUNNING
AT HOME
HOME SEQUENCE COMPLETE
IN POSITION
ERROR OUTPUT 8
OUTPUT 7
OUTPUT 6
OUTPUT 5
OUTPUT 4
OUTPUT 3
OUTPUT 2
OUTPUT 1
INPUT 16
INPUT 15
INPUT 14
+24 VDC
321
F1F1
X1X1
X4X4
X3X3
X2X2
F4F4F3F3F2F2
STATUSSTATUS
MODEMODE
CLEARCLEAR
4
7
0
5
8
6
9
NONO
-
YESYES
ENTERENTER
Operator Terminal
GML Software
Brushless Motor
Master Encoder
PC CompatiblePersonal Computer
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3-22 Wire the ULTRA Plus PDM Components
Figure 3.17 Typical Digital I/O wiring
P2
P1
12
11
10
9
8
7
6
5
4
3
2
1
12
13
14
11
10
9
8
7
6
5
4
3
2
1
OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM
INPUT SWITCHES: RESISTANCE IS 3000 OHM MAXIMUM
24 VOLT COMMON
FORWARD LIMIT
REVERSE LIMIT
ENABLE
START
HOME SWITCH
HOME COMMAND
JOG REVERSE
JOG FORWARD
PAUSE
ERETURN
INTERRUPT #1
INTERRUPT #2
GENERAL PURPOSE INPUT INPUT 13
INPUT 12
INPUT 11
INPUT 10
INPUT 9
INPUT 8
INPUT 7
INPUT 6
INPUT 5
INPUT 4
INPUT 3
INPUT 2
INPUT 1
GENERAL PURPOSE INPUT
GENERAL PURPOSE INPUT
GENERAL PURPOSE INPUT
GENERAL PURPOSE OUTPUT
GENERAL PURPOSE OUTPUT
GENERAL PURPOSE OUTPUT
PROGRAM RUNNING
AT HOME
HOME SEQUENCE COMPLETE
IN POSITION
ERROR OUTPUT 8
OUTPUT 7
OUTPUT 6
OUTPUT 5
OUTPUT 4
OUTPUT 3
OUTPUT 2
OUTPUT 1
INPUT 16
INPUT 15
INPUT 14
+24 VDC
W4 INTERNAL 24 VDC SUPPLY
TYPICAL INPUT
3.3 K
24 VOLT COMMON
TYPICAL OUTPUT
W3 INTERNAL 24 VDC SUPPLY
INTERNAL
75mA MAX PER OUTPUT500mA TOTAL
Publication 1398-5.1 — January 2000
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Wire the ULTRA Plus PDM Components 3-23
I/F 24V Sourcing
,3&**0-!"$@5, !"$@5 < &@ 0$D $@5 !"
PDM pin connection with the IF 24V Conversion Card
0$D !%7/ "*0- *%*/ *0-
PDM Connector PDM PinNumber
WireColor
IF Card PinNumber
CablePair
P1 General purpose inputs 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
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3-24 Wire the ULTRA Plus PDM Components
5 $@4 $@5 /2=0. $@4 /2=0. />1>=0.; 5/2 29> 7>.%7/ /2;
& G$@4. . H / ! "
P2 General purpose inputs and outputs
1 (Input) WHITE 1 Pair 8
2 (Input) BLACK 2 Pair 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
(Continued)
PDM Connector PDM PinNumber
WireColor
IF Card PinNumber
CablePair
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Wire the ULTRA Plus PDM Components 3-25
Digital Inputs
O/2=0.-/2!" $ 5D544 /24 & 3 C C *,< *
*0- $% $%8 $$% $%> $$%%$%/$ $$%/$%8
$ 5 C &* 0C
Connector Pin Signal Name Assignable Function (1)
P2 General purpose inputs and outputs
12 +24 VDC
3 Input 16 Program Select MSB
2 Input 15 Program Select
1 Input 14 Program Select
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3-26 Wire the ULTRA Plus PDM Components
P1 General purpose inputs
14 Input 13 Program Select
13 Input 12 Int2 / Program Select
12 Input 11 Int1 / Program Select
11 Input 10 Emergency Return
10 Input 9 Pause
9 Input 8 Jog Forward
8 Input 7 Jog Reverse
7 Input 6 Home Command
6 Input 5 Home Switch
5 Input 4 Start Program
4 Input 3 Enable
3 Input 2 Reverse Limit
2 Input 1 Forward Limit
1 24 VDC Common
(1) Even if an input is assigned a function, it may be used as a general purpose input.
(Continued)
Connector Pin Signal Name Assignable Function (1)
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Wire the ULTRA Plus PDM Components 3-27
Digital Outputs
5% 5; /2
Digital outputs and assignable functions
97 %558595; C.$*< 5 5552* &57C
Connecting Inputs and Outputs Together
*0-*0- *0- $$@5 /2=0.!*%%"
- 5&$ !"
ATTENTION
!,3&**0- 544
<
4 )
Connector Pin Signal Name Assignable Function
P3 Analog I/O 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
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3-28 Wire the ULTRA Plus PDM Components
< *3.
- $ *3. (
Analog Input
4 1%; 0 !0."0.%3*1 7 S%>=
Analog inputs and signal names
. *1 2. %>0. />= & #-3,
Figure 3.18 Analog input and output - typical internal circuits
Connector Pin Signal Name
P3 Analog I/O and status 4 Analog Common
5 Analog Input (ADC1)
P3+15 VDCMONITOR ANALOG OUTPUTDAC1 ANALOG OUTPUTADC1 ANALOG INPUTANALOG COMMON
ENABLED RELAY
READY RELAY
RELAY COMMON
+15 VDC
-15 VDC+15 VDC
-15 VDC +15 VDC
+15 VDC
-15 VDC-15 VDC
1
2
3
4
5
6
7
8
-
+
-
+
-
+
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Wire the ULTRA Plus PDM Components 3-29
Analog Output
0. !0."0.%*1 8 S%>
Analog output and signal names
.*1 2%/0. 7=& #-3,
Monitor Output
* - - = - ,
Monitor output an signal names
S%>; & #-3,
Connector Pin Signal Name
*1$@5 4 .
6 5!0."
Connector Pin Signal Name
P3 Analog I/O and status 4 Analog Common
7 Programmable Monitor
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3-30 Wire the ULTRA Plus PDM Components
Ready Relay Output
4 1%? 1 1> &!*1 %" *0- *0-
Ready relay output and signal names
&.!*1 1" >1/2=0.&
Figure 3.19 Enable and Ready Relay - Typical Internal Circuits
Connector Pin Signal Name
P3 Analog I/O and status 1 Ready (Relay output)
3 Relay Common
+15 VDC
8 BIT DAC OUT (MONITOR)
12 BIT DAC OUT
10 BIT A/D IN
ANALOG COMMON
RELAY COMMONENABLED
READY NORMALLYOPEN
NORMALLYOPEN
P38
76
5
43
2
1
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Wire the ULTRA Plus PDM Components 3-31
Enabled Relay Output
<!*1 /" <*0-*0-
Enabled relay output and signal names
&.!*1 1" >1/2=0.
*0- *0- 97>C(! " 27 *0- % / + />>> *0-;>>>
*0- ! " 7 4 1/>*0-$!$" . O O $O$ O7=0.
ATTENTION
!,3&**0- 544
<
4 )
Connector Pin Signal Name
P3 Analog I/O and status 2 Enabled (Relay output)
3 Relay Common
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3-32 Wire the ULTRA Plus PDM Components
Figure 3.20 Encoder input circuitry example
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Wire the ULTRA Plus PDM Components 3-33
Encoder 1
4 1/% < %
Encoder 1 and signal names
< %
Connector Pin Signal Name
P5 Encoder input 1 1 A+
2 A-
3 B+
4 B-
5 I+ (Index)
6 Common
7 Common
8 No connection
9 +5 VDC
10 I- (Index)
11 TS- (thermostat)
12 TS+ (thermostat)
13 Analog (absolute position)
14 +5 VDC
15 Shield
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3-34 Wire the ULTRA Plus PDM Components
Figure 3.21 Encoder 1 connections
R
T
G
S
BRUSHLESS MOTOR
P5-15
P5-14
P5-13
P5-12
P5-11
P5-10
P5-9
P5-8
P5-7
P5-6
P5-5
P5-4
P5-3
P5-2
P5-1
SHIELD
+5 VDC
ANALOGTS+
TS-
I-
+5 VDC
NC
COMMON
COMMON
I+
B-
B+
A-
A+
Publication 1398-5.1 — January 2000
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Wire the ULTRA Plus PDM Components 3-35
Encoder 2
4 1// 1 18< / $
< / % < /
Encoder 2 and signal names
*0- ! " 7 *0-$!$" . O O $O$ O7$O$
< / *0- C *0-. *2 !*%7" & G,3&**0-*2 *7 < !, "!*@D?%>% />1%"H 1 7>
Connector Pin Signal Name
P4 Encoder input 2 1 A+
2 A-
3 B+
4 B-
5 I+ (Index)
6 Common
7 Common
9 +5 VDC!/7>"
10 I- (Index)
15 Shield
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3-36 Wire the ULTRA Plus PDM Components
Figure 3.22 Encoder 2 connections
Slaving an ULTRA Plus PDM to Another
$ ,3&**0-GH ,3&**0- *2 ,3&**0-< / !",3&**0- ,3&**0- *2 & G,3&**0-*2*2/!*@D?%>% /%/9"H 1 7%
MASTER ENCODER
P4-15P4-14P4-13P4-12P4-11P4-10P4-9P4-8P4-7P4-6P4-5P4-4
P4-2P4-3
P4-1
SHIELD+5 VDCDIR-
STEP+I-
DIR+COMMONCOMMONI+
B-B+A-A+
+5 VDC
STEP-
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Wire the ULTRA Plus PDM Components 3-37
Step and Direction Inputs
4 1/1 *0- *2 $ *2 < / < %
Step and direction inputs and signal names
%>7=0.3
Figure 3.23 Step and direction input connections
Connector Pin Signal Name
P4 Encoder input 2 8 DIR+
11 STEP+
12 STEP-
13 DIR-
15 Shield
470 470
470
POSITIONING MODULE POSITIONING MODULE
Step + Step +
Step - Step -
Dir + Dir +
Dir - Dir -
470
P4-13 P4-13
P4-8 P4-8
P4-12 P4-12
P4-11 P4-11
Step and Direction Step and Direction
Active Low Active High
Indexer Indexer+5V
Step
Step
Dir
Dir
IndexerCommon
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3-38 Wire the ULTRA Plus PDM Components
O7=0.< %> 7=0.
;>>C( 2
D *0- '
$ *0-*2 %7
REVcc 1.8–
10----------------------- 0.470
RE External resistance kΩ( )
Vcc Signal Voltage=
=
–=
Motor Encoder Counts N step pulses( ) ab---
Motor Encoder Counts The distance the motor moves
N step pulses The number of pulses from an indexer
ab--- The software gear ratio=
=
=
=
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Wire the ULTRA Plus PDM Components 3-39
Serial Port Connections *0- % !*9" /. !*8"5 *0- *9 *8 *. #-3, *8 C
0 *&$D&<0 & #-3,
& /1/. & 2// %/>>/2>>2;>>?8>> %?/>>& #-3,
'
• ?8>>
• D
• ;
• %
• C5D
• & /1/.
Host Computer
/. !*8" *0- C
Host computer and signal names
5 ,3&**0-& 2// & /1/ $ ,3&*
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3-40 Wire the ULTRA Plus PDM Components
*0- +%& GD H 1 22
4 1/2& /1/ !*." *8*0- *0-
Figure 3.24 Personal Computer RS-232 connections
& GD H 1 22 & 2//,3&**0-
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
Personal ComputerSerial
Connector9-pin
2 RXD3 TXD5 GND
ULTRA PlusSerial Port (P6)
Connector
RXD- P6-2TXD- P6-3COM P6-5Shield P6-6
Personal ComputerSerial
Connector25-pin
2 TXD3 RXD7 GND
ULTRA PlusSerial Port (P6)
Connector
RXD- P6-2TXD- P6-3COM P6-5Shield P6-6
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Wire the ULTRA Plus PDM Components 3-41
Operator Terminal
1398-HMI-002
5 *0- %!*9".5-% 5
P7 at Serial Port 1 on PDM
$ *0-%1?; C-$ >>J5 *0- & #-3,
COM1 connector on the back of the Operator Terminal
.5-% 0 5 & /1/. %7 !7>"4 & 2//& #-3, !*9" & 2//
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
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 TXD- (RS-422 transmit)
16 RXD+ (RS-422 receive)
17 RXD- (RS-422 receive)
7 Signal ground
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3-42 Wire the ULTRA Plus PDM Components
Figure 3.25 Operator Terminal RS-232 connections
Figure 3.26 Operator Terminal RS-422 connections
1398-HMI-003 ULTRA Plus PDM (P7, Serial 1 Auxiliary)
,3&**0-5 & /1/ %7 !7>"
Pin Signal names
RS-232 RS-422
1 No connection RxD+
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
OperatorTerminalCOM1
Connector
2 TXD3 RXD7 GND
ULTRA Plus PDMP7
Connector
RXD- P7-2TXD- P7-3COM P7-5Shield P7-6
OperatorTerminalCOM1
Connector
15 TXD-
17 RXD-16 RXD+
ULTRA Plus PDMP7
Connector
RXD+ P7-1RXD- P7-2TXD- P7-3TXD+ P7-4COM P7-5Shield P7-6
14 TXD+
7 COM
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Wire the ULTRA Plus PDM Components 3-43
Operator Terminal (screw terminal on back) .
Figure 3.27 ULTRA Plus PDM connects to the Operator Terminal
Pin and Signal names
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
IMPORTANT ) ! "12,3&*5 & /1/
12 3 TxD45 COMMON6 SHIELD789
RxDPin
1 2 3 4 5 6 7 8 9 10
Tx
Rx
RT
SC
TS
CO
MM
ON
TxA TxB
RxA
RxB
CO
MM
ON
ULTRA PlusPositioning Drive Module(1398-PDM)
ULTRA PlusOperator Terminal(1398-HMI-003)
JUM
PE
R
customer suppliedjumper
9101-2205-XXX ULTRA Plus to 1398-HMI-003ULTRA Plus Operator Terminal cable
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3-44 Wire the ULTRA Plus PDM Components
Networking
ULTRA Plus PDM Controls
5 *0-& 2// & /1/ $ *0- *0- +%0$* 4 1/;
Figure 3.28 Dip Switch SW1
4 1/? 7+% % +% 8 +% %+% 8 $ >*0- ! .". (*0-C & ! "
Figure 3.29 Dip Switch SW1 set for address 5 example
4 1/? 1 22+% 95D +% 9 %$+% 9544 %
OFF
1 2 3 4 5 6 7 8
OFF
1 2 3 4 5 6 7 8
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Wire the ULTRA Plus PDM Components 3-45
$+% 95D % / ! "
Figure 3.30 Dip Switch SW1-7 set ON for daisy-chain mode example
;0$**0-544 >$ *0-0$*+%544
OFF
1 2 3 4 5 6 7 8
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3-46 Wire the ULTRA Plus PDM Components
RS-422 Multi-Drop
4 11% 1 28 *0-& 2// & 0$*+% *0-& 2// //+#
Figure 3.31 RS-422 Multi-drop connections
RS-232 Daisy-Chain
90$*+% & *0- //+#
Figure 3.32 RS-232C Daisy-chain connections
Host
COM
RXD-RXD+
TXD-TXD+
COM P6-5 COM P6-5 COM P6-5
RXD- P6-2 RXD- P6-2 RXD- P6-2RXD+ P6-1 RXD+ P6-1 RXD+ P6-1
TXD- P6-3 TXD- P6-3 TXD- P6-3TXD+ P6-4 TXD+ P6-4 TXD+ P6-4
AXIS 1Port 2
AXIS 2Port 2
AXIS nPort 2
SW1-7 OFF SW1-7 OFF SW1-7 OFF
HostTXDRXDGND
TXD RXD GND(3) (2) (5)
TXD RXD GND(3) (2) (5)
SW1-7 ONAXIS #1
TXD RXD GND(3) (2) (5)
TXD RXD GND(3) (2) (5)
SW1-7 ONAXIS #2
TXD RXD GND(3) (2) (5)
TXD RXD GND(3) (2) (5)
SW1-7 OFFAXIS #n
P6 Port #2 P6 Port #2 P6 Port #2 P7 Port #1P7 Port #1P7 Port #1
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Wire the ULTRA Plus PDM Components 3-47
Operator Terminal (1398-HMI-002)
4 111 5 *0- & 2// *0- D5 *0-5 #-3,
Figure 3.33 Operator Terminal RS-422 multi-drop connections
COM 7
RXD- 17RXD+ 16
TXD- 15TXD+ 14
COM P7-5 COM P7-5 COM P7-5
RXD- P7-2 RXD- P7-2 RXD- P7-2RXD+ P7-1 RXD+ P7-1 RXD+ P7-1
TXD- P7-3 TXD- P7-3 TXD- P7-3TXD+ P7-4 TXD+ P7-4 TXD+ P7-4
AXIS 1Port 1
AXIS 2Port 1
AXIS nPort 1
OperatorTerminalCOM1
Connector
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3-48 Wire the ULTRA Plus PDM Components
Operator Terminal (1398-HMI-003)
55 ,3&%>> 0 & 2// ,3&**0- GD5H ,3&**0- & #-3,
Figure 3.34 ULTRA Plus PDM RS-422 multiple drop connections
IMPORTANT %+%@2
ULTRA PlusOperator Terminal
ULTRA PlusPositioning Drive ModulesRS-422 Multiple Drop Connections
1 RxD +2 RxD -3 TxD -4 TxD +5 COMMON6 SHIELD7 Not used8 Not used9 Not used
Pin
AU
XIL
IAR
YS
ER
IAL
1
P76
9 5
1
1 RxD +2 RxD -3 TxD -4 TxD +5 COMMON6 SHIELD7 Not used8 Not used9 Not used
Pin
AU
XIL
IAR
YS
ER
IAL
1
P76
9 5
1
1 RxD +2 3 TxD -4 TxD +5 COMMON6 SHIELD7 Not used8 Not used9 Not used
RxD -Pin
AU
XIL
IAR
YS
ER
IAL
1
P76
9 5
1
1 2 3 4 5 6 7 8 9 10
Tx
Rx
RT
SC
TS
CO
MM
ON
TxA
TxB
RxA
RxB
CO
MM
ON
1KTe
rmin
atin
gR
esis
tor
customer supplied cabling
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Wire the ULTRA Plus PDM Components 3-49
Cables & - . 8
Figure 3.35 ULTRA Plus PDM P7 to Operator Terminal (P/N 9101-2205)
Figure 3.36 ULTRA Plus PDM P6 to PC Serial Port (9 pin) (P/N 9101-2024)
OPERATOR TERMINALSERIAL PORT CONNECTOR
POSITIONINGMODULE
CONNECTORP7
OPERATORTERMINAL
SERIAL PORTCONNECTOR
25 PIN FEMALE
POSITIONINGMODULE
CONNECTORP7
9 PIN MALE
POSITIONINGMODULE
CONNECTORP6
9 PIN MALE
POSITIONINGMODULE
CONNECTORP6
PC SERIAL PORTCONNECTOR
PC SERIAL PORTCONNECTOR
9 PIN FEMALE
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3-50 Wire the ULTRA Plus PDM Components
Figure 3.37 ULTRA Plus PDM P4 or P5 to Auxiliary Encoder (Unterminated) (P/N 9101-2031)
POSITIONINGMODULE
CONNECTORP4
INDEXERENCODER
CONNECTIONS
SHIELD P4-15
COM
+5V +5V
COM
RED
BLACKP4-6
P4-9
I-
I+ I+
I-
YELLOW
BLACKP4-10
P4-5
B-
B+ B+
B-
BLUE
BLACKP4-4
P4-3
A-
A+ A+
A-
GREEN
BLACKP4-2
P4-1
COM
+5V +5V
COM
WHITE
BLACKP4-7
P4-14
DIR-
DIR+ DIR+
DIR-
BROWN
BLACKP4-13
P4-8
STEP-
STEP+ STEP+
STEP-
BLACK
ORANGEP4-12
P4-11
POSITIONINGMODULE
CONNECTORP4
15 PIN MALEHIGH-DENSITY
INDEXER/ENCODER
CONNECTIONS
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Wire the ULTRA Plus PDM Components 3-51
Figure 3.38 ULTRA Plus PDM P4 to P4, 2 foot (P/N 9101-2127)
Figure 3.39 ULTRA Plus PDM P5 to H, or F-Series Motor Encoder (P/N 9101-2027)
A-
A+
B+
B-
I+
I-
A-
A+
B+
B-
I+
I-
MASTER AXISCONNECTOR
P4
SLAVE AXISCONNECTOR
P4
SHIELD
MASTER AXISCONNECTOR
P4
15 PIN MALEHIGH-DENSITY
SLAVE AXISCONNECTOR
P4
15 PIN MALEHIGH-DENSITY
15 PIN MALEHIGH DENSITY
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3-52 Wire the ULTRA Plus PDM Components
Figure 3.40 ULTRA Plus PDM P5 to N-Series Motor Encoder (9101-1474)
2(E=feet)
START OF BEND RADIUS
MARKED WITH ELECTRO-CRAFTP/N & REV, MANUFACTURERSP/N & REV, AND DATE CODE
B A M
C P N L
D R V U K
E S T J
F G H
MOLDING ADAPTER, ALUMINUM,BLACK COBALT PLATED
MACHINED THUMBSCREW4-40 RETRACTABLE
CONNECTOR, ITT CANNON#KPSE05E14-19S-A71
™0.395
™1.16
12.0±0.5
E
45˚
0.12 THREAD
1.34
PROTRUSION
1.32
0.65
1.96
2.50
3.31
F G
(FACE VIEW)
KPSE05E14-19S-A71CONNECTOR
G
T
U
V
N/C
N/C
N/C
N/C
N/C
N/C
N/C
DENOTES TWISTED PAIR
DRAIN
15 POSITION HIGH DENSITY 45˚ 'D'-SUB PLUGWITH MALE PIN CONTACTS
(FACE VIEW)
H
E S T J
KUVRD
C P N L
MAB
R
P
N
S
L
K
N/C
M
J
H
F
E
D
A
C
B
BLACK
ORANGE
BLACK
BLACK
WHITE
RED
BLACK
BROWN
BLACK
YELLOW
BLUE
BLACK
9
13
5
10
4
11
15
6
14
7
12
8
PIN
10
PIN
6
PIN
11
PIN
15
PIN
5
PIN
1
BLACK
GREEN
WIRING DIAGRAM
1
3
2
CONNECTOR BACKSHELL SHIELDED 360˚ (BOTH ENDS)
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Chapter 4
Apply Power for the First Time
5 ,3&**0-- 5 & #-3, '
• %1?; 7%>
• %1?; 7%%
• %1?; 7%/
*.!#-3, 'T"
B #-3, #-3,
1398-PDM-10, 20, 30, 75, and 150B
ATTENTION
!
C ,3&**0-
4 )
1 Publication 1398-5.1 — January 2000
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4-2 Apply Power for the First Time
* ,3&**0- !%>>I/2>=."
+ '
$ 3%,J3/@D,J
+ ,3&**0- &= ,3&**0- &#D0#D0#D07>>$ ,3&**0- &
. !*%I*9"*0-
-
3<0
0.,3<0
,3<0
0 5-
$( * - *0-
ULTRA Plus PDM Phasing ofPower Source
Phasing Connections
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
ATTENTION
!*
$
IMPORTANT *0-,3<0 . ?
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Apply Power for the First Time 4-3
'
! 5-
"# $%$(*-
,3&**0- 0
-
= < $
& (* -
* - ('! *0-,*-
(%
$,3<0 '
<
") ! ** $%$@5-
. & < -< 5 7 2
.$@5-
(%
0&0 5- ,3&**0-
= ,3<0 $,3<0
= ,3&**0-
0,3&**0- '
<544
044N++$%(%
5-
= '
%* ,!$% <
-* (*! .>
& .
& .
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4-4 Apply Power for the First Time
(%<
(*!
<,3&**0- '
• <5D
• 04N.$%(%
=
. '
• <)
• 0A5- A$% A A(%A
• ,5- 4N544
• & 3<0
1398-PDM-25, 50, 100, and 150
,3&**0- * -!*-",3&**0-*- *0-* *0-*-
ATTENTION
!0 P
.0. * - ,3&**0-
Publication 1398-5.1 — January 2000
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Apply Power for the First Time 4-5
Power Supply Module
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4-6 Apply Power for the First Time
Start-up Procedure for PDM
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Apply Power for the First Time 4-7
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4-8 Apply Power for the First Time
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Apply Power for the First Time 4-9
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4-10 Apply Power for the First Time
D $
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Apply Power for the First Time 4-11
Operator Terminal 5 & 5 1 %8 3<0D ,3&**0- ,3&**0- +5 ,3&**0- 5
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4-12 Apply Power for the First Time
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Chapter 5
Check for Problems in the System
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5-2 Check for Problems in the System
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DC Bus Power (1398-PDM-25, 50, 100, and 150)
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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
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Check for Problems in the System 5-3
Operator Terminal Status Screens
,3&**0-? ,<, .:*.< .3<&:
5 ! "
Personality Module Default Initialization
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 NVRAM settings.
Variable Name DescriptionRefer 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. 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 I/O or Memory and Expansion I/O card is installed.
Output Status Outputs 1 through 8. Outputs 9 through 24 if an Expansion I/O or Memory and Expansion I/O card is installed.
Current Status ICMD, IAVE, IN PEAK CURRENT
CommandedPosition Status
PGEN, PJOG, PEXT
Peak Status PFE, PVEL1, PICMD
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.
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5-4 Check for Problems in the System
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Check for Problems in the System 5-5
<
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 LOOP 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.
20212223
KP Out of RangeKFF Out of RangeKI Out of RangeKPZ Out of Range
The parameter listed has exceeded the internal system limit. The limit is determined at run time based on the Scale parameter. Check the gain values under the Parameter menu.
24 Gear Out Of Range The calculated value for the gear ratio denominator is greater than 32,767. Check that the value is correct.
303132
Calculations:S-CurveAccelVelocity
The calculation listed has exceeded the internal system limit. The limit is determined at run time based on the Scale parameter. Check the velocity and acceleration values under the Parameter menu.
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5-6 Check for Problems in the System
33 Iavg Fault The average current output of the GML exceeded safe levels for the motor or GML. Check for correct connection of the motor encoder to the GML or of the motor leads to the GML. 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 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.
41 Power Module FaultorHeat 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 UndervoltageorLogic 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 problem in the GML internal power supply.
(Continued)
No. Error Messages Description
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Check for Problems in the System 5-7
43 Peak Overcurrent 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.
4546
Encoder 1 FaultEncoder 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).
47 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.
51 EPROM Checksum One of the EPROMs failed the checksum test at power up. All three EPROMs, U66, U67, 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.
(Continued)
No. Error Messages Description
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5-8 Check for Problems in the System
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Appendix A
Specifications
1398-PDM-10, 20, 30, 75, and 150B
,3&**0-
1398-PDM-10, 20, 30, 75, and 150B Specifications
Drive Module Type
1398PDM-10 (1Φ)
1398PDM-20 (1Φ)
1398PDM-30 (1Φ)
1398PDM-75 (3Φ)
1398PDM-150B (3Φ)
Peak Output Current/Phase
10 amps 20 amps 30 amps 75 amps 150 amps
Continuous Output Current/Phase
5 amps 10 amps 15 amps 35 amps 65 amps
Continuous Output Power
1 kW 2 kW 3 kW 7 kW 15 kW
Electrical Specifications
Line Voltage Input (50/60 Hz)
100-240 VAC
100-240 VAC
100-240 VAC
100-240 VAC
100-240 VAC
Continuous Shunt Power
50 W 50 W 50 W 50 W 180W
Peak Shunt Power
4.5 kW 4.5 kW 4.5 kW 10 kW 19 kW
Continuous Shunt External
2.4 kW 2.4 kW 2.4 kW 4 kW 8 kW
Peak Shunt External
6 kW 6 kW 6 kW 10 kW 19 kW
Physical Specifications
Weight 15 lb (5 kg)
15 lb (5 kg)
15 lb (5 kg)
21 lb10 kg
31 lb14 kg
Operating Temperature
32° to 140°F (0° to 50°C)
Storage Temperature
-40° to 176°F (-40° to 80°C)
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A-2 Specifications
1398 PDM-25, 50, 100, and 150
Relative humidity
5% to 95% non-condensing
External Shunt Resistor P/N 9101-1079
Continuous Shunt Power
200 W
Peak Shunt Power
6000 W
1398-PDM-10, 20, 30, 75, and 150B Specifications (Continued)
Drive Module Type
1398PDM-10 (1Φ)
1398PDM-20 (1Φ)
1398PDM-30 (1Φ)
1398PDM-75 (3Φ)
1398PDM-150B (3Φ)
1398-PDM-25, 50, 100, and 150 Specifications
Positioning Drive Module
1398PDM-25
1398PDM-50
1398PDM-100
1398PDM-150
Peak Output Current/Phase
25 amps 50 amps 100 amps 150 amps
Continuous Output Current/Phase
20 amps 40 amps 50 amps 65 amps
Continuous Output Power
4 kW 8 kW 10 kW 12 kW
Physical Specifications
Weight 15 lb (5 kg)
15 lb (5 kg)
15 lb (5 kg)
21 lb10 kg
Operating Temperature
32° to 122°F (0° to 50°C)
Storage Temperature
-40° to 176°F (-40° to 80°C)
Relative humidity
5% to 95% non-condensing
External Shunt Modules
Continuous Shunt Power
200 W 900W
Peak Shunt Power
6000 W 10kW
Power Supply Module
1398-PSM-50 1398-PSM-125
Line Voltage Input (3Φ 50/60 Hz)
100 to 240 VAC
100 to 240 VAC
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Specifications A-3
Operator Terminals
Fused Disconnect
Class RK5 40 amps
Class RK5 90 amps
Output Bus Voltage
100-340 VDC 100-340 VDC
Continuous Output Current
50 amps 100 amps
Continuous Shunt Dissipation
600 W 1200 W
Peak Shunt Power
20 kW 40 kW
Terminal Block Torque
11.0 lb-in(1.25 Nm)
24.0 lb-in (2.75 Nm)
1398-PDM-25, 50, 100, and 150 Specifications (Continued)
Positioning Drive Module
1398PDM-25
1398PDM-50
1398PDM-100
1398PDM-150
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
TemperatureOperatingStorage
32° to 131°F (0° to 55°C) ambient-40° to 158°F (-40° to 70°C) ambient
32° to 104°F (0° to 40°C) ambient4° to 176°F (-20° to 80°C) ambient
Humidity 5% to 95% non-condensing 80% maximum, non-condensing
Weight 7 lb. (3 kg) 2.3 lb. (0.1 kg)
Display Vacuum Fluorescent Display, 4 lines by 20 charactersCharacters 5 mm high
Vacuum Fluorescent Display, 4 lines by 20 charactersCharacters 5 mm high
Front panel seal NEMA 4 (IP64)NEMA 12 (IP66)
NEMA 4/IP65
RS-232 cable 9101-2205 9101-2205
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A-4 Specifications
Transformers -
Single Phase Transformer specifications
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Three Phase Transformer specifications
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Specification Value
Rating 3.0 kVA
Input 220/ 230/ 240/ 440/ 460/ 480 VAC RMS
Outputa 115/ 230 VAC RMS
Ambient temperature 32° to122°F (0° to 50°C)
Single phase input and output (50/60 Hz)
Specification Model
TF-03 TF-06 TF-12 TF-18
Rating 3 kVA 6 kVA 12 kVA 18 kVA
Weight 86 lb 135 lb 200 lb 325 lb
31 kg 61 kg 91 kg 148 kg
Input 208/ 230/ 240/ 380/ 460/ 480 VAC RMS
Outputa 115/ 230 VAC RMS
Ambient temperature 32° to122°F (0° to 50°C)
Three phase input and output (50/60 Hz)
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Appendix B
Options and Accessories
PDMs and Optional Accessories
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Item Number Description Alternate Number
1398-PDM-10 Positioning Drive Module 9101-2185
1398-PDM-20 Positioning Drive Module 9101-2186
1398-PDM-25(1)
(1) Requires use of 1398-PSM-XXX Power Supply.
Positioning Drive Module 9101-3058
1398-PDM-30 Positioning Drive Module 9101-2187
1398-PDM-50(1) Positioning Drive Module 9101-3059
1398-PDM-75 Positioning Drive Module 9101-2188
1398-PDM-100(1) Positioning Drive Module 9101-3060
1398-PDM-150(1) Positioning Drive Module 9101-3061
1398-PDM-150B Positioning Drive Module 9101-2234
Fuse, Drive Module F1 1 Amp(for 24 VDC circuits Bussman MDL 1 or Littelfuse 313 001)
9101-0228
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(1)
(1) 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.
9101-2226
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B-2 Options and Accessories
I/F Conversion Card /2=
Power Supply Modules
Description Alternate Number
I/F Conversion Card, 24V Sourcing(1)
(1) Required for compliance with the European Union Low Voltage Directive (LVD). It must be mounted in the same enclosure as ULTRA Plus PDM.
9103-0152
Cable, I/F Conversion Card 3ft (1m), 44-0141-003
Cable I/F Conversion Card 10ft (3m), 44-0141-010
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 FuseBussman KLM-8 or Littelfuse KLK D 8
9101-0225
1398-PSM-125 FuseBussman KLM-20 or Littelfuse KLK D 20
9101-1076
Fuse F1, PSM-AUXBussman MDX-7 or Littelfuse 313 007
9101-0123
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Options and Accessories B-3
AC Line Filters .34 .<!<-."
Description Alternate Number
1398-PDM-10(10 Amps continuous, single phase)
9101-1517
1398-PDM-20(23 Amps continuous, single phase)
9101-1518
1398-PDM-30(36 Amps continuous, single phase)
9101-1387
Multiple drives (1)
(50 Amps continuous, single phase)
(1) For multiple PDMs using one filter, the combined PDMs input current must not exceed filter ratings.
9101-1388
1398-PDM-75(36 Amps continuous, three phase)
9101-1389
1398-PDM-150B(50 Amps continuous, three phase)
9101-1575
Multiple drives(1)
(80 Amps continuous, three phase)9101-1390
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B-4 Options and Accessories
Cables *0- !%"- !JJJ" '>%>N%>!1">/7N/7!9">7>N7>!%7">97N97!/1"
PDM Motor Description Alternate Number
1398-PDM-10, 20, 30 or 75
H-2000 or H-3000 Motor 9101-1080-XXX
1398-PDM-10, 20, 30 or 75
H-4000 or F-4000 Motor 9101-1081-XXX
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)
(1) RS-232 cables are available in 3m and 7m (10 and 25 ft) lengths only.
9101-2024-XXX
ULTRA Series Operator Terminal Cable (RS-232) (P7)
9101-2025-XXX
ULTRA Series Motor Encoder Cable (P5 Connector)
9101-2027-XXX
ULTRA Series Control Station Cable 9101-2030-010
ULTRA Series Encoder Cable 9101-2031-XXX
1398-PDM-25, 50, 100 or 150 for H-3000 Motor Power Cable with Motor Connector
9101-0250-XXX
1398-PDM-25, 50, 100 or 150 for H-4000/F-4000 Motor Power Cable
9101-0251-XXX
1398-PDM-25, 50, 100 or 150 for H-6000/F-6000 Motor Power Cable
9101-0252-XXX
1398-PDM-25, 50, 100 or 150 for H-8000 Motor Power Cable
9101-0253-XXX
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 Connector) with right angle motor connector
9101-2135-025 or 9101-2135-050
N-Series Encoder Cable (P5 Connector) with right angle motor connector
9101-1677-XXX or9101-1679-XXX
1398 PDM-10, 20, 30 or 75 for H-6000/F-6000 Motor Power Cable
9101-2179-XXX
ULTRA Plus to I/O Conversion Card, 3-foot Cable 44-0141-003
ULTRA Plus to I/F 24V Conversion Card, 10-foot Cable
44-0141-010
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Options and Accessories B-5
Transformers ,3&**0-
Motor Identification
Description Alternate Number
3 KVA three phase transformer 0020-5091-001
6 KVA three phase transformer 0020-5091-002
12 KVA three phase transformer 0020-5091-003
18 KVA three phase transformer 0020-5091-004
Auxiliary PSM transformer 0020-5093
3 KVA single phase transformer (1398 PDM-10, 20, 30 or 75) 0020-5097
FACTORY DESIGNATED SPECIAL OPTIONSAA = STANDARD FLANGEAN = NEMA56C FLANGE
OPTIONS00 = STANDARD01 = 90 Vdc BRAKE04 = 24 Vdc BRAKE
OPTICAL ENCODER LINE COUNT*F = 1000H = 2000 (S T A N D A R D)J = 2500K = 5000L = 500M = 3000N = 1500
MOTOR WINDING KE DESIGNATORNOTE: SPECIAL ORDER WINDINGS AVAILABLE
FRAME SIZESeries DESIGNATOR
F = FERRITE MAGNETH = LOW INERTIAN = NEMA
* Not all line counts are available on all motors
H - 4 0 3 0 - Q H 00 - AA
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B-6 Options and Accessories
Motor Connectors C4D
ConnectorType
Motor Series Straight Right Angle
Power connectors
H-Series (2000 and 3000)
9101-0325(MS3106F18-4S)
9101-0398(MS3108F18-4S
Power connectors
H and F-Series (4000)
9101-0326(MS3106F20-4S)
9101-0399(MS3108F20-4S)
Power connectors
H and F-Series (6000)
9101-0327(MS3106F24-22S)
9101-0400(MS3108F24-22S)
Power connectors
H-Series (8000) 9101-0328(MS3106F32-17S)
9101-0401(MS3108F32-17S)
Power connectors
N-Series 9101-1557 (Solder)MS3116F14-5S (Solder)MS3126F14-5S (Crimp)
KPT08F14-5S (Solder)KPSE08F14-5S (Crimp)
PT08E14-5S (Solder)PT08SE14-5S (Crimp)
Encoder connectors
H-Series and F-Series
9101-0329MS3106F20-29S
9101-0402MS3108F20-29S
Encoder connectors
N-Series 9101-1558 (Solder)MS3116F14-19S (Solder)MS3126F14-19S (Crimp)
KPT08F14-19S (Solder)KPSE08F14-19S (Crimp)
PT08E14-19S (Solder)PT08SE14-19S (Crimp)
Brake connectors H-Series and F-Series
9101-0330MS3106F12S-3S
9101-0403MS3108F12S-3S
Brake connectors N-Series 9101-1698 (Solder)MS3116F12-3S (Solder)MS3126F12-3S (Crimp)
KPT08F12-3S (Solder)KPSE08F12-3S (Crimp)
PT08E12-3S (Solder)PT08SE12-3S (Crimp)
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Options and Accessories B-7
Motor Shaft Seal Kits C4D
Description (Outside Dia x Inside Dia x Width) Alternative Number
Shaft seal kit, H-2000 motor 22 mm x 12 mm x 7 mm
0041-5056
Shaft seal kit, H-3000 motor28 mm x 15 mm x 7 mm
0041-5057
Shaft seal kit, H-4000 motor47 mm x 20 mm x 7 mm
0041-5058
Shaft seal kit, H-6000 motor80 mm x 38 mm x 8 mm
0041-5059
Shaft seal kit, H-8000 motor85 mm x 45 mm x 8 mm W
0041-5053-005
Shaft seal kit, F-4000 motor1.437 inch x 0.875 inch x 0.25 inch
0041-5060
Shaft seal kit, F-6000 motor2.125 inch x 1.438 inch x 0.31 inch
0041-5061
Shaft seal kit, N-2300 motor mm/in0.035 x 0.001 x 0.005 / 0.875 x 0.250 x 0.125
0041-5068
Shaft seal kit, N-3400 motor mm/in0.044 x 0.019 x 0.010 / 1.125 x 0.500 x 0.250
0041-5069
Shaft seal kit, N-4200 motor mm/in0.044 x 0.025 x 0.010 / 1.125 x 0.625 x 0.250
0041-5070
Shaft seal kit, N-5600 motor mm/in0.054 x 0.030 x 0.010 / 1.375 x 0.750 x 0.250
0041-5071
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.
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B-8 Options and Accessories
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Index
AAbsolute positioning 1 7, 1 9AC
3-phase power 1 %Coils suppressed with RC filters / 27Line filterInstallation / 2>, / 2%Order 1Rasmi / 1?Roxburgh / 1?Schaffner / 1?Power transformer / 1;Power wiring / 1;
Accel calculation error 7 7Analog to Digital converter
Resolution 1 /;ANSI
C62 and C63 / 19Assignable function
Home Sequence Complete (output) 1 /9Assignable functions
Digital Outputs 1 /9At Home output
Assignable function 1 /9Auxiliary power supply
Description % 9Logic power 1 7, 1 9
BBCD Input Range error 7 7Bonding
Mounting / 1%Sub panels / 1/
BusDC Power Supply 1 9Overvoltage error 7 9Undervoltage error 7 8
CCable
Description % 9Order 2Shielding / /?
Cam Profile Overflow error 7 8COM1 connector 1 2%Connections
Motor power 1 %;
Operator Terminal power supply 1 %8PDM terminal block 1 %, 1 8
Contents of manual * /Conventions
Conventions used in this manual * 1Conversion Card 24V Sourcing / /%
DDC
Coils suppressed with diode / 27Multiple power installations 1 8
DC BusPower supply 1 9
DelayOut of Range error 7 7
DiagnosticsDC Bus Power LED 7 /Error Messages 7 2LED 7 %Personality Module Default Initialization
7 1Diagram
Auxiliary Power Supply Connections 1 ;External Shunt Mounting and Connection
Diagram / %9, / %;Power Wiring Diagram (1398-PDM-25,
50, 100, and 100 1 7Power Wiring Diagram for 1398-PDM-10,
20, and 30 1 /Power Wiring for 1398-PDM-150B 1 2Power Wiring for 1398-PDM-75 1 1PSM AUX Outline and Connection
Diagram / %7Transformer Load Regulation (1398
PDM-10, 20, 30, 75, and 150B)Curve / 8
Transformer Outline Diagram (1398PDM-10, 20, 30, 75, and 150B)/ ;
Transformer Outline Diagram(1398-PDM-25, 50, 100, 150)/ ?
DigitalAssignable output functions 1 /9Multiple outputs 1 /9
Digital to Analog Converter (DAC)Resolution 1 /?
Dip Switch
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2 Index
Jumpers / /8RS-232 operation 1 28SW-1 in network 1 2>SW1-1 1 22SW1-6 1 22SW1-7 1 22
Divide by Zero error 7 7Documentation
Related documentation * 1Drive Not Ready error 7 8
EEarth ground 1 %Electrical Noise / 18Electronic gearing 1 18EMC
Defined / 18European Directive / /;Noise / 18PDM mounting requirements / /?Performance / /9Requirements / /;Cable shielding / /?Requirements - Flying leads / /?Requirements - Lead length / /?System Installation / 18
Emergency Return 1 /8Emergency stop contactor / 17EMI
Bonding / 1%Defined / 18Model / 18Problems / 27Source-Victim Model / 19Standards / 19
EN60529 (IEC 529) / /61000-4-X series / 19
EnableAssignable Function 1 /8Enable Input 1 %>Enabled output 1 1%
EnclosureFaraday cage / 21IP4X / 11Metal / /NEMA / /Shielding / 21Sizing / 1
EncoderEncoder Fault error 7 9Feedback 1 1%, 1 11, 1 17Shield 1 17
EPROM Checksum error 7 9EPROMs
Installation / /8Error
BCD Input Range 7 7Bus Overvoltage 7 9Bus Undervoltage 7 8Calculation 7 7Cam Profile Overflow 7 8Delay Out of Range 7 7Divide by Zero 7 7Drive Not Ready 7 8Encoder Fault 7 9EPROM Checksum 7 9Excessive FE 7 8Excessive Speed 7 8Gear Out Of Range 7 7Heat Sink Overtemperature 7 8Home Not Defined 7 7Iavg Fault 7 8Invalid Opcode 7 7KFF Out of Range 7 7KI Out of Range 7 7KP Out of Range 7 7KPZ Out of Range 7 7Logic Supply Fault 7 8LOOP Count Out of Range 7 7LOOP Variable Range 7 7Math Overflow 7 7Motor Overtemperature 7 8Peak Overcurrent 7 9Personality Fault 7 9POS Track Overflow 7 8Power Module Fault 7 8PRECISION Out of Range 7 7Profile Calculation 7 7RAM R/W Fault 7 9Reentrancy Fault 7 7Serial 2 Busy 7 8TEXT Checksum 7 9Watchdog Reset 7 9Watchdog Test Fault 7 9
Error outputAssignable function 1 /9Multiple axis 1 /;
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Index 3
European Directive ComplianceDirective / /;Emergency Stop Contactor / 17I/O Conversion Card / 12Low Voltage Directive / 11Motors and Cables / 11
ExcessiveExcessive FE error 7 8Excessive Speed error 7 8
External ShuntDescription % ;Installation / %9Power dissipation ratings 1 %1
FFaraday shield / 1;Fault
Encoder 7 9Iavg 7 8Logic Supply 7 8Personality 7 9Power Module 7 8RAM R/W 7 9Reentrancy 7 7Watchdog Test 7 9
Filter types / 1?Firmware
Installation / /7Flying leads
Motor shield termination / /?Forward Limit 1 /8Full Load Amperage / //Fuse
Short Circuit Protection / //
GGear
Out Of Range error 7 7GML Ultra Software
Description % 1Installation 2 %
GroundGround bus bar / 2/Safety ground / 2/Single Point Ground Types / 2/Torroid encoder shielding / 27
HHeat
Heat Losses for sizing enclosures / 1Heat Sink Overtemperature error 7 8
High frequency energy / 1/Home
Home Command 1 /8Home Not Defined error 7 7Home Sequence Complete (output) 1 /9Home Switch 1 /8
HostPLC 1 /;
II/F Conversion Card 24VDC Sourcing / /%,
1 /1I/O
24VDC Sourcing 1 /1Iavg Fault 7 8In Position output
Assignable function 1 /9Incremental encoder 1 1%, 1 17Input
Isolating input power 1 %Step and direction 1 19
InstallationEMC Motors and Cables / 11Installing for European Union Compliance
/ /;, / 11Emergency Stop Contactor / 17I/F Conversion Card / 12Motor guidelines / %8
InternalInternal logic power supply 1 7, 1 9Internal shunt 1 %/
Invalid Opcode error 7 7IP4X Enclosure / 11
JJog
Forward 1 /8Reverse 1 /8
JumperPDM internal power supply / /8PDM Internal shunt connection / %9
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4 Index
KKFF
Out of Range error 7 7KI
Out of Range error 7 7KP
Out of Range error 7 7KPZ
Out of Range error 7 7
LLead length
EMC requirements / /?LED 7 %Limit
Forward 1 /7, 1 /8Reverse 1 /7, 1 /8
Logic Supply Fault 7 8LOOP
Count Out of Range error 7 7Variable Range error 7 7
MManuals % 7Math Overflow error 7 7MIL-STD-461 / 19Monitor Output 1 /?Motor
Compatibility with PDM Control % 7Description % 7Encoder 1 11Mating Connectors % 9, 8Mounting / %2Ordering Information 7Overtemperature error 7 8Power leads 1 %;Shaft Seal Kits 9Shielded power cables % 9, / 11, / 22,
1 %?Thermostat 1 11
Mounting / %Auxiliary PSM Transformer / %2Bonding / 1%Environment / /Motors / %8Positioning Drive Module / %2Requirements / %>Shunt Resistor / %9, / %;
Ventilation / 1
NNational Electrical Code
Requirements / //NEMA enclosure / /Noise / 18
Emission supression diagrams / 28Operator terminal suppression 1 2;Problems / 18See Bonding / 1%
OOperating Environment / /Operator Terminal
Description % 8Installation / %?Mounting / %?Specifications 1Start-up Procedure 2 %%
Optically isolated inputs 1 /7Ordering Information
Cable 2Motor Mating Connectors 8Motor Shaft Seal Kits 9Motors 7Transformers 7
OutputAnalog Output 1 /?Connecting inputs and outputs 1 /9Enabled Relay output 1 1%Monitor output 1 /?Ready Relay output 1 1>Sinking signal of output 1 /9
PPause input 1 /7PDM
EMC mounting requirements / /?PDM with integral power supply % 2PDM with separate power supply % 2
Peak Overcurrent error 7 9Personal Computer (PC) % ;Personality Module
Description % 7Factory Default Initialization 7 1InitializationPDM-10, 20, 30 or 75 2 /
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Index 5
PDM-25, 50, 100 or 150 2 8Installation / /1Location / /1Personality Module Fault 7 9
POS Track Overflow error 7 8Positioning Drive Module
LEDs 7 %Mounting / %2
Power cableMotor / 11Shielding 1 %?
Power losses / 1Power Module Fault 7 8Power supply
Auxiliary % 9Connections 1 %8Digital I/O 1 />I/F 24V Conversion Card 1 /2Internal Logic 1 7Isolating input power 1 %Location / %2Module mounting / %2Motor connections 1 %;Operating environment / /Operator Terminal 1 %9Power supply module % 7
PRECISION Out of Range error 7 7Profile Calculation error 7 7Program Running output
Assignable function 1 /9Programmable Monitor 1 /?
QQuadrature signals 1 1%, 1 17
RRAM R/W Fault 7 9Rasmi AC Line filter / 1?Ready output 1 1>Reentrancy Fault error 7 7Regulatory requirements / /9Related documentation * 1Reverse Limit 1 /8Roxburgh AC line filter / 1?RS-232 1 2/, 1 28
Daisy-chain network 1 1?Jumper 1 21
RS-422
Multi-drop network 1 1?, 1 22, 1 28Operator Terminal connections 1 29,
1 2;
SSafety ground / 17, / 2/Schaffner AC Line filter / 1?S-Curve calculation error 7 7Serial 1 Auxiliary (P7) 1 1?, 1 2%Serial 2
Busy error 7 8Computer (P6) 1 1?
Shielded cableEncoder 1 17Motor 1 2
Shunt ResistorConnection Diagram / %9, / %;Internal in some PDMs 1 %1Mounting / %9, / %;
Single Point Ground Types / 2/Sinking (active low) I/O / 12Sourcing (active high) I/O / 12Specifications
1398 PDM-25, 50, 100, and 150 /1398-PDM-10, 20, 30, 75, and 150B %Operator Terminal 1Transformers 2
Start Program 1 /8Start-up Procedure 2 %
1398-PDM-10, 20, 30, 75, and 150B 2 %1398-PDM-25, 50, 100 or 150 2 8Motors 2 ;Operator Terminal 2 %%Personality Module 2 %%
Status outputs 1 %>Step and direction inputs 1 19Storage * 2Suitable filter types / 1?Support
Local product * 2Technical product assistance * 2
SW1 dip switchNework settings 1 22Unique addresses in network 1 2>
Symbols and Conventions * 2System firmware
Location / /7System Overview % /
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6 Index
TTerminal block
Connections 1 %, 1 8TEXT Checksum error 7 9Transformer
Description % 9Isolation 1 8Load Regulation (1398 PDM-10, 20, 30,
75, and 150B) Curve / 8Ordering 7Outline Diagram (1398-PDM-25, 50, 100,
150) / ?Sizing / 2
Troubleshooting, see “Check for Problems in the System”
Typographical Conventions * 2
UUnderwriter Laboratories
Listing / //
VVelocity calculation error 7 7Ventilation / 1
WWatchdog
Watchdog Reset error 7 9Watchdog Test Fault error 7 9
Wording Conventions * 2
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Publication 1398-5.1 — January 2000 2 PN 0013-1048-002 Rev ASupersedes Publication 1398-5.1 — August 1997 © 2000 Rockwell International Corporation. Printed in the U.S.A..