1398-5.1 jan00 ultra plus series positioning drive module ......check for mechanical binding,...

156
1398 ULTRA Plus Series Positioning Drive Module (Catalog Nos. 1398-PDM-10, -20, -30, -50, -75, -100, -150, and -150B) Installation Manual

Upload: others

Post on 23-Mar-2021

4 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

1398ULTRA Plus SeriesPositioning Drive Module(Catalog Nos. 1398-PDM-10, -20, -30, -50, -75, -100, -150, and -150B)

Installation Manual

Page 2: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Important User Information

! "

#$ %% ! "

& &

'

'

• (

• (

• (

$OOHQ%UDGOH\LVDWUDGHPDUNRI5RFNZHOO$XWRPDWLRQ*0/8OWUD6RIWZDUHLVDWUDGHPDUNRI5RFNZHOO$XWRPDWLRQ8/DQGF8/DUHUHJLVWHUHGWUDGHPDUNVRI8QGHUZULWHUV/DERUDWRULHV:LQGRZVLVDWUDGHPDUNRI0LFURVRIW&RUSRUDWLRQ

ATTENTION

!$ )

IMPORTANT $

Page 3: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Table of Contents

Preface$ * %+,- * %* - * %.- * /&0 * 1.,- * 1* & & * 2 * 2

3* * 2* * 2

Chapter 1Overview of the ULTRA Plus PDM System

40 % %5 % /

#-3, 6 +6 % 1*0 - % 2* -!*-" % 7- % 7* -!*-" % 7- % 7

% 85 % 8 % 9 * -!*-" % 9. % 9: % ;* . !*." % ;

Chapter 2Install the ULTRA Plus PDM Components

- / %< / /= / 1 ( / 2-& / %>%1?; *0- /77>%>>%7>* - / %2*- / %2- / %8< / %95 / %?$@4. . /2=0. / /%

*0-4& / // . * / //

* -$ / /1

i Publication 1398-5.1 — January 2000

Page 4: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

ii

$* -!*-" / /14 $ / /7

$4 <*&5- / /8A 0$* / /8& & / /9

< .0 / /;B / 1%- . / 113=0 / 11

< . / 184 / 1;.34 / 2># / 2/ / 21

Chapter 3Wire the ULTRA Plus PDM Components

* . 1 %%1?; *0- %>/>97%7> 1 %%1?; *0- /77>%>>%7> 1 7

< . 1 %/&*-4 1 %7

5 1 %8* .!%1?; C-$ >>/" 1 %8* .!%1?; C-$ >>1" 1 %9

- 1 %;* . 1 %; 1 %?

0$5 1 />$@4/2= 1 /10$ 1 /705 1 /9.$5 1 /9$ 1 /;5 1 /?- 5 1 /?&&5 1 1><&5 1 1%< % 1 11< / 1 17,3&**0- 1 180 $ 1 19

* . 1 1?C. 1 1?5 1 2%D 1 22

. 1 2?

Publication 1398-5.1 — January 2000

Page 5: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

iii

Chapter 4Apply Power for the First Time %1?; *0- %>/>1>97%7> 2 %

%1?; *0- /77>%>>%7> 2 2* - 2 7 * *0- 2 8

- 2 ;5 2 %%* - 2 %%

Chapter 5Check for Problems in the System 3<0!3<0" 7 %

*0 -,3<0 7 %0.* !%1?; *0- /77>%>>%7>" 7 /

5 7 1* -0$( 7 1< -< 5 7 2

Appendix ASpecifications %1?; *0- %>/>1>97%7> %

%1?;*0- /77>%>>%7> /5 1 2

* 2 * 2

Appendix BOptions and Accessories *0-5 %

$@4. . /* - /.34 1. 2 7- $ 7- . 8- : 9

Publication 1398-5.1 — January 2000

Page 6: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

iv

Publication 1398-5.1 — January 2000

Page 7: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Preface

Introduction & ( '

• +

• .

• &

• .

• *

Who Should Use this Manual

, ,3&**0-

$ ,3&**0-

Purpose of this Manual ,3&**0 -!*0-" &@ ,3&**0-$ ,3&**0-

1 Publication 1398-5.1 - January 2000

Page 8: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 - January 2000

Page 9: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Preface 3

Related Documentation

Conventions Used in this Manual

'

• D

• +

• +

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

Publication 1398-5.1 - January 2000

Page 10: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Preface 4

Product Receiving and Storage Responsibility

B .!" $ 3

3 $ '

• >87E.!1/%2?E4"

• 7F?7F

Allen-Bradley Support 97@ 57%/ (0 /8> ($ , )

Local Product Support

. '

Technical Product Assistance

$ G. * H 4

Publication 1398-5.1 - January 2000

Page 11: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Chapter 1

Overview of the ULTRA Plus PDM System

Functional Description ,3&**0- ,3&**0-

Figure 1.1 ULTRA Plus PDM Product Family

,3&**0- 5$@5

1 Publication 1398-5.1 - January 2000

Page 12: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

1-2 Overview of the ULTRA Plus PDM System

! " ! ",3&**0-

,3&**0-'

• *0 -

• * -,3&**0-

• * - ,3&**0-%1?; *0- %>/>1>97%7>" ,3&**0-!%1?; *0- /77>%>>%7>"

• 5

.,3&**0- >12D;;%2D!1@97>@"8>>>&*-

System Overview ,3&**0 -!*0-" ,3&**0 -!*0-"

Publication 1398-5.1 - January 2000

Page 13: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Overview of the ULTRA Plus PDM System 1-3

Figure 1.2 ULTRA Plus PDM Control System

GML Ultra™ for Windows™

#-3# -. 3 #-3 $ - +6 ,3&**0-

#-3, B ! "! " <

PSM PDM

PSM USEDONLY WITH

1398-PDM-0251398-PDM-0501398-PDM-100

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

Publication 1398-5.1 - January 2000

Page 14: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

1-4 Overview of the ULTRA Plus PDM System

,3&**0-

Positioning Drive Modules

,3&**0- ,3&**0- - & /1/@& 2// 5 5$@5

,3&**0- %1?; *0- %>/>1>97%7> 127>I %1?; *0- /77>%>>%7> />97>

Integral Power Supply Modules

%1?; *0- %>/>1>97%7> %>/>1>97%7> (

$ %1?;-*0- %>/> 1>%%7 /1>=.$ %1?; *0- 97 %1?; *0- %7> %%7 /1>=. ,3&**0- G H 0. ,3&**0-

Separate Power Supply Modules

%1?; *0- /77>%>>%7> /77>%>>%7> ,3&**0- !%1?; *- 7> %1?; *- %/7" ,3&**0-5 ,3&**0-

Publication 1398-5.1 - January 2000

Page 15: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Overview of the ULTRA Plus PDM System 1-5

Power Supply Module (PSM)

%1?; *0- /77>%>>%7>* -!*-"0. ,3&**0-*-%>>I/2>=. 0.*- ) G H0. $ 0.

Motors

C 4 D ,3&**0-< - @ - !-" C 4

Personality Module (PM)

* - (,3&**0- *- * - ,3&**0- *-

Manuals

,3&**0-#-3, ,3&**0-

Publication 1398-5.1 - January 2000

Page 16: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

1-6 Overview of the ULTRA Plus PDM System

Accessories Operator Terminal

%1?;5 5 2/>

5 4 !/2" ) #-3, 4 GJH K

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

321

F1

X1

X4

X3

X2

F4F3F2

STATUS

MODE

CLEAR

4

7

0

5

8

6

9

NO

-

YES

ENTER

function keys

numeric keypad

programmable keys

Publication 1398-5.1 - January 2000

Page 17: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Overview of the ULTRA Plus PDM System 1-7

Transformers

- & 7

Auxiliary Power Supply Module (PSM)

!*- ,J"0. ,3&**0-!*- 544"*- ,J%%7=. %1?; *0- /77>%>>%7> ,3&**0-

*- ,J,3&**0- 5D !*-"*- ,J ,3&**0- & *- ,J5.0 / %7 *- ,J*- ,J & * - /

Cables

- 19%7/1 !%>/77>97"- G0H D 19 !%>/7"& . 2

Motor Connectors

- & - . 8

Publication 1398-5.1 - January 2000

Page 18: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

1-8 Overview of the ULTRA Plus PDM System

Shunt Kits

%1?; *0- %>/>97%7> $ ,3&**0- 4 < :!/7Ω/>>+" < :!%;Ω?>>+" & *0-5 %

Personal Computer (PC)

*. #-3, #-3,

Publication 1398-5.1 - January 2000

Page 19: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Chapter 2

Install the ULTRA Plus PDM Components

,3&**0-

* ,3&**0- < ,3&**0- $%1?; *0- /77>%>>%7>

Mounting *0- * - 5 )

ATTENTION

!5

+

4 )

ATTENTION

!0

.

4

1 Publication 1398-5.1 — January 2000

Page 20: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

2-2 Install the ULTRA Plus PDM Components

Environment

,3&**0- <D8>7/?!$<.7/?"$*72 D<-%/ $*87 (! " ,3&**0-& GH %

Publication 1398-5.1 — January 2000

Page 21: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Install the ULTRA Plus PDM Components 2-3

Ventilation

(

Maximum power losses for help in sizing enclosures

( '

+ !E4"L !+" !M"

+ !"!"!"

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

T 4.08 QA----

1.1+=

A2dw + 2dh + 2wh( )

144-----------------------------------------------=

Publication 1398-5.1 — January 2000

Page 22: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

2-4 Install the ULTRA Plus PDM Components

Transformer Sizing

,3&**0- ( ,3&**0- !:=" $ *0-:+ :+

0'

:+N G H:=N

:= N! "/>

Intro

IMPORTANT . /> %7 (

IMPORTANT $ &@ ( $ @ *0-@

KVASpeed RPM( ) Torque lb in–( )×

63 025,-------------------------------------------------------------------------------- 746Watts

HP------------------------× KVA

1000Watts---------------------------× 2.0×=

Publication 1398-5.1 — January 2000

Page 23: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Install the ULTRA Plus PDM Components 2-5

( %1?;*0- 1>C 2>97 '

IMPORTANT @ *0-/1>=.4 %%7=.

KVA3000RPM 75lb in–×

63 025,------------------------------------------------------ 746Watts

HP------------------------× KVA

1000Watts---------------------------× 2.0×=

Transformer Size 5.3KVA=

Publication 1398-5.1 — January 2000

Page 24: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

11-22-91

11-22-91BC JH

UNLESS OTHERWISE SPECIFIED

9101-1057

11-22-91

1 1

JHBC

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

S V

OLT

AG

E (

VD

C)

330

0 10 20 30 40 50200

260

270

280

290

300

310

320

233

226

219

212

205

198

191

184

142

149

156

163

170

177(V

AC

RM

S L

INE

TO

LIN

E, 3

PH

AS

E)

TR

AN

SF

OR

ME

R S

EC

ON

DA

RY

VO

LTA

GE

0020-5097 3

kVAPART NUMBER

RELIANCE MOTION CONTROL1 PHASE TRANSFORMER

NOTES:

Publication 1398-5.1 — January 2000

Page 25: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

E (

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

AC

RM

S L

INE

TO

LIN

E, 3

PH

AS

E)

TR

AN

SF

OR

ME

R S

EC

ON

DA

RY

VO

LTA

GE

0020-5091-0010020-5091-0020020-5091-0030020-5091-004

36

1218

kVAPART NUMBER

RELIANCE MOTION CONTROL3 PHASE TRANSFORMERS

NOTES:

Publication 1398-5.1 — January 2000

Page 26: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 27: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 28: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 29: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 30: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 31: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 32: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 33: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 34: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

2-16 Install the ULTRA Plus PDM Components

Motors

'

• 0

• -

• . - %>>E.!/%/E4" 2>E.

ATTENTION

!< (

< @ -

4 )

Publication 1398-5.1 — January 2000

Page 35: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 36: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 37: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 38: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 39: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 40: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 41: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 42: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 43: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 44: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 45: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 46: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 47: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 48: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 49: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Install the ULTRA Plus PDM Components 2-31

Bonding Your System

!<-$"

,

4 //> $ <

Figure 2.20 Recommended bonding practices

Publication 1398-5.1 — January 2000

Page 50: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 51: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 52: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 53: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 54: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

2-36 Install the ULTRA Plus PDM Components

Electromagnetic Compatibility

* ) ) (

) C

< ' !<-$" <-$ <-$<-$K< -.!<-."

< < , <-. *0- $ &

4 //1<-$<-$ <-$0 <-$ = <-$

Publication 1398-5.1 — January 2000

Page 55: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 56: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 57: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 58: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 59: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 60: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 61: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 62: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 63: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 64: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 65: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 66: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 67: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 68: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 69: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 70: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 71: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 72: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 73: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 74: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 75: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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.

Publication 1398-5.1 — January 2000

Page 76: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 77: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 78: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 79: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 80: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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)

Publication 1398-5.1 — January 2000

Page 81: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 82: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 83: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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 )

Publication 1398-5.1 — January 2000

Page 84: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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 *%*/

Publication 1398-5.1 — January 2000

Page 85: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 86: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 87: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 88: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 89: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 90: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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)

Publication 1398-5.1 — January 2000

Page 91: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 92: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

-

+

-

+

-

+

Publication 1398-5.1 — January 2000

Page 93: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 94: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 95: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 96: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

3-32 Wire the ULTRA Plus PDM Components

Figure 3.20 Encoder input circuitry example

Publication 1398-5.1 — January 2000

Page 97: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 98: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 99: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 100: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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-

Publication 1398-5.1 — January 2000

Page 101: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 102: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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=

=

=

=

Publication 1398-5.1 — January 2000

Page 103: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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&*

Publication 1398-5.1 — January 2000

Page 104: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 105: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 106: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 107: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 108: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 109: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 110: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 111: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 112: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 113: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 114: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 115: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 116: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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)

Publication 1398-5.1 — January 2000

Page 117: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 118: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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 . ?

Publication 1398-5.1 — January 2000

Page 119: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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-

= '

%* ,!$% <

-* (*! .>

& .

& .

Publication 1398-5.1 — January 2000

Page 120: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Page 121: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Apply Power for the First Time 4-5

Power Supply Module

* *- !%/>@/2>=.1"

+ *- 3%3/31 *

0 *-0. O $*- = 0. !1/7=0./1>=.". *-&<0B3<0 3<0 *-

0 3<00.%7=0.

&*- &0. *- O $*-

ATTENTION

!00.

4 ,3&**0-

Publication 1398-5.1 — January 2000

Page 122: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

4-6 Apply Power for the First Time

Start-up Procedure for PDM

< *-

0 !*% *9" ,3&**0-

+ ,3&**0- &= ,3&**0- &#D0#D0#D07>>$ ,3&**0- &

= 0. ,3&**0-

. !*%I*9",3&**0-

-

3<0

0.,3<0

,3<0

,3&**0-,3<0 . ?

0 5-

$( * - ,3&**0- '

! 5-

"# $%$(*-

,3&**0- 0

-

= <

ATTENTION

!* $

Publication 1398-5.1 — January 2000

Page 123: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Apply Power for the First Time 4-7

$

& (* -

* - ('! ,3&**0-,*-

(%

$,3<0 '

<

") ! ** $%$@5-

. & < -< 5 7 2

.$@5-

(%

0&0 5- ,3&*

= ,3<0 $,3<0

= ,3&**0-

0,3&**0- '

• <544

• 044N++$%(%

5-

= '

%* ,!$% <

-* (*! .>

& .

& .

(%<

(*!

<,3&**0- '

• <5D

• 04N.$%

Publication 1398-5.1 — January 2000

Page 124: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

4-8 Apply Power for the First Time

(%

=

. '

• <)

• 0A5- A$% A A(%A

,5- 4N544

& 3<0

&8 /> ,3&**0-

Motors

ATTENTION

!-

ATTENTION

!

*

$

ATTENTION

!

& )

-

Publication 1398-5.1 — January 2000

Page 125: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Apply Power for the First Time 4-9

0 $

0 ,3&**0- !%1?; *0- /77>%>> %7>".2 !& " ,3&**0-$,3&**0- ,3&**0-

0,3&**0- '

• <544

• 044N++$%(%

& ,3<0

3 '

0<5-

/!0 12)+3!

.. 3 !/7F "

$%

(%<

(*!

. '

• <)

• 0A5- A$% A (%A

,5- 4N544

$ ,3&**0-

0,3&**0- 544 - 0. %7=0.

Publication 1398-5.1 — January 2000

Page 126: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

4-10 Apply Power for the First Time

D $

Publication 1398-5.1 — January 2000

Page 127: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Apply Power for the First Time 4-11

Operator Terminal 5 & 5 1 %8 3<0D ,3&**0- ,3&**0- +5 ,3&**0- 5

Personality Module & #-3, , - * ,3&* #-35-

Publication 1398-5.1 — January 2000

Page 128: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

4-12 Apply Power for the First Time

Publication 1398-5.1 — January 2000

Page 129: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Chapter 5

Check for Problems in the System

,3&**0- GH,3&**0-* !%1?; *0- /77>%>>%7>"* - ,3&**0- $#-3 *0-* -

-,3&**0- ,3&**0- (

Light Emitting Diodes (LED) #-3*-3<0 3<0

Positioning Drive Module STATUS LED

#-3,3<0 3<0 !544"

Green

3<0,3&**0- #-30 3<0 3<0 #-3

Red

$3<0 #-3 U #-3 4

1 Publication 1398-5.1 — January 2000

Page 130: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

5-2 Check for Problems in the System

3<0B4,3 ! "

Not lit (OFF)

+ #-3,3<0$#-30.,3<05D,3<0544

DC Bus Power (1398-PDM-25, 50, 100, and 150)

%0.,3<03<00.

$3<0 5D! " *- &*-

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

Publication 1398-5.1 — January 2000

Page 131: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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.

Publication 1398-5.1 — January 2000

Page 132: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

5-4 Check for Problems in the System

(* - '

$(,3&**0- 4$(* -

.4 0$(

.4 $(*-(*-* . (

Error Messages and Error Output

$ #-3, $ #-3 *8 - 5

< < ;< *

< ,3&**0-,3&**0- <D3<5445D &<< C&<< 2/27I728;8?9192& G< -H 7 7

5,3&**0- 04* $ '$- 5 4 3& 3< 5D!"C 04* ,3&**0- < !*3."

Publication 1398-5.1 — January 2000

Page 133: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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.

Publication 1398-5.1 — January 2000

Page 134: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 135: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 136: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

5-8 Check for Problems in the System

Publication 1398-5.1 — January 2000

Page 137: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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)

1 Publication 1398-5.1 — January 2000

Page 138: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 139: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 140: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

A-4 Specifications

Transformers -

Single Phase Transformer specifications

%1?; *0- %>/>1>97

& * 3&. / 8& * 50 / ;

Three Phase Transformer specifications

%1?; *0- /77>%>>%7> & * 3&. / 9& * 50 / ?

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)

Publication 1398-5.1 — January 2000

Page 141: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

Appendix B

Options and Accessories

PDMs and Optional Accessories

,G$D H!5 " G D H!- " G$D H

,3&**0-

,3&**0-

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

1 Publication 1398-5.1 — January 2000

Page 142: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 143: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 144: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 145: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 — January 2000

Page 146: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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)

Publication 1398-5.1 — January 2000

Page 147: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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.

Publication 1398-5.1 — January 2000

Page 148: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

B-8 Options and Accessories

Publication 1398-5.1 — January 2000

Page 149: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 - January 2000

Page 150: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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 /;

Publication 1398-5.1 - January 2000

Page 151: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 - January 2000

Page 152: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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 /

Publication 1398-5.1 - January 2000

Page 153: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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 % /

Publication 1398-5.1 - January 2000

Page 154: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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

Publication 1398-5.1 - January 2000

Page 155: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The
Page 156: 1398-5.1 JAN00 ULTRA Plus Series Positioning Drive Module ......Check for mechanical binding, excessive duty cycle, or faulty motor wiring. (1398-PDM-10, 20, 30, 75, and 150B) The

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..

TDuggan
Text Box
For more information refer to our web site: www.ab.com/motion For Rockwell Automation Technical Support information refer to: www.rockwellautomation.com/support or Tel: (1) 440.646.3434