1398 ULTRA Plus Series Positioning Drive Module

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1 1398 ULTRA Plus Series Positioning Drive Module (Catalog Nos PDM-10, -20, -30, -50, -75, -100, -150, and -150B) Installation Manual

2 Important User Information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ÃLVÃDÃWUDGHPDUNÃRIÃ5RFNZHOOÃ$XWRPDWLRQ *0/Ã8OWUDŒÃ6RIWZDUHÃÃLVÃDÃWUDGHPDUNÃRIÃ5RFNZHOOÃ$XWRPDWLRQ 8/ÃDQGÃF8/ÃDUHÃUHJLVWHUHGÃWUDGHPDUNVÃRIÃ8QGHUZULWHUVÃ/DERUDWRULHV :LQGRZVŒÃLVÃDÃWUDGHPDUNÃRIÃ0LFURVRIWÃ&RUSRUDWLRQ

3 Table of Contents Preface,QWURGXFWLRQ 3 :KR6KRXOG8VHWKLV0DQXDO 3 3XUSRVHRIWKLV0DQXDO 3 &RQWHQWVRIWKLV0DQXDO 3 5HODWHG'RFXPHQWDWLRQ 3 &RQYHQWLRQV8VHGLQWKLV0DQXDO 3 3URGXFW5HFHLYLQJDQG6WRUDJH5HVSRQVLELOLW\ 3 $OOHQ%UDGOH\6XSSRUW3 /RFDO3URGXFW6XSSRUW 3 7HFKQLFDO3URGXFW$VVLVWDQFH 3 Overview of the ULTRA Plus PDM System Install the ULTRA Plus PDM Components Chapter 1 )XQFWLRQDO'HVFULSWLRQ 6\VWHP2YHUYLHZ *0/8OWUDŒIRU:LQGRZVŒ 3RVLWLRQLQJ'ULYH0RGXOHV 3RZHU6XSSO\0RGXOH360 0RWRUV 3HUVRQDOLW\0RGXOH30 0DQXDOV $FFHVVRULHV 2SHUDWRU7HUPLQDO 7UDQVIRUPHUV $X[LOLDU\3RZHU6XSSO\0RGXOH360 &DEOHV 6KXQW.LWV 3HUVRQDO&RPSXWHU3& Chapter 2 0RXQWLQJ (QYLURQPHQW 9HQWLODWLRQ 7UDQVIRUPHU6L]LQJ 0RXQWLQJ5HTXLUHPHQWV 3'0DQG3RZHU6XSSO\0RGXOH 360$X[LOLDU\7UDQVIRUPHUV 0RWRUV ([WHUQDO6KXQW 2SHUDWRU7HUPLQDO,)&RQYHUVLRQ&DUG9'&6RXUFLQJ 3'0)XVLQJ5HTXLUHPHQWV 6KRUW&LUFXLW3URWHFWLRQ 3HUVRQDOLW\0RGXOH,QVWDOODWLRQ i

4 ii,qvwdoolqjwkh3huvrqdolw\0rgxoh30 6\VWHP)LUPZDUH,QVWDOODWLRQ,QVWDOOLQJWKH)LUPZDUH(3520V -XPSHUDQG',36ZLWFKHV 5HJXODWRU\5HTXLUHPHQWV (OHFWURPDJQHWLF&RPSDWLELOLW\'LUHFWLYH %RQGLQJ<RXU6\VWHP 0RWRUVDQG&DEOHV /RZ9ROWDJH'LUHFWLYH (OHFWURPDJQHWLF&RPSDWLELOLW\ )LOWHULQJ $&/LQH)LOWHU6HOHFWLRQ *URXQGLQJ 6KLHOGLQJDQG6HJUHJDWLRQ Wire the ULTRA Plus PDM Components Chapter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

5 iii Apply Power for the First Time Check for Problems in the System Specifications Options and Accessories Chapter 4 3'0DQG% 3'0DQG 3RZHU6XSSO\0RGXOH 6WDUWXS3URFHGXUHIRU3'0 0RWRUV 2SHUDWRU7HUPLQDO 3HUVRQDOLW\0RGXOH Chapter 5 /LJKW(PLWWLQJ'LRGHV/(' 3RVLWLRQLQJ'ULYH0RGXOH67$786/(' '&%XV3RZHU3'0DQG 2SHUDWRU7HUPLQDO6WDWXV6FUHHQV 3HUVRQDOLW\0RGXOH'HIDXOW,QLWLDOL]DWLRQ (UURU0HVVDJHVDQG(UURU2XWSXW Appendix A 3'0DQG% $ 3'0DQG $ 2SHUDWRU7HUPLQDOV $ 7UDQVIRUPHUV $ 6LQJOH3KDVH7UDQVIRUPHUVSHFLILFDWLRQV $ 7KUHH3KDVH7UDQVIRUPHUVSHFLILFDWLRQV $ Appendix B 3'0VDQG2SWLRQDO$FFHVVRULHV%,)&RQYHUVLRQ&DUG % 3RZHU6XSSO\0RGXOHV % $&/LQH)LOWHUV % &DEOHV% 7UDQVIRUPHUV % 0RWRU,GHQWLILFDWLRQ% 0RWRU&RQQHFWRUV% 0RWRU6KDIW6HDO.LWV%

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7 Preface Introduction 5HDGWKLVSUHIDFHWRIDPLOLDUL]H\RXUVHOIZLWKWKHUHVWRIWKHPDQXDO7KLV SUHIDFHFRYHUVWKHIROORZLQJWRSLFV :KRVKRXOGXVHWKLVPDQXDO 7KHSXUSRVHRIWKLVPDQXDO &RQWHQWVRIWKLVPDQXDO 5HODWHGGRFXPHQWDWLRQ &RQYHQWLRQVXVHGLQWKLVPDQXDO 3URGXFWUHFHLYLQJDQGVWRUDJHUHVSRQVLELOLW\ $OOHQ%UDGOH\VXSSRUW Who Should Use this Manual 8VHWKLVPDQXDOLI\RXDUHUHVSRQVLEOHIRUGHVLJQLQJLQVWDOOLQJSURJUDPPLQJ RUWURXEOHVKRRWLQJWKH8/75$3OXV3'0,I\RXGRQRWKDYHDEDVLFXQGHUVWDQGLQJRIWKH8/75$3OXV3'0FRQWDFW \RXUORFDO$OOHQ%UDGOH\UHSUHVHQWDWLYHIRULQIRUPDWLRQRQDYDLODEOHWUDLQLQJ FRXUVHVEHIRUHXVLQJWKLVSURGXFW Purpose of this Manual 7KLVPDQXDOGHVFULEHVWKHIXQFWLRQDQGLQVWDOODWLRQRIWKH8/75$3OXV 3RVLWLRQLQJ'ULYH0RGXOH3'0SURGXFWVDQGVWDQGDUG5RFNZHOO $XWRPDWLRQ$OOHQ%UDGOH\PRWRUVUHFRPPHQGHGIRUXVHZLWKWKH8/75$ 3OXV3'0,WLVLQWHQGHGIRUHQJLQHHUVRUWHFKQLFLDQVGLUHFWO\LQYROYHGLQWKH LQVWDOODWLRQRSHUDWLRQDQGILHOGPDLQWHQDQFHRIWKH8/75$3OXV3'0 1 Publication January 2000

8 Preface 2 Contents of this Manual 5HIHUWRWKHIROORZLQJPDQXDOIRUWKHGHVFULSWLYHFRQWHQWVRIWKLVLQVWDOODWLRQ PDQXDO 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 3 Wire the ULTRA Plus PDM Components 4 Apply Power for the First Time 5 Check for Problems in the System Provides mounting information for the ULTRA Plus PDM system. Provides connection information for the ULTRA Plus PDM system. Outline steps when applying power to equipment for the first time. 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 January 2000

9 Preface 3 Related Documentation 7KHIROORZLQJGRFXPHQWVFRQWDLQDGGLWLRQDOLQIRUPDWLRQFRQFHUQLQJUHODWHG $OOHQ%UDGOH\SURGXFWV7RREWDLQDFRS\FRQWDFW\RXUORFDO$OOHQ%UDGOH\ RIILFHRUGLVWULEXWRU For this information Read This Document Document Number An overview of the ULTRA Plus Positioning Drive ULTRA Plus Brochure A description and specifications for the ULTRA Series family. ULTRA Series Product Data Information to help you install and set up your GML Ultra software. GML Ultra Getting Started Manual Step oriented information that will help you use GML Ultra to GML Ultra User Manual program your ULTRA Plus system. Reference material that explains the theory behind how you program GML Ultra Reference Manual your ULTRA Plus for your application needs. An article on wire sizes and types for grounding electrical equipment National Electrical Code Published by the National Fire Protection Association of Boston, MA. A complete listing of current Allen-Bradley documentation, including 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 Conventions Used in this Manual 7KHIROORZLQJFRQYHQWLRQVDUHXVHGWKURXJKRXWWKLVPDQXDO %XOOHWHGOLVWVVXFKDVWKLVRQHSURYLGHLQIRUPDWLRQQRWSURFHGXUDOVWHSV 1XPEHUHGOLVWVSURYLGHVHTXHQWLDOVWHSVRUKLHUDUFKLFDOLQIRUPDWLRQ :RUGVWKDW\RXW\SHRUVHOHFWDSSHDULQEROG :KHQZHUHIHU\RXWRDQRWKHUORFDWLRQWKHVHFWLRQRUFKDSWHUQDPHDSSHDUV LQLWDOLFV Publication January 2000

10 Preface 4 Product Receiving and Storage Responsibility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ƒ&WRƒ) ZLWKLQDUHODWLYHKXPLGLW\UDQJHRIWRQRQFRQGHQVLQJ LQDQDUHDZKHUHLWFDQQRWEHH[SRVHGWRDFRUURVLYHDWPRVSKHUH LQDQRQFRQVWUXFWLRQDUHD Allen-Bradley Support $OOHQ%UDGOH\RIIHUVVXSSRUWVHUYLFHVZRUOGZLGHZLWKRYHU6DOHV6XSSRUW 2IILFHVDXWKRUL]HG'LVWULEXWRUVDQGDXWKRUL]HG6\VWHPV,QWHJUDWRUV ORFDWHGWKURXJKRXWWKH8QLWHG6WDWHVDORQHSOXV$OOHQ%UDGOH\UHSUHVHQWDWLYHV LQHYHU\PDMRUFRXQWU\LQWKHZRUOG Local Product Support &RQWDFW\RXUORFDO$OOHQ%UDGOH\UHSUHVHQWDWLYHIRU VDOHVDQGRUGHUVXSSRUW SURGXFWWHFKQLFDOWUDLQLQJ ZDUUDQW\VXSSRUW VXSSRUWVHUYLFHDJUHHPHQWV Technical Product Assistance,I\RXQHHGWRFRQWDFW$OOHQ%UDGOH\IRUWHFKQLFDODVVLVWDQFHSOHDVHUHYLHZWKH LQIRUPDWLRQLQWKH &KHFNIRU3UREOHPVLQWKH6\VWHPµFKDSWHUILUVW7KHQFDOO \RXUORFDO$OOHQ%UDGOH\UHSUHVHQWDWLYH)RUWKHTXLFNHVWSRVVLEOHUHVSRQVH SOHDVHKDYHWKHFDWDORJQXPEHUVRI\RXUSURGXFWVDYDLODEOHZKHQ\RXFDOO Publication January 2000

11 Chapter 1 Overview of the ULTRA Plus PDM System Functional Description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igure 1.1 ULTRA Plus PDM Product Family 7KH8/75$3OXV3'0GULYHPD\EHXVHGDVDGLVWULEXWHGPRWLRQFRQWURO HOHPHQWLQWHJUDWHGZLWKDKRVWFRPSXWHULQDIOH[LEOHDXWRPDWLRQV\VWHPRUDV DVWDQGDORQHSURJUDPPDEOHPRWLRQFRQWUROOHU2SWLFDOO\LVRODWHG,2DQG SRZHUVXSSOLHVDUHLQWHJUDWHGLQWRWKHSURGXFWV 1 Publication January 2000

12 1-2 Overview of the ULTRA Plus PDM System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ystem Overview $Q8/75$3OXV3RVLWLRQLQJ'ULYH0RGXOH3'0PRWLRQFRQWUROV\VWHP FRQVLVWVRIDQXPEHURIFRPSRQHQWVFRQQHFWHGWRDFFRPSOLVKDVSHFLILF IXQFWLRQ7KLVVHFWLRQSURYLGHVDEULHIRYHUYLHZRIWKHYDULRXVFRPSRQHQWVRI WKH8/75$3OXV3RVLWLRQLQJ'ULYH0RGXOH3'0PRWLRQFRQWUROV\VWHP Publication January 2000

13 Overview of the ULTRA Plus PDM System 1-3 ULTRA PLUS POWER SUPPLY MODULE ULTRA PLUS POSITIONING DRIVE MODULE Figure 1.2 ULTRA Plus PDM Control System PERSONALITY MODULE PSM PDM PSM USED ONLY WITH 1398-PDM PDM PDM-100 OR 1398-PDM-150 ULTRA PLUS OPERATOR TERMINAL (Optional) MANUALS PERSONAL COMPUTER (Windows compatible user supplied) MOTOR SERIES F-SERIES H-SERIES N-SERIES AUXILIARY ENCODER (User supplied option) GML ULTRA SOFTWARE GML Ultra for Windows *0/LVDQH[FOXVLYH*UDSKLFDO0RWLRQ&RQWURO/DQJXDJHIURP$OOHQ%UDGOH\ *0/LQWHJUDWHVVRIWZDUHSURJUDPPLQJDQGGHEXJJLQJWRVROYH\RXUPRWLRQ FRQWUROSUREOHPV,WRIIHUVD0LFURVRIW:LQGRZVŒLQWHUIDFHWRWKH8/75$ 3OXV3'0VHULHVRIFRQWUROOHUV *0/8OWUD6RIWZDUHXVHVDIORZFKDUWDSSURDFKWRPRWLRQFRQWURO SURJUDPPLQJ<RXSURGXFHDGLDJUDPPRWLRQSURJUDPE\SODFLQJIXQFWLRQ EORFNVUHSUHVHQWLQJWKHVSHFLILFDFWLRQVRQWKHFRPSXWHUWKHQFRQQHFWWKHP LQWKHSURSHURUGHURIRSHUDWLRQV7KHQ\RXHQWHUWKHPRWLRQDQGSURFHVV VSHFLILFDWLRQVXVLQJDILOOLQWKHIRUPDSSURDFK(DFKEORFNKDVLWVRZQIRUP Publication January 2000

14 1-4 Overview of the ULTRA Plus PDM System $IWHUDGLDJUDPLVGRZQORDGHGWRWKH8/75$3OXV3'0LWLVWUDQVODWHGLQWRD SURJUDPRUVFULSWLQWKHQDWLYHODQJXDJHRIWKHPRWLRQFRQWUROOHU Positioning Drive Modules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²SRXQGVLQFRPELQDWLRQZLWKVWDQGDUGPRWRUV7KH 3'0DQGXVHDVHSDUDWHSRZHUVXSSO\PRGXOHZKLFK FDQEHVKDUHGDPRQJPXOWLSOHGULYHVDQGSURYLGHFRQWLQXRXVWRUTXHVRIWR LQFKSRXQGVZLWKWKHVWDQGDUGPRWRUV Integral Power Supply Modules 7KH3'0DQG%DUHUDWHGIRUDQG DPSSHDNFXUUHQWVUHVSHFWLYHO\7KHVHPRGXOHVDUHSDFNDJHGZLWKDQLQWHJUDO SRZHUVXSSO\WRDFKLHYHDVPDOOVL]H,QSXWSRZHUWRD-3'0RULVVLQJOHSKDVHRU9$&,QSXWSRZHUWRD3'0RU3'0%LVWKUHHSKDVHRU 9$&7KHLQSXWSRZHUPD\EHRSWLRQDOO\LVRODWHGWKURXJKDWUDQVIRUPHU 7KHVH8/75$3OXV3'0VKDYHDEXLOWLQVROLGVWDWH VRIWFKDUJHµRIWKH LQWHUQDO'&EXVFDSDFLWRU7KH\DOVRLQFOXGHDEXLOWLQGLVVLSDWLYHVKXQW UHJXODWRUWKDWSURYLGHVV\QFKURQRXVPRWRUG\QDPLFEUDNLQJ7KH8/75$ 3OXV3'0VDOORZXVHRIDQRSWLRQDOH[WHUQDOVKXQWUHVLVWRUIRUDSSOLFDWLRQV UHTXLULQJKLJKHUVKXQWSRZHUFDSDELOLW\WKDQSURYLGHGE\WKHLQWHUQDOVKXQW UHVLVWRU Separate Power Supply Modules 7KH3'0DQGDUHUDWHGIRUDQGDPS SHDNFXUUHQWVUHVSHFWLYHO\7KHVH8/75$3OXV3'0PRGXOHVXVHDVHSDUDWH SRZHUVXSSO\PRGXOH360RU360ZKLFKPD\EHVKDUHG DPRQJPXOWLSOH8/75$3OXV3'0VWRDFKLHYHWKHPRVWHFRQRPLFDOV\VWHP SDFNDJH2WKHUWKDQWKHSDFNDJLQJDQGSRZHUUDQJHVDOOWKH8/75$3OXV 3'0VDUHDOOLGHQWLFDOLQVHWXSDQGSURJUDPPLQJ Publication January 2000

15 Overview of the ULTRA Plus PDM System 1-5 Power Supply Module (PSM) 7KHSRZHUVXSSO\PRGXOHLVRQO\UHTXLUHGIRU3'0DQG V\VWHPV7KH3RZHU6XSSO\0RGXOH360FDQVXSSO\'&SRZHUWRDVPDQ\DV VL[8/75$3OXV3'0PRGXOHV7KHRQO\LQSXWWRWKH360LV²9$& VLQJOHRUWKUHHSKDVHSRZHU7KHLQSXWSRZHUPD\EHRSWLRQDOO\LVRODWHG WKURXJKDWUDQVIRUPHU7KHRXWSXWLVDWZRZLUH'&EXV7KH360UHTXLUHVQR DGMXVWPHQWVSURWHFWVLWVHOISURYLGHVWURXEOHVKRRWLQJGLDJQRVWLFVDQGKDVD EXLOWLQVROLGVWDWH VRIWFKDUJHµRIWKH'&EXVFDSDFLWRUV,WDOVRLQFOXGHVD EXLOWLQGLVVLSDWLYHVKXQWUHJXODWRUWKDWSURYLGHVTXLFNGLVFKDUJHRIWKH'&EXV FDSDFLWRUVDQGGRXEOHVDVDQHPHUJHQF\V\QFKURQRXVPRWRUG\QDPLFEUDNH Motors $ZLGHUDQJHRI$OOHQ%UDGOH\+6HULHV)6HULHVDQG16HULHVSHUPDQHQW PDJQHWV\QFKURQRXVPRWRUVDUHDYDLODEOHIRUXVHZLWKWKH8/75$3OXV3'0 PRGXOHV(DFKPRWRULQFOXGHVDQLQWHJUDOO\PRXQWHGHQFRGHU0RVWPRWRUV DUHDYDLODEOHZLWKRSWLRQVLQFOXGLQJVSULQJVHWEUDNHDQGRUVKDIWRLOVHDO 0LOLWDU\6WDQGDUG06FRQQHFWRUVDUHVWDQGDUGIRUDOO+6HULHVDQG)6HULHV PRWRUV Personality Module (PM) 7KH3HUVRQDOLW\0RGXOHLVDQRQYRODWLOHPHPRU\GHYLFHZKLFKVWRUHVWKH LQIRUPDWLRQQHFHVVDU\WRFXVWRPL]HDQ8/75$3OXV3'0IRUDVSHFLILF DSSOLFDWLRQ7KH30KROGVSDUDPHWHUVWRPDWFKWKHHQFRGHUIHHGEDFNPRWRU DQGWKHGULYHDVZHOODVXVHUSURJUDPVDQGSDUDPHWHUV$3HUVRQDOLW\0RGXOH PD\EHSK\VLFDOO\UHPRYHGDQGWUDQVIHUUHGWRDQRWKHU8/75$3OXV3'0LI WKHUHSODFHPHQWRID30LVQHFHVVDU\WRVLPSOLI\VHUYLFLQJWKHPDFKLQH Manuals 7KLVLQVWDOODWLRQPDQXDOFRQWDLQVDOOWKHLQIRUPDWLRQUHTXLUHGIRUPRXQWLQJ DQGZLULQJWKHPRWRUDQG8/75$3OXV3'07KH*0/8OWUD6RIWZDUH PDQXDOVFRQWDLQDOOWKHLQIRUPDWLRQWRTXLFNO\FRQILJXUHWKH8/75$3OXV 3'0DQGGHYHORSDSSOLFDWLRQSURJUDPV Publication January 2000

16 1-6 Overview of the ULTRA Plus PDM System Accessories Operator Terminal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µnh\vsurylghh[wudioh[lelolw\zlwklqdxvhu VSURJUDP Figure 1.3 ULTRA Plus 1398-HMI-002 Operator Terminal (front) numeric keypad function keys programmable keys Figure 1.4 ULTRA Plus 1398-HMI-003 Operator Terminal (front) function keys numeric keypad F1 F2 F3 F4 programmable keys X1 STATUS YES X2 MODE NO X3 CLEAR X4 0 ENTER Publication January 2000

17 Overview of the ULTRA Plus PDM System 1-7 Transformers 0XOWLWDSVLQJOHSKDVHDQGWKUHHSKDVHLVRODWLRQWUDQVIRUPHUVDUHDYDLODEOHLQD YDULHW\RISRZHUUDWLQJVIRUOLQHYROWDJHPDWFKLQJ5HIHUWR 7UDQVIRUPHUVRQ SDJH % Auxiliary Power Supply Module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ables 0RWRUSRZHUFDEOHVZLWKFRQQHFWRUVDUHDYDLODEOHLQIRXUVWDQGDUGOHQJWKV DQGPHWHUVDQGIW0RWRUHQFRGHUFDEOHVZLWK FRQQHFWRUVDQGILIWHHQSLQ 'µfrqqhfwruvduhdydlodeohlqwkhirxuvwdqgdug OHQJWKV1LQHSLQVHULDOFDEOHVDUHDYDLODEOHLQDQGPHWHUIWDQGIW OHQJWKV5HIHUWR &DEOHVRQSDJH % Motor Connectors 0DWLQJFRQQHFWRUVDUHDYDLODEOHLI\RXFKRRVHWREXLOG\RXURZQPRWRUFDEOHV 5HIHUWR 0RWRU&RQQHFWRUVRQSDJH % Publication January 2000

18 1-8 Overview of the ULTRA Plus PDM System Shunt Kits 7KH3'0DQG%KDVDEXLOWLQVKXQWUHJXODWRU,IWKH DSSOLFDWLRQUHTXLUHVDKLJKHUFRQWLQXRXVSRZHUGLVVLSDWLRQWKH8/75$3OXV 3'0SURYLGHVHDV\DFFHVVIRUDQH[WHUQDOVKXQWFRQQHFWLRQ)DFWRU\DYDLODEOH ([WHUQDO6KXQW.LWΩ:RUDQ([WHUQDO6KXQW.LWΩ:FDQEH XVHG7KHVHH[WHUQDOVKXQWVFDQEHDUUDQJHGWRSURYLGHPD[LPXPSRZHU GLVVLSDWLRQDVORQJDVWKHPLQLPXPUHVLVWDQFHUHTXLUHPHQWLVPHW5HIHU WR 3'0VDQG2SWLRQDO$FFHVVRULHVRQSDJH % Personal Computer (PC) $XVHUVXSSOLHG3&LVUHTXLUHGWRUXQ*0/8OWUD6RIWZDUH7KHPLQLPXP FRPSXWHUUHTXLUHPHQWVWRUXQWKLVVRIWZDUHDUHFRQWDLQHGLQWKH*0/8OWUD 6RIWZDUHPDQXDOV Publication January 2000

19 Chapter 2 Install the ULTRA Plus PDM Components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ounting %HIRUHPRXQWLQJWKH3'0\RXVKRXOGLQVWDOODQ\RSWLRQFDUGV3HUVRQDOLW\ 0RGXOHVDQGV\VWHPILUPZDUH2WKHURSHUDWLRQVVXFKDVUHPRYLQJMXPSHUVRQ WKHORJLFERDUGVKRXOGDOVREHSHUIRUPHGEHIRUHPRXQWLQJWKHV\VWHP ATTENTION! 'XULQJLQVWDOODWLRQSURWHFWHTXLSPHQWIURPPHWDOFKLSV ZHOGVSODWWHUVDQGRWKHUGHEULV &RPSOHWHDOOGULOOLQJFXWWLQJZHOGLQJHWFEHIRUH PRXQWLQJWKHHTXLSPHQW )DLOXUHWRREVHUYHWKLVSUHFDXWLRQFRXOGUHVXOWLQGDPDJHWR RUGHVWUXFWLRQRIWKHHTXLSPHQW 1

20 2-2 Install the ULTRA Plus PDM Components Environment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µRQSDJH $

21 Install the ULTRA Plus PDM Components 2-3 Ventilation 7KHPD[LPXPSRZHUORVVHVDUHVKRZQEHORZWRKHOSLQVL]LQJDQHQFORVXUH DQGDQ\UHTXLUHGYHQWLODWLRQ7\SLFDOKHDWORVVHVFDQUXQDSSUR[LPDWHO\ RQHKDOIPD[LPXPSRZHUORVVHV Maximum power losses for help in sizing enclosures Model Maximum Loss (Watts) 1398-PDM dissipative shunt 1398-PDM dissipative shunt 1398-PDM PDM dissipative shunt 1398-PDM PDM dissipative shunt 1398-PDM PDM PDM-150B dissipative shunt 1398-PSM dissipative shunt 1398-PSM dissipative shunt Operator Terminal kva Transformer 350 TF-03 (3 kw transformer) 350 TF-06 (6 kw transformer) 600 TF-18 (18 kw transformer) 1200 $VDQDGGLWLRQDODLGLQVL]LQJDQHQFORVXUHZLWKQRDFWLYHPHWKRGRIKHDW GLVVLSDWLRQWKHIROORZLQJDSSUR[LPDWHHTXDWLRQLVXVHG Q T = A :KHUH7LVWHPSHUDWXUHGLIIHUHQFHEHWZHHQLQVLGHDLUDQGRXWVLGHDPELHQW ƒ)4lvkhdwjhqhudwhglqhqforvxuh:dwwvdqg$lvhqforvxuhvxuidfhduhd IWñ 7KHH[WHULRUVXUIDFHRIDOOVL[VLGHVRIDQHQFORVXUHLVFDOFXODWHGDV ( 2dw + 2dh + 2wh) A = :KHUHGGHSWKZZLGWKDQGKKHLJKWDUHLQLQFKHV

22 2-4 Install the ULTRA Plus PDM Components Transformer Sizing 8/75$3OXV3'0V\VWHPVGRQRWUHTXLUHLVRODWLRQWUDQVIRUPHUV$ WUDQVIRUPHUPD\EHUHTXLUHGKRZHYHUWRPDWFKWKHYROWDJHUHTXLUHPHQWVRI WKHFRQWUROOHUWRWKHDYDLODEOHVHUYLFH7RVL]HDWUDQVIRUPHUIRUD8/75$3OXV 3'0WKHSRZHURXWSXW.9$RIHDFKD[LVPXVWEHNQRZQ7KLVFDQEH GHULYHGE\FDOFXODWLQJWKHKRUVHSRZHUIRUHDFKD[LVDQGFRQYHUWLQJWKDW KRUVHSRZHULQWRXQLWVIZDWWV,I\RXDUHVXSSOLQJSRZHUWRPRUHWKDQRQH PRWRUDQG3'0VLPSO\DGGWKH.:UDWLQJVWRJHWKHUIURPHDFKFDOFXODWLRQWR JHWDV\VWHP.:WRWDO 'HILQLWLRQV.: SRZHURU UHDOSRZHUµ.9$ DSSDUHQWSRZHU 7UDQVIRUPHU.9$UDWLQJ 6XPRIDYHUDJHRXWSXWSRZHURIHDFKD[LV[ IMPORTANT &DOFXODWLRQVDUHPXOWLSOLHGE\DIDFWRUWRFRPSHQVDWHIRU WKHSRZHUDQGORVVHOHPHQWVZLWKLQDSRZHUV\VWHP$ IDFWRURILVXVHGZLWKDVLQJOHSKDVHV\VWHPDQGDIDFWRU RILVXVHGZLWKDWKUHHSKDVHV\VWHP7KLVIDFWRUVKRXOG PLQLPL]HWKHHIIHFWVRIWKHVHFRQGDU\OLQHYROWDJHVDJJLQJ LQWKHWUDQVIRUPHUGXULQJSHDNFXUUHQWSHULRGV Intro Speed( RPM) Torque( lb in) 746Watts KVA KVA = , 025 HP 1000Watts IMPORTANT,I\RXDUHXVLQJWKH5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\ V\VWHPVL]LQJSURJUDPWKHDYHUDJHVSHHGDQGDYHUDJH WRUTXHGDWDKDVDOUHDG\EHHQFDOFXODWHGDQGFDQEHXVHGLQ WKHDERYHHTXDWLRQ,I\RXDUHQRWVXUHRIWKHH[DFWVSHHG DQGWRUTXHLQ\RXUDSSOLFDWLRQDQRWKHUDSSURDFKLVWRORRN DWWKHVSHHGWRUTXHFXUYHIRU\RXU3'0PRWRU FRPELQDWLRQDQGXVHWKHYDOXHVIRUWKHZRUVWFDVH FRQWLQXRXVVSHHGDQGWRUTXH

23 Install the ULTRA Plus PDM Components 2-5 6L]LQJDWUDQVIRUPHUZLWKDQ3'0DQG+PRWRU IMPORTANT 7KHVSHHGWRUTXHFXUYHLQIRUPDWLRQLVEDVHGXSRQD3'0 PRGXOHLQSXWYROWDJHRI9$&)RUD9$&LQSXW YROWDJHWKHPD[LPXPVSHHGLVUHGXFHGE\KDOI 3000RPM 75lb in 746Watts KVA KVA = , 025 HP 1000Watts Transformer Size = 5.3KVA

24 2-6 Install the ULTRA Plus PDM Components Figure 2.1 Single PhaseTransformer Load Regulation Curve 1 BUS VOLTAGE (VDC) PHASE TRANSFORMER SECONDARY VOLTAGE AND CORRESPONDING DC BUS VOLTAGE, VERSUS DC BUS CURRENT 3 kva TRANSFORMER BUS CURRENT (ADC) TRANSFORMER SECONDARY VOLTAGE (VAC RMS LINE TO LINE, 3 PHASE) C B A REV NOTES: 1 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 JL UPDATE TITLE BLOCK BC PDM UPDATE BC DC BUS VOLTAGE AND CURRENT IS MEASURED AT MOTOR POWER CIRCUITS INTERNAL TO THE DRIVE MODULE (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. BC ECOCHKR BY REVISION DESCRIPTION DATE UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING DIMENSIONS ARE IN INCHES BREAK ALL EDGES.02 MAX FILLETS AND ROUNDS.02 R MAX TOLERANCE ON: ANGLES ±1ANGLES FRACTIONS:±1/64" DECIMALS.XX±.020.XXX±.010 RELIANCE MOTION CONTROL 1 PHASE TRANSFORMER PART NUMBER kva RELEASED DRAWN BY BC DATE DATE DIAG, XFMR LOAD REG PART NO. SCALE DESIGN ENGR JH DWG SIZE JH SHEET 1:1 A 1 of 1

25 Install the ULTRA Plus PDM Components BUS VOLTAGE (VDC) PHASE TRANSFORMER SECONDARY VOLTAGE AND CORRESPONDING DC BUS VOLTAGE, VERSUS DC BUS CURRENT FOR 3, 6, 12, AND 18 kva TRANSFORMERS 3 kva BUS CURRENT (ADC) Figure 2.2 Three PhaseTransformer Load Regulation Curves 6 kva 1 12/18 kva D B-C A REV TRANSFORMER SECONDARY VOLTAGE (VAC RMS LINE TO LINE, 3 PHASE) JL UPDATE TITLE BLOCK B-19866,C NOTES: 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. BC ECOCHKR BY REVISION DESCRIPTION DATE UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING DIMENSIONS ARE IN INCHES BREAK ALL EDGES.02 MAX FILLETS AND ROUNDS.02 R MAX TOLERANCE ON: ANGLES ±1ANGLES FRACTIONS:±1/64" DECIMALS.XX±.020.XXX±.010 RELIANCE MOTION CONTROL 3 PHASE TRANSFORMERS PART NUMBER DC BUS VOLTAGE AND CURRENT IS MEASURED AT POS & NEG OUTPUT TERMINALS OF THE POWER SUPPLY MODULE. RELEASED DRAWN BY BC DATE DATE DIAG, XFMR LOAD REG PART NO. SCALE 1:1 kva DESIGN ENGR JH DWG SIZE A JH SHEET 1 of 1

26 2-8 Install the ULTRA Plus PDM Components Figure 2.3 Single PhaseTransformer Outline Diagram NOTES: 1. DIMENSIONS ARE IN INCHES (mm) 1/4-20 GROUND STUD (6.35 DIA) (TRANSFORMER CHASSIS) SECONDARY CONNECTIONS 8-32 THD BOLTS 2 (4.17 DIA) CONNECTION INSTRUCTIONS 2 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING CONNECTIONS TO TRANSFORMER TERMINAL STRIPS. PRIMARY CONNECTIONS 8-32 THD BOLTS (4.17 DIA) MAX. (230) 8.20 MAX. (210) 8.00 MIN. (200) CLEARANCE RECOMMENDED FOR ACCESS TO WIRING 9.20 MAX. (235) 3kVA TRANSFORMER ELECTRO-CRAFT P/N ±0.06 (84 ±1.5) MOUNTING HOLES: 0.28 ±0.02 DIA (4) (7.1 ±0.5) B1 A00759 TM CHG'D TEXT B SJ UPDATED TITLE BLOCK BC A BC RELEASED JH REV ECOCHKR BY REVISION DESCRIPTION DATE 8.00 ±0.06 (203 ±1.5) UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING DIMENSIONS ARE IN INCHES BREAK ALL EDGES.02 MAX FILLETS AND ROUNDS.02 R MAX TOLERANCE ON: ANGLES ±1ANGLES FRACTIONS:±1/64" DECIMALS.XX±.010.XXX±.005 DRAWN BY DATE DESIGN ENGR DATE BC BB DIAGRAM,OUTLINE,TRANSFORMER PART NO. SCALE 1: DWG SIZE SHEET C 1 of 1

27 Install the ULTRA Plus PDM Components 2-9 Figure 2.4 Three Phase Transformer Outline Diagram PART NO PRIMARY CONNECTIONS CONNECTION INSTRUCTIONS G REF 1 SECONDARY CONNECTIONS B MAX E ± ±0.03 DIA THRU (4) GROUND STUD (TRANSFORMER CHASSIS) MIN CLEARANCE RECOMMENDED FOR ACCESS TO WIRING C MAX RELIANCE MOTION CONTROL TRANSFORMER PART NO KVA RATING OVERALL DIMENSIONS MOUNTING HOLES LOCATION SCREW SIZES A B C D E F G PRIMARY SECONDARY REF D ±0.06 F REF A MAX NOTES: 1 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING CONNECTIONS TO TRANSFORMER TERMINAL STRIPS.TERMINAL STRIP SCREW SIZES ARE LISTED IN THE DIMENSION CHART. 2 USE LUGS DESIGNED FOR #6 SCREW MOUNTING. C1 A00761 TM B-C 19866,20625 A BC REDRAWN RELEASED REV ECOCHKR BY REVISION DESCRIPTION DATE DATE DATE UNLESS OTHERWISE SPECIFIED DRAWN BY DESIGN ENGR DO NOT SCALE DRAWING BCB JH DIMENSIONS ARE IN INCHES BREAK ALL EDGES.02 MAX DIAG,OUTLINE,XFMR,BRU-500/IQ5000 FILLETS AND ROUNDS.02 R MAX TOLERANCE ON: PART NO. ANGLES ±1ANGLES FRACTIONS:±1/64" DECIMALS.XX±.010 SCALE DWG SIZE SHEET.XXX±.005 1:1 D 1 of JH

28 2-10 Install the ULTRA Plus PDM Components Mounting Requirements 3RVLWLRQWKH8/75$3OXV3'0LQDYHUWLFDOSRVLWLRQRQDIODWVROLGVXUIDFH WKDWPHHWVWKHPRXQWLQJUHTXLUHPHQWVIRUZHLJKWKXPLGLW\DQGWHPSHUDWXUH OLVWHGLQ$SSHQGL[$7KHIROORZLQJGLDJUDPVOLVWGLPHQVLRQDOPRXQWLQJ UHTXLUHPHQWV Figure PDM-10, 20 and 30 Mounting CLEARANCE HOLES FOR #10 (M5) MOUNTING SCREWS AIR EXHAUST Allen-Bradley External Shunt Internal Ultra Plus Series 1 2 Status P7 Serial 1 Auxiliary U10 3 TB2 P6 Serial 2 Computer P5 Encoder 1 Motor WARNING: High Voltage May Exist Up To Five Minutes After Removing Power P4 Encoder 2 Auxiliary DC Bus Motor R S T 5 P3 Status/ Analog I/O Vac 50/60 Hz DC Bus+ DC Bus- L1 L2/N P2 Digital Inputs And Outputs 5 1 L1 Aux L2/N Aux 10 P1 TB1 Digital Inputs 5 1 SW1 AIR INTAKE

29 Install the ULTRA Plus PDM Components 2-11 Figure PDM-75 Mounting AIR EXHAUST Allen-Bradley Ultra Plus Series Status External Shunt Internal P7 Serial 1 Auxiliary U10 TB2 P6 Serial 2 Computer FINAL INSPECTION Encoder P5 1 Motor WARNING: High Voltage May Exist Up To Five Minutes After Removing Power DC Bus P4 Encoder 2 Auxiliary Motor R S T 5 P3 Status/Analog I/O 1 DC Bus+ 10 DC Bus- L1 P2 Digital Inputs And Outputs Vac 50/60 Hz L2/N L3 5 1 L1 Aux L2/N Aux 10 TB1 P1 Digital Inputs 5 1 SW1 AIR INTAKE AIR INTAKE

30 2-12 Install the ULTRA Plus PDM Components Figure PDM-25, 50, 100, and 150 Mounting AIR EXHAUST Allen-Bradley Ultra Plus Series P7 Serial Port 1 P6 Serial Port 2 P5 Encoder Input 1 P4 Encoder Input 2 P3 Analog I/O And Status P2 General Purpose Inputs And Outputs P1 General Purpose Inputs WARNING: Do Not Apply Power With Cover Removed. Do Not Remove Cover With Power Applied. Dangerous Voltages May Exist Up To 5 Minutes After Removing Power. AIR INTAKE

31 Install the ULTRA Plus PDM Components 2-13 Figure PDM-150B Mounting AIR EXHAUST Allen-Bradley Ultra Plus Series Status P8 P9 P External Shunt Internal TB2 DC BUS WARNING:High Voltage May Exist Up To Fifteen Minutes After Removing Power. P7 Serial 1 Auxiliary P6 Serial 2 Computer FINAL INSPECTION U10 U10 POT1 POT2 POT3 R P5 Encoder 1 Motor Vac 50/60 Hz Auxiliary AC Mains (30 Only) Motor S T DC Bus+ DC Bus- L1 L2 L3 L1 Aux L2/N Aux P4 Encoder 2 Auxiliary P3 Status/Analog I/O P2 Digital Inputs And Outputs U57 U57 U66 U66 U87 U87 U67 U67 TB1 P1 Digital Inputs [31.8] [139.7] AIR INTAKE AIR INTAKE AIR INTAKE

32 2-14 Install the ULTRA Plus PDM Components 1398-PDM-25, 50, 100, and 150 Power Supply Module 7KHSRZHUVXSSO\PRGXOHVKRXOGEHFHQWUDOO\ORFDWHGWRPLQLPL]HWKHGLVWDQFH EHWZHHQLWDQGWKH3'0PRGXOHV7KHKLJKHUFXUUHQWUDWLQJ3'0PRGXOHV VKRXOGEHORFDWHGFORVHVWWRWKHSRZHUVXSSO\PRGXOH PSM Auxiliary Transformers )LJXUHVKRZVWKHPRXQWLQJGLDJUDPDQGFRQQHFWLRQVIRUWKH360 $X[LOLDU\7UDQVIRUPHU Figure 2.9 PSM Auxiliary Transformer mounting 5.50 MAX SPECIFICATIONS: OUTPUT 50/60Hz 110 VAC OUTPUT VOLTAGE 50 C MAX. TEMPERATURE RISE 500 VA MIN. H1 H3 H2 H4 NOMINAL OPERATING VOLTAGES 480 OR 240 INPUT, 120 OUTPUT 460 OR 230 INPUT, 115 OUTPUT 440 OR 220 INPUT, 110 OUTPUT CONNECTION INSTRUCTIONS 6.25 MAX X2 X SCHEMATIC SYMBOL TERMINAL SCREWS (6) 0.31 H1 H3 H2 H4 INPUT (PRIMARY) CONNECTIONS: H1,H4 480 VAC INPUT: JUMPER H3 to H2 240 VAC INPUT: JUMPER H1 to H3 AND H2 to H4 8.0 MIN. CLEARANCE RECOMMENDED FOR ACCESS TO WIRING OUTPUT (SECONDARY) CONNECTIONS: X1,X2 120 VAC X2 X MAX NOTES: 1. RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING CONNECTIONS TO THE TRANSFORMER.

33 Install the ULTRA Plus PDM Components 2-15 Figure 2.10 PSM-AUX Outline and Connection Diagram 3.50 (89) 0.50 (13) 0.25 (6.5) 1.75 (44.5) 0.50 (13) 0.50 (13) 9.00 (229) 8.38 (213) 3.00 (77) 2.00 (50) DIAGRAM, OUTLINE & CONNECTION DRAWING AUXILIARY POWER SUPPLY MODULE DOCUMENT NO REV D1

34 2-16 Install the ULTRA Plus PDM Components Motors 7KHLQVWDOODWLRQDQGRSHUDWLRQRIPRWRUVVKRXOGDGKHUHWRWKHIROORZLQJ JXLGHOLQHV 'RQRWUXQPRWRUVWKDWDUHQRWSURSHUO\PRXQWHG$WWDFKDOOPRWRUFDEOHV DIWHUPRWRULVPRXQWHG 0RXQWPRWRUZLWKFRQQHFWRUVSRLQWLQJGRZQZDUGDQGXVHDGULSORRSWR NHHSOLTXLGVIORZLQJDZD\IURPFRQQHFWRUV &RQVLGHUPRWRUFDVHWHPSHUDWXUHLIQHFHVVDU\WRVDIHJXDUGRSHUDWRUDQG PDLQWHQDQFHVWDII0D[LPXPFDVHWHPSHUDWXUHLVDSSUR[LPDWHO\ƒ& ƒ)irudprwruxvhgdwfrqwlqxrxvudwlqjlqdƒ&dpelhqw WHPSHUDWXUH ATTENTION! (QVXUHDOOPRYLQJFRPSRQHQWVDUHVDIHEHIRUHHQHUJL]LQJD V\VWHP (TXLSPHQWWREHZRUNHGRQVKRXOGEHDSSURSULDWHO\ LGHQWLILHGDQGDFFHVVWRSRZHUUHVWULFWHGDFFRUGLQJWR UHTXLUHGORFNRXWWDJRXWSURFHGXUHV0RWRUVDQGOLQNDJHV PXVWEHVHFXUHO\DWWDFKHGEHIRUHDV\VWHPLVPDGH RSHUDWLRQDO )DLOXUHWRREVHUYHWKHVHVDIHW\SURFHGXUHVFRXOGUHVXOWLQ SHUVRQDOLQMXU\DQGGDPDJHWRHTXLSPHQW

35 Install the ULTRA Plus PDM Components 2-17 External Shunt 7KHIROORZLQJSURFHGXUHRXWOLQHVWKHLQVWDOODWLRQRI([WHUQDO6KXQW: DQG([WHUQDO6KXQW:XQLWV 5HPRYHMXPSHUEHWZHHQWHUPLQDOVDQGDWWKHLQWHUQDOVKXQW FRQQHFWLRQ7KHMXPSHULVVXSSOLHGZLWKWKHDPSOLILHU :LUHDQH[WHUQDOVKXQWUHVLVWRUEHWZHHQWHUPLQDOVDQGDWWKHH[WHUQDO VKXQWFRQQHFWLRQV8VHZLUHRIWKHUHFRPPHQGHGZLUHVL]H Figure 2.11 External Shunt (200W) mounting and connection diagram 3.05 (77.5) #10 (M5) MTG HOLES (3) (50.8) (12.7) 1.00 (25.4) 0.25 (6.3) 8.60 (218.4) EXTERNAL SHUNT RESISTOR A 600V (132) (120.6) 4.00 (101.6) EXTERNAL SHUNT RESISTOR MIN (86.3) AIR EXHAUST Terminal TERMINAL 1 CONNECTION DIAGRAM NOTES: FOR INTERNAL SHUNT RESISTOR: JUMPER INSTALLED BETWEEN PINS 1 & 2 OF TERMINAL. FOR EXTERNAL SHUNT RESISTOR: REMOVE JUMPER INSTALLED BETWEEN PINS 1 & 2 OF TERMINAL. INSTALL WIRING AS SHOWN. 36" OF #14 AWG WIRE IS SUPPLIED WITH EXTERNAL SHUNT RESISTOR. CUT TO LENGTH AS REQUIRED. #6-32 STUD (NUT AND WASHER SUPPLIED) FOR CUSTOMER GROUNDING. LITTLEFUSE PART NUMBER : CCMR-4.5 TB1 INCHES (mm) AIR INTAKE

36 0 F E D CB 2-18 Install the ULTRA Plus PDM Components Figure 2.12 External Shunt (900W) mounting and connection diagram At terminal block, remove jumper installed at factory for internal shunt Cabinet There must be 155mm (6.1 in.) Of clearance on all sides of shunt module EXTERNAL SHUNT INTERNAL TB2 STATUS A1 A2 COM A There must be 155mm (6.1 in.) of clearance on all sides of shunt module J5 Motor VAC 50/60 Hz WARNING: High Voltage May Exist Up To Five Minutes After Removing Power DC Bus R S DC Bus + DC Bus - L1 L2/N L3 T L1 AUX L2/N AUX TB1 CONTROLLER MOTOR ENCODER AUXILIARY SERIAL 2 SERIAL 1 J4 J3 J2 J1 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 Connect wires to terminal block inside front cover

37 Install the ULTRA Plus PDM Components 2-19 Operator Terminal 3.50 (88.9) 0.65 (16.5) )LJXUHDQG)LJXUHRQSDJHLOOXVWUDWHWKHGLPHQVLRQVRIWKHWZR DYDLODEOH2SHUDWRU7HUPLQDOV$OOGLPHQVLRQVDUHLQLQFKHVPP$OORZILIW\ PLOOLPHWHUVWZRLQFKHVFOHDUDQFHDERYHDQGEHORZWKH2SHUDWRU7HUPLQDOIRU DLUIORZDQGPLOOLPHWHUVIRXULQFKHVFOHDUDQFHEHKLQGWRDOORZIRUFDEOH FRQQHFWRUV 5HIHUWR 6SHFLILFDWLRQVµRQSDJH $IRUDGGLWLRQDOWHFKQLFDOLQIRUPDWLRQ Figure 2.13 Operator Terminal (1398-HMI-002) Dimensions (266.7) 5.05 (128.3) 6.00 (152.4) GASKET

38 2-20 Install the ULTRA Plus PDM Components Figure 2.14 Operator Terminal (1398-HMI-003) Dimensions 8.11 [206.0] GASKET SUPPLIED WITH UNIT 3.86 [98.0] 3.86 [98.0] 0.20 [5.0] 3.28 [83.25] 6.89 [175.0] 6.13 MAX. [155.7] 3.28 [83.25] 7.40 [188.0] 2.22 [56.5] 0.17 [4.25] [159.0] 3.13 [79.5] 3.28 [83.25] Not used 7.27 MAX. [184.7] 24 VDC RS-232 connector 3.86 [98.0] 3.70 [94.0] Ø 0.14 (8) Ø [3.5] RECOMMENDED PANEL CUTOUT DIMENSIONS

39 Install the ULTRA Plus PDM Components 2-21 I/F Conversion Card, 24VDC Sourcing )LJXUHLOOXVWUDWHVWKHGLPHQVLRQVRIWKH,)9&RQYHUVLRQ&DUGDQGWKH ',1PRXQWLQJSDQHO$OOGLPHQVLRQVDUHLQPLOOLPHWHUVLQFKHVDUH DSSUR[LPDWHFRQYHUVLRQV7KHFRQYHUVLRQFDUGPXVWEHPRXQWHGLQWKHVDPH HQFORVXUHDVWKH8/75$3OXV3'0WRFRPSO\ZLWKWKH(8/9'GLUHFWLYH Figure 2.15 I/F 24 Volt Sourcing Conversion Card Mounting Dimensions P (1.9) P2 1 USER (6.7) 47.0 (1.9) 77.0 (1.9) 7.5 (0.3) 42.5 (1.7) 85.0 (3.4) 17.5 (0.7) 35.0 (1.4) 25 (1.0) (6.7)

40 2-22 Install the ULTRA Plus PDM Components PDM Fusing Requirements )XVLQJIRUWKH8/75$3OXV3'0VGLIIHUVEHFDXVHRIWKHVHSDUDWHSRZHU VXSSO\IRUVRPHPRGHOV Short Circuit Protection,QWKH8QLWHG6WDWHVWKH1DWLRQDO(OHFWULFDO&RGHVSHFLILHVWKDWIXVHVHOHFWLRQ PXVWEHEDVHGRQWKHPRWRU V)XOO/RDG$PSHUDJH)/$ZKLFKLVQRWWREH FRQIXVHGZLWKWKH3'0LQSXWFXUUHQW7KHODUJHVWIXVHDOORZHGXQGHUDQ\ FLUFXPVWDQFHVLVIRXUWLPHVWKHPRWRU V)/$7KHUHIRUHWKHODUJHVWIXVHV SHUPLVVLEOHIRUXVHDUHIRXUWLPHVWKHPRWRU V)/$PDUNHGRQWKHPRWRU FRQYHUWHGWRD506YDOXH7KH8/75$3OXV3'0VKDYHEHHQHYDOXDWHGDQG OLVWHGE\8QGHUZULWHU/DERUDWRULHV Š,QFDFFRUGLQJWR8/&ZLWKIXVHV VL]HGDVIRXUWLPHVWKHFRQWLQXRXVRXWSXWFXUUHQW)/$RIWKH3'0,QDOPRVWDOOFDVHVIXVHVVHOHFWHGWRPDWFKWKH3'0LQSXWFXUUHQWUDWLQJZLOO PHHWWKH1DWLRQDO(OHFWULFDO&RGHUHTXLUHPHQWVDQGSURYLGHWKHIXOO3'0 FDSDELOLWLHV'XDOHOHPHQWWLPHGHOD\IXVHVVKRXOGEHXVHGWRDYRLGQXLVDQFH WULSVGXULQJSRZHULQLWLDOL]DWLRQGXHWRLQUXVKFXUUHQW 6ROLGVWDWHPRWRURYHUORDGSURWHFWLRQRSHUDWHV ZLWKLQPLQXWHVDWRYHUORDGDQG ZLWKLQVHFRQGVDWRYHUORDG 1398-PDM-10, 20, 30, 75, and 150B $VKRUWFLUFXLWFXUUHQWUDWLQJZLWKRXWIXVHUHVWULFWLRQVPXVWEHVXLWDEOHIRUXVH RQDFLUFXLWFDSDEOHRIGHOLYHULQJQRWPRUHWKDQ506V\PPHWULFDO $PSHUHV 9ROWVPD[LPXP $VKRUWFLUFXLWFXUUHQWUDWLQJZLWKIXVHUHVWULFWLRQVPXVWEHVXLWDEOHIRUXVHRQ DFLUFXLWFDSDEOHRIGHOLYHULQJQRWPRUHWKDQ506V\PPHWULFDO $PSHUHV9ROWVPD[LPXPZKHQSURWHFWHGE\KLJKLQWHUUXSWLQJFDSDFLW\ FXUUHQWOLPLWLQJIXVHV&ODVV&&*-/ PDM-25, 50, 100, and 150 $VKRUWFLUFXLWFXUUHQWUDWLQJVXLWDEOHIRUXVHRQDFLUFXLWFDSDEOHRIGHOLYHULQJ QRWPRUHWKDQ506V\PPHWULFDO$PSHUHV9ROWVPD[LPXPZKHQ SURWHFWHGE\ 360FODVV5IXVHVUDWHG$DQG 360FODVV5IXVHVUDWHG$ 5HIHUWR 3RZHU6XSSO\0RGXOHVµRQSDJH %IRUSURGXFWQXPEHUV

41 Install the ULTRA Plus PDM Components 2-23 Personality Module Installation 7KH3HUVRQDOLW\0RGXOHLVDOUHDG\LQVWDOOHGRQWKH8/75$3OXV3'07KH IROORZLQJSURFHGXUHLVWREHXVHGLIWKH3HUVRQDOLW\0RGXOHQHHGVWREH FKDQJHGIRUPDFKLQHVHUYLFLQJ5HIHUWR)LJXUHIRUWKHORFDWLRQRIWKH 3HUVRQDOLW\0RGXOHRQWKH8/75$3OXV3'0ORJLFERDUG Figure 2.16 Location of Personality Module F1 DS1 U10 Personality Module DS1 F1 U10 1 SW1 1 SW PDM-10, 20, 30, 75, and 150B LOGIC BOARD (component side) 1398 PDM-25, 50, 100, and 150 LOGIC BOARD (component side) Installing the Personality Module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

42 2-24 Install the ULTRA Plus PDM Components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

43 Install the ULTRA Plus PDM Components 2-25 System Firmware Installation $OO8/75$3OXV3'0VFRPHZLWKWKHV\VWHPILUPZDUHLQVWDOOHG7KHUHIRUH XQOHVV\RXDUHXSJUDGLQJ\RXU8/75$3OXV3'0WRDQHZHUYHUVLRQRI ILUPZDUH\RXZLOOQRWQHHGWRLQVWDOOV\VWHPILUPZDUH5HIHUWR)LJXUHIRU V\VWHPILUPZDUHORFDWLRQ Figure 2.17 Location of system firmware U57 U66 U67 SYSTEM FIRMWARE U57 U66 U67 U87 U PDM-10, 20, 30, 75, and 150B LOGIC BOARD (component side) 1398 PDM-25, 50, 100, and 150 LOGIC BOARD (component side)

44 2-26 Install the ULTRA Plus PDM Components Installing the Firmware EPROMs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umper and DIP Switches -XPSHUV:DQG:PD\EHUHPRYHGLIDQH[WHUQDO9'&SRZHUVXSSO\LV XVHG5HPRYLQJWKHVHMXPSHUVZLOOGLVFRQQHFWWKHLQWHUQDOVXSSO\7KH MXPSHUVGRQRWQHHGWREHUHPRYHGLIRQO\WKH9FRPPRQ3SLQLV FRQQHFWHGWRPDFKLQHFRPPRQEXWPXVWEHUHPRYHGLIDQH[WHUQDO9'& VXSSO\LVFRQQHFWHGWR3SLQ 'LSVZLWFK6:VHWVWKHDGGUHVVZKHQPXOWLSOH8/75$3OXV3'0VDUH FRQQHFWHGLQPXOWLGURSVHULDOFRPPXQLFDWLRQVPRGHDQGVHWVWKHPRGHRI RSHUDWLRQIRUWKH2SHUDWRU7HUPLQDO6HULDO$X[LODU\35HIHU WR 1HWZRUNLQJµRQSDJH IRUPRUHLQIRUPDWLRQ

45 Install the ULTRA Plus PDM Components HIHUWR /RFDWLRQRIMXPSHUDQG',3VZLWFKµRQSDJH IRUWKHORFDWLRQV RIMXPSHUV::DQGGLSVZLWFK6:RQWKH8/75$3OXV3'0ORJLF ERDUG Figure 2.18 Location of jumper and DIP switch DS1 U10 F1 DS1 F1 U10 DIP SWITCH Sw1 W3 W4 1 SW PDM-10, 20, 30, 75, and 150B LOGIC PC BOARD (component side) JUMPERS W3 W4 1 SW PDM-25, 50, 100, and 150 LOGIC PC BOARD (component side) Regulatory Requirements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

46 2-28 Install the ULTRA Plus PDM Components Electromagnetic Compatibility Directive,WLVLPSRVVLEOHWRJXDUDQWHHDVSHFLILF8/75$3OXV3'0LQVWDOODWLRQZLOO PHHWWKH(0&UHTXLUHPHQWVZLWKRXWWHVWLQJ7KH3'0 DQG%LQVWDOOHGDVGHVFULEHGEHORZVKRXOGEHFRPSOLDQWZLWK(XURSHDQ (0&UHTXLUHPHQWV7KH3'0DQGDUHQRW&( FRPSOLDQW Figure 2.19 Recommended installation for EMC Encoder Leads Bulkhead Connectors or Clamps R S T Bracket R S T No Shield Connection Required ENCLOSURE MOTOR POWER CABLE Ground Bus Bar FILTER ALTERNATIVE MOTOR POWER CABLE SHIELD TERMINATION MOTOR LEADS Bulkhead Connector or Clamp

47 Install the ULTRA Plus PDM Components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µ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

48 2-30 Install the ULTRA Plus PDM Components 7KH3'0LQSXWFXUUHQWUDWLQJVDQGVXLWDEOHVXSSO\ILOWHUVRQHILOWHUSHU3'0 DUHOLVWHGEHORZ PDM current ratings and suitable supply filters PDM Current Rating Schaffner Roxburgh 1398-PDM-10 1φ 10 A FN MDF16 or MIF PDM-20 1φ 19 A FN MDF18 or MIF PDM-30 1φ 28 A FN MDF36 or MIF PDM-75 3φ 28 A FN MDF336 or MIF PDM-150B 3φ 50 A --- MDF 350 5R[EXUJKILOWHUVPD\EHRUGHUHGGLUHFWO\IURP5RFNZHOO$XWRPDWLRQLQWKH 8QLWHG6WDWHVRU(XURSH3DUWQXPEHUVDQGUDWLQJVDUHLQGLFDWHGEHORZ Roxburgh filters available directly from Rockwell Automation Roxburgh Current Rating Rockwell - USA Rockwell - Crewe MDF18 1φ 18A NONE MDF36 1φ 36A MDF336 3φ 36A MDF50 1 1φ 50A NONE MDF350 3φ 50A NONE MDF φ 70A NONE MIF10 1φ 10A NONE MIF23 1φ 23A NONE 1.MDF50 & MDF370 can be used for multiple PDMs $VXSSO\ILOWHUIRUWKHDX[LOLDU\VXSSO\LVXQQHFHVVDU\DVDILOWHULVLQFOXGHGLQ WKH3'0DQG% ATTENTION! 6KLHOGHGSRZHUFDEOHVPXVWEHJURXQGHGDWDPLQLPXPRI RQHSRLQWIRUVDIHW\ )DLOXUHWRREVHUYHWKLVVDIHW\SURFHGXUHFRXOGUHVXOWLQ SHUVRQDOLQMXU\RUGDPDJHWRHTXLSPHQW

49 Install the ULTRA Plus PDM Components 2-31 Bonding Your System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igure 2.20 Recommended bonding practices

50 2-32 Install the ULTRA Plus PDM Components Multiple Sub Panels %RQGLQJPXOWLSOHVXESDQHOVFUHDWHVDFRPPRQORZLPSHGDQFHH[LWSDWKIRU WKHKLJKIUHTXHQF\HQHUJ\LQVLGHWKHFDELQHW6XESDQHOVWKDWDUHQRWERQGHG WRJHWKHUPD\QRWVKDUHDFRPPRQORZLPSHGDQFHSDWK7KLVGLIIHUHQFHLQ LPSHGDQFHPD\DIIHFWQHWZRUNVDQGRWKHUGHYLFHVWKDWVSDQPXOWLSOHSDQHOV 5HIHUWRWKHLOOXVWUDWLRQEHORZIRUUHFRPPHQGHGERQGLQJSUDFWLFHV Figure 2.21 Multiple sub-panels and cabinet

51 Install the ULTRA Plus PDM Components 2-33 Motors and Cables 7KHV\VWHPWHVWVZHUHPDGHXVLQJ5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\ PRWRUVDQGERWKVKLHOGHGDQGXQVKLHOGHGSRZHUFDEOHV7KHVKLHOGHGFDEOHV KDYHDµSRUWLRQRIWKHFDEOHMDFNHWVWULSSHGRIIH[SRVLQJWKHVKLHOG DSSUR[LPDWHO\µIURPWKH3'0HQGRIWKHFDEOH7KLVVWULSSHGDUHDLVWREH FODPSHGRQWRWKHFKDVVLVIRUVKLHOGWHUPLQDWLRQZKHQXVHGZLWKWKH8/75$ 3OXV3'0V5HIHUWR 0RWRUSRZHU(0&VKLHOGFRQQHFWLRQµRQSDJH Low Voltage Directive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

52 2-34 Install the ULTRA Plus PDM Components I/F 24V Sourcing Conversion Card 7KH8/75$3OXV3'0KDVVLQNLQJDFWLYHORZ,2ZKLFKLVFRPPRQLQWKH 866RXUFLQJDFWLYHKLJK,2VDUHSUHIHUUHGLQ(XURSH5RFNZHOO $XWRPDWLRQRIIHUVD',1UDLOPRXQWHGFDUGZKLFKFRQYHUWVWKH,2IURP VLQNLQJWRVRXUFLQJ7KLVFDUGPXVWEHPRXQWHGLQWKHVDPHHQFORVXUHDVWKH 3'0 IMPORTANT $XVHUVXSSOLHGH[WHUQDO9'&SRZHUVXSSO\LVUHTXLUHG IRUWKLVRSWLRQ ULTRA Plus PDM I/F Conversion Card Description I/F Conversion Card, 24V Sourcing (1) Alternate Number Cable, I/F Conversion Card 3ft (1m) Cable I/F Conversion Card 10ft (3m) (1) Required for compliance with the European Union Low Voltage Directive (LVD). It must be mounted in the same enclosure as ULTRA Plus PDM.