Rockwell Automation 1326 User Manual

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Allen-Bradley

1394 Digital AC Multi-Axis Motion Control System

(Catalog No. 1394-50)

User Manual

Important User Information

Because of the variety of uses for the products described in this publication, those res ponsible for the application and use of this control equipment must sati sfy themselves that all nec essary steps have been taken to ass ure that each applica tion and use meets al l performance and safety requiremen ts, inclu ding any a pplicable l aws, re gulations, c odes and standards.

The illustrations, c harts, sample progr ams and layout ex amples shown in this guide ar e inte nded so lely f or pur poses of exa mple . Since ther e are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellec tual property liabil ity) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (ava ilable from your local Allen-Bradley off ice), describes some important differences between solid-state equipment and electromechanical de vices that should be taken into consid eration when applying products such as those described in thi s publication.

Reproduction of the content s of this copyri ghted publication, in whole or in part, without writte n permission of Allen-Bradley Compa ny , Inc., is prohibited.

Throughout this manua l we use notes to make you aware of safet y considerations:

ATTENTIO N: Identifies information about practices or circumstances that can lead to personal injury or

Attention statements help you to:

• identify a hazard

• avoid the hazard

• recognize the consequences Important: Identifies information that is critical for successful

GML, IMC, Flex I/O, PanelView, Data Highway Plus, SCANport, SLC, SLC 5/03, SLC 5/04, and SLC 5/05 are t rademarks of Allen-Bradley Company, Inc. PLC is a registered trademark of Allen-Bradley Company, Inc.

death, property damage or economic loss.

application and understanding of the product.

Preface

Overview

Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-1

Purpose of this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-1

Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-2

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-3

Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-3

Module Series Designator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-3

1394 Product Receiving and Storage Responsibility . . . . . . . . . . . . . . . . .P-4

Allen-Bradley Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-4

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-4

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-4

Chapter 1

The 1394 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Series Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1394 System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

GMC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

CNC Interface System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SERCOS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Analog Servo System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

9/440 CNC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -8

What is a 1394 System?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

System Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

External Shunt Module (used with 22 kW System) . . . . . . . . . . . . . . .1-11

1326AB Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1326AS Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1326AH Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Drive Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

DC Link Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Standard Features of the 1394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Installing Your 1394 (applies to all systems)

Chapter 2

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Complying With European Union Directives. . . . . . . . . . . . . . . . . . . . . . . .2-1

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -2

Before Mounting Your System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Storing Your 1394 Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Unpacking Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Determining Your System Mounting Hole Layout . . . . . . . . . . . . . . . . .2-4

Mounting Your 1394 Through the Back of the Cabinet . . . . . . . . . . . . .2-6

Bonding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -8

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ii Table of Contents

Wiring System, Axis, and Shunt Modules, and Motors (for all systems)

Mounting Your 1394 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Mounting Your 1394-DCLM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Mounting the External Shunt Resistor for 5 and 10 kW System Modules 2-11

Mounting External Shunt Modules for 22 kW System Modules. . . . . . . . 2-11

Shunt Module Mounting Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Shunt Module Mounted Outside the Cabinet . . . . . . . . . . . . . . . . . . . 2-13

Shunt Module Mounted Inside the Cabinet . . . . . . . . . . . . . . . . . . . . . 2-14

Mounting the Shunt Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Mounting Considerations for GMC and GMC Turbo Systems . . . . . . . . . 2-16

Mounting GMC and GMC Turbo Systems Next to Flex I/O . . . . . . . . . 2-16

Chapter 3

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Finding Additional Wiring Information for 1394 Systems . . . . . . . . . . . . . . 3-1

Understanding Basic Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . 3-2

Routing High and Low Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

System Module Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

EMI/RFI Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

EMI/RFI Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Determining Your Type of Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Grounded Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Ungrounded Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Setting the Ground Jumper in a 5 or 10 kW System Module for

Ungrounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Setting the Ground Jumper in a 22 kW System Module for

Ungrounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Grounding Your 1394 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Grounding your System to the Subpanel . . . . . . . . . . . . . . . . . . . . . . 3-12

Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Wiring System Module Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Terminal Block Locations for 5 and 10 kW System Module

(Series A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Connector Locations for 5 and 10 kW System Module (Series C) . . . 3-15

Terminal Block Locations for a 22 kW System Module . . . . . . . . . . . . 3-16

Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Connecting Power Wiring for 5 and 10 kW (Series A and B)

and 22 kW System Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Connecting Power Wiring for 5 and 10 kW System Modules

(Series C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Connecting Motor Power to Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Connecting Thermal and Brake Leads to Axis Modules . . . . . . . . . . . 3-20

Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Wiring Motor Power, Thermals and Brakes . . . . . . . . . . . . . . . . . . . . . 3-21

Connecting Feedback to System Modules. . . . . . . . . . . . . . . . . . . . . . . . 3-24

Connecting Your Motor Cables to Motors. . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Connecting Your External Shunt Resistor . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Connecting Your External Shunt Resistor (Series A and B) . . . . . . . . 3-27

Connecting Your External Shunt Resistor (Series C) . . . . . . . . . . . . . 3-28

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Wiring 1394 GMC and GMC Turbo Systems

Table of Contents iii

Connecting Your Shunt Module (required for 22 kW system) . . . . . . . . . 3-28

Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Wiring the Shunt Module Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Wiring Shunt Module Fan Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Chapter 4

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Finding Additional Wiring Information for 1394 Systems. . . . . . . . . . . . . . 4-1

Understanding GMC and GMC Turbo Wiring and Connections . . . . . . . . 4-1

Understanding Input Wiring Board Layout. . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Using the Terminal Operating Tool to Insert Wires . . . . . . . . . . . . . . . . 4-4

Input Wiring Board Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Connecting Your Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Encoder Feedback Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Data Highway Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

AxisLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

GMC Turbo System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Flex I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

SLC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Connecting a GMC and GMC Turbo to a 1394-DIM . . . . . . . . . . . . . . . . 4-19

1394-DIM System Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

1394-DIM with 1398-DDM-

1394-DIM Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

1394-System Module Input Power Wiring When

Not Using Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Understanding DIM Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

DROK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Drive Enable Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Wiring and Configuring an External Drive to the 1394-DIM. . . . . . . . . . . 4-26

Connecting the Remote Drive to the DIM Connector . . . . . . . . . . . . . 4-26

Connecting the Position Feedback Encoder to the Feedback Input . . 4-29

Connecting the DIM Ground Wire to the 1394 System Ground . . . . . 4-30

Installing the Resolver Feedback Input Plug . . . . . . . . . . . . . . . . . . . 4-30

xxx

System Example . . . . . . . . . . . . . . . . 4-20

Wiring Your 1394 Analog Servo System

Chapter 5

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Finding Additional Wiring Information for 1394 Systems. . . . . . . . . . . . . . 5-1

Understanding Analog Servo Wiring and Connections . . . . . . . . . . . . . . . 5-1

Input Wiring Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Using the Terminal Operating Tool to Insert Wires . . . . . . . . . . . . . . . . 5-2

Input Wiring Board Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Connecting AQB and SCANport Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Analog Servo Encoder (A Quad B) Wiring . . . . . . . . . . . . . . . . . . . . . . 5-5

SCANport Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

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iv Table of Contents

Commissioning 1394 GMC and GMC Turbo Systems

Commissioning Your 1394 Analog Servo System

Chapter 6

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Applying Power to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Setting Up Your System Using GML Commander . . . . . . . . . . . . . . . . . . . 6-3

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Preparing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Setting Up Your System Using GML 3.x.x . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Preparing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Chapter 7

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Setting Up Your 1394 Analog Servo System . . . . . . . . . . . . . . . . . . . . . . . 7-2

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Exiting Before You’re Finished . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Continuing From Where You Left Off . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Removing and Re-Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Setting Up at the System Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Setting Up Analog Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Defining Your Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Defining a Reference Source for Your Axes . . . . . . . . . . . . . . . . . . . . . 7-6

Defining Analog Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Defining Analog Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Defining Digital Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Defining Digital Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Defining Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Auto Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Before You Perform an Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Performing the Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Configuring Your 1394 Analog Servo System

Troubleshooting

Publication 1394-5.0 — May 2000

Chapter 8

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Where to Look fo r Other Programming Information. . . . . . . . . . . . . . . . . . 8-1

Conventions Used in this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Understanding Analog Servo System Parameters. . . . . . . . . . . . . . . . . . . 8-3

1394 Analog Servo Software Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Chapter 9

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Understanding How to Detect a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Understanding System and Axis Module LEDs . . . . . . . . . . . . . . . . . . . . . 9-2

Understanding System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Finding GMC Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Viewing Instantaneous Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Viewing Continuous Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Finding Analog Servo System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Table of Contents v

Finding 9/440 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Finding CNC Interface Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Understanding GMC Turbo and GMC Controller Faults. . . . . . . . . . . . . . . 9-9

Understanding Analog Servo System Module Faults . . . . . . . . . . . . . . . 9-10

Understanding Analog Servo System Axis Faults . . . . . . . . . . . . . . . 9-12

Troubleshooting General System Problems. . . . . . . . . . . . . . . . . . . . . . . 9-13

Replacing System and Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

Removing an Axis Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Installing a Replacement Axis Module . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Removing a System Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

Installing a Replacement System Module . . . . . . . . . . . . . . . . . . . . . 9-20

Replacing System Modules of the Same Series . . . . . . . . . . . . . . 9-22

Replacing System Modules of a Different Series . . . . . . . . . . . . . . 9-22

Completing Connections and Downloading Parameters . . . . . . . . 9-22

Checking fo r a Blown Fuse in the 1394-DCLM . . . . . . . . . . . . . . . . . . . . 9-23

Replacing the 1394 Shunt Module Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

Replacing the 1394-SR10A Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

Replacing the 1394-SR9A, -SR9AF, -SR36A, and -SR36AF Fuse . . 9-26

Replacing the AM50 and AM75 Axis Module Fan. . . . . . . . . . . . . . . . . . 9-28

Removing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

Installing the New Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

Specifications

Appendix A

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

System Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Contact Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

DC Link Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Drive Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

User-Supplied Contactor (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

User-Supplied Line Input Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

User-Supplied 24V Logic Input Power . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Input Transformer for 24V Control Power . . . . . . . . . . . . . . . . . . . . . . . A-6

User-Supplied 5V Auxiliary Encoder Power Supply . . . . . . . . . . . . . . . A-6

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

External Shunt Resistor Kit for 5 and 10 kW Systems . . . . . . . . . . . . . A-8

1394 Shunt Module for the 22 kW System . . . . . . . . . . . . . . . . . . . . . . A-8

Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

System Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

DC Link Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Drive Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Internal Shunt Resistor for the 5 and 10 kW System (standard) . . . . A-11

Communication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Encoder Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Publication 1394-5.0 — May 2000

vi Table of Contents

Interconnect and CE Diagrams

Dedicated Discrete I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . A-12

Serial I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

DH-485 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

Flex I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

GMC System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-14

Remote I/O Adapter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .A-15

AxisLink Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-16

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-17

1394 System Module Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17

Axis Module Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-18

Filter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-20

External Shunt Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-22

Motor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-25

Servo Motor Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-32

1326AB Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32

1326AS Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-33

Appendix B

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

GMC, Analog Servo, and CNC Interface Interconnect Diagrams. . . . . . . . B-2

1394 GMC Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

1394 Analog Servo Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

1394 CNC Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12

Thermal Interconnect Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

1394 GMC Systems (1394x-SJTxx-C and -T) . . . . . . . . . . . . . . . . . . B-15

1394 GMC Systems (1394C-SJTxx-L) . . . . . . . . . . . . . . . . . . . . . . . . B-19

1394 Analog Servo Systems (1394x-SJTxx-A) . . . . . . . . . . . . . . . . . B-21

Cable Pin-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-23

1326 Cable Pin-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-23

1394 Cable Pin-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-26

Grounding for 1394 CE Requirements . . . . . . . . . . . . . . . . . . . . . . . .B-30

Using the Human Interface Module (HIM)

Publication 1394-5.0 — May 2000

Appendix C

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

The Human Interface Module (HIM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Understanding HIM Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Understanding HIM Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4

Understanding HIM Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

Link Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

Startup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

EEProm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

Search Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Control Status Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Linking Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Using Copy Cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7

Copying a System’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8

Catalog Numbers

Table of Contents vii

Pasting a System’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

Auto Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10

Getting an Overview of HIM Programming . . . . . . . . . . . . . . . . . . . . . C-11

Removing the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Removing the HIM from the HIM Cradle . . . . . . . . . . . . . . . . . . . . . . C-14

Disconnecting the HIM from the System Module . . . . . . . . . . . . . . . . C-14

Setting Up the HIM fo r Hand-Held Use . . . . . . . . . . . . . . . . . . . . . . . C-15

Placing the HIM in the HIM Cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16

Appendix D

Understanding Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Determining Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

System Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

1394 System Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

9/440 System Module (Resolver based systems) . . . . . . . . . . . . . . . . D-2

CNC Serial Drive System Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

9/440 High Resolution/Absolute CNC System Module . . . . . . . . . . . . D-3

Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

External Shunt Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Shunt Resistor Kit for 5 and 10 kW System Modules . . . . . . . . . . . . . . D-4

Shunt Modules for 22 kW System Modules . . . . . . . . . . . . . . . . . . . . . D-4

System Module Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Control Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Single Axis Flying Lead Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Two-Axis Prewired Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

1326AB Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6

1326 Shaft Oil Seal Kit for 1326AB Motors . . . . . . . . . . . . . . . . . . . . . D-6

Motor Junction Box Kit for 1326AB Motors . . . . . . . . . . . . . . . . . . . . . . D-7

Feedback Mounting Adapter Kit for 1326AB Motors . . . . . . . . . . . . . . D-7

1326AS Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

1326 Shaft Oil Seal Kit for 1326AS Motors . . . . . . . . . . . . . . . . . . . . . D-8

Motor Junction Box Kit for 1326AS Motors . . . . . . . . . . . . . . . . . . . . . . D-9

Feedback Mounting Adapter Kit for 1326AS Motors . . . . . . . . . . . . . . D-9

1326AH Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

Power and Feedback Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11

Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11

Motor Feedback Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12

Encoder Feedback Cables for 1326AB Motors . . . . . . . . . . . . . . . . . D-12

Miscellaneous Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

Publication 1394-5.0 — May 2000

viii Table of Contents

Publication 1394-5.0 — May 2000

Preface

Read this preface to familiarize yourself with the rest of the manual. This preface co vers the following topics:

• Who should use this manual

• The purpose of this manual

• Contents of this manual

• Related documentati on

• Conventions used in this manual

• 1394 product receiving and storage responsibility

• Allen-Bradley support

Who Should Use this Manual

Purpose of this Manual

Use this manual if you are respons ible for designing, inst al ling, programming, or troubles hooting the Allen-Bradley 1394 fa mily of products.

If you do not have a basic understanding of the 1394, contact your local Allen-Bradley re presenta tiv e for inf ormation on a va ilable traini ng courses before using this product.

This manual is a user guide for the 1394. It gives you an overview of the 1394 family and describes the procedures you use t o install, set up, us e , and troubleshoot the 1394.

Publication 1394-5.0 — May 2000

P-2 Preface

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.

Overview Explains and illustrates the theory behind the

1394’s operation. Covers hardware and software features.

Appendix A

Appendix B

Appendix C

Appendix D

Installing Your 1394 (applies to all systems)

Wiring System, Axis, and Shunt Modules, and Motors (for all systems)

Wiring 1394 GMC and GMC Turbo Systems

Wiring Your 1394 Analog Servo System

Commissioning 1394 GMC and GMC Turbo Systems

Commissioning Your 1394 Analog Servo System

Configuring Your 1394 Analog Servo System

Troubleshooting Explains how to interpret and correct problems

Specifications Provides physical, electrical, environmental, and

Interconnect and CE Diagrams

Using the Human Interface Module (HIM)

Catalog Numbers Provides catalog number descriptions of 1394

Provides mounting information for your 1394 system.

Provides information on how to connect your 1394 system components together.

Provides information on how to wire your 1394 GMC and GMC Turbo System Mod ules.

Provides information on how to wire your 1394 Analog Servo System Module.

Provides information about parameters used to configure your 1394 GMC and GMC Turbo.

Provides information about parameters used to configure your 1394 Analog Servo Module.

Provides supplemental information on using communication tools.

with your 1394 system.

functional specifications for the 1394. Provides diagrams showing the interconnections

for the available 1394 configurations and installation requirements to meet CE directives.

Provides information that will help you to use the HIM.

and related products.

Publication 1394-5.0 — May 2000

Preface P-3

BULLETIN 1394 300W SHUNT MODULE

ALLEN-BRADLEY

CAT.

PART

SER.

INPUT DC

INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

Conventions Used in this Manual

Module Series Designator

The following conventions are used throughout this manual:

• Bulleted lists su ch as this one pro vide in formation, not procedural steps.

• Numbered lists provide sequential steps or hierarchical information.

• Words that you type or select appear in bold.

• When we refer you to another location, the section or chapter name appears in italics .

To determine the series designator, check the seri es f ie ld on the Alle nBradley label attached to your system, axis, and shunt modules. The series designator is located as shown in the example below.

Figure P.1 Allen-Bradley Label

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE

CAT.

INPUT DC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

PART

SER.

INPUT AC

Series Field

Shunt Module Example

1394 Digital Servo Controller

300W Shunt Module

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

Publication 1394-5.0 — May 2000

P-4 Preface

1394 Product Receiving and Storage Responsibility

Allen-Bradley Support

You, the customer, are responsible for thoroughly inspecting the equipment before accept ing the shipment from the freight company. Check the item(s) you receive against your purchase order. If any items are obviously damaged, it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill. Should you discover any concealed damage during unpacking, you are responsible for not ifying the freig ht agent. Lea ve the shipping container intact and request that the freight agent make a visual inspection of the equipment.

Leave the pro duct in its shi pping contai ner prior to installat ion. If you are not going to use the equipment for a period of time, store it:

• in a clean, dry location

• within an ambient temperature range of 0 to 65° C (32 to 149° F)

• within a relative humidity range of 5% to 95%, non-condensing

• in an area where it cannot be exposed to a corrosive atmosphere

• in a non-construction area

Allen-Bradley offers support services worldwide, with over 75 Sales/ Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world.

Local Product Support

Contact your local All en-Bradley representat ive for:

• sales and order support

• product technical traini ng

• warranty support

• support service agreements

Technical Product Assistance

If you need to contact Allen-Bradley for technical assistance, please review the information in the Troubleshooting chapter first. Then call your local Allen-Bradley representative. For the quickest possible response, please have the catalog numbers of your products available when you call.

Publication 1394-5.0 — May 2000

Overview

Chapter

The 1394 System

The 1394 is a modular, multi-axis motion control and drive system family. Its unique design allows the 1394 to be used as an integrated motion controller and drive sys te m (GMC) with Turbo or standard IMC S Class Compact functionality, an integrated 9/440 CNC system, a 9/Series CNC digital interface drive system, a SERCOS servo drive system, or an analog serv o drive system.

All 1394 systems pro vide direct line conne ction (transformerless) for 360 and 480V three-phase input power, efficient IGBT power conv e rsi on, and slide-and-lock, module-to -module connection systems. Each system module can be configured with up to four axis modules, with each axis module interfacing to a motor. The 1394 provides significant panel space and interconnect savings.

Series Note

Series C system modules (catalog numbers 1394C-SJTxx-x) and axis modules (catalog numbers 1394C-AMxx and -AMxx-IH) include features not available on Series A and B modules (catalog numbers 1394-SJTxx-x and 1394-AMxx).

System Module Features:

Connector (plug-in) input power ter mi nati on Cable Clamp (strain relief, shield bond) EMI filter (24V input power, registration) Smart Power (Soft Start, power monitor)

Feature Availability

Series C Series A and B

Yes No Yes No Yes No Yes 22 kW systems only

Axis Module Features:

Cable Clamp (strain relief, shield bond) EMI filter (motor brake and thermal circuit)

Series C system modules are interchangeable with Ser ies A and B. Likewise, Series A, B, and C axis modules are interchangeable with each other.

Series C is recommended for all ne w app li cat ions. See the tables above for feature availabil ity. For help in dete rmining the se ries of your module(s), refer to the section Module Series Designator in the Preface.

Feature Availability

Series C Series A and B

Yes No Yes No

Publication 1394-5.0 — May 2000

1-2 Overview

Safety Precautions

The following general precautions apply to the 1394:

ATTENTIO N: Only those familiar with the 1394 Digital, AC, Multi-Axis Motion Co ntrol System and

associated machinery should plan or implement the installation, startup, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.

ATTENTIO N: This product contains stored energy devices. To avoid haza rd of e lectr ical shock, w ait five minutes after r emoving po wer or verify that all vol tage on the capacitors has been discharged before attempting to service, repair, or remove this unit. You should only attempt the procedures in this manual if you are qualif ied to do so and fa miliar with solid-stat e control equipment and the safety procedures in publication NFPA 70E.

ATTENTIO N: The system integrator is responsible for local safety and electrical codes.

ATTENTIO N: An incorrec tly applied or installe d drive can res ul t in compone nt damage or a reduc ti on in product life. Wiring or applicatio n errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatu res can result in malfunction of the drive.

ATTENTIO N: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control p recau tions are required when installing, testing, servicing, or repairing this assembly. Component damage can result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to AllenBradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook.

Publication 1394-5.0 — May 2000

Overview 1-3

AEC

1394 System Overview

GMC System

The 1394 GMC System provides all the functionality of the IMC S Class Compact Motion Controller and power conversion within the 1394 system module. Allen-Bradley offers two versions of the 1394 GMC system module (Standard GMC and GMC Turbo). Both systems are completely programmed and commissioned using GML (Graphical Motion Control Language), offer Allen-Bradley DH485, RS-232, and RS-422 as standard communications, and have Remote I/O and AxisLink available as communication options.

The 1394x-SJTxx-C (Standard GMC) system supports four axis modules and provides four channels of auxiliary encoder input. The 1394C-SJTxx-L (Standard GMC) provides the same functionality of the 1394x-SJTxx-C, but supports only one axis module and provides two channels of auxiliary encoder input.

In addition, the 1394x-SJTxx-T (GMC Turbo) provides more GML application program memory and executes the programs faster. The 1394x-SJTxx-T offers 64K of memory with a 32-bit processor while the 1394x-SJTxx-C offers 32K of program memory with a 16-bit processor. The 1394x-SJTxx-T also inc lud es a dire ct , high speed link to the SLC 5/ 03, 5/04, or 5/05 that simplifies the programming required to transfer data between the 1394x-SJTxx-T and the SLC.

PanelView 550

SLC 5/03, 5/04, or 5/05

1746-C7 or -C9

GML

RS-232/-422

Discrete Outputs

Discrete Inputs

Analog Outputs

Analog Inputs

SLC 500

DH-485

Flex I/O

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Reset

Axis 0 Axis 1

SSIControl

is x A

ConfigurationConfiguration

2 1

Encoder EncoderPower

1 is

Switches Switches

SSI Control

AEC

4100-AEC

Figure 1.1 Two GMC Turbo Systems (1394

RIO

AxisLink

1394x-SJTxx-T

DANGER

1326AB and 1326AS Motors

842A Encoder

This interface is only available with the 1394

-SJTxx-T)

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

-SJTxx-T system module.

AxisLink

ALEC

845H Encoder

-SJTxx-T

1394

1326AB and 1326AS Motors

Flex I/O

Publication 1394-5.0 — May 2000

1-4 Overview

AEC

Figure 1.2 Two Standard GMC Systems (1394

-SJTxx-C and 1394C-SJT-xx-L)

SLC 500

PanelView 550

DH-485

GML

Discrete Outputs

Discrete Inputs

Analog Outputs

Analog Inputs

RS-232/-422

Flex I/O

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Reset

Axis 0 Axis 1

SSIControl

is x A

ConfigurationConfiguration

2 1

Encoder EncoderPower

1 is

Switches Switches

SSI Control

AEC

4100-AEC

ALEC

RIO

AxisLink

845H Encoder

AxisLink

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394C-SJT

DANGER

-L

1326AB or 1326AS Motor

1394

-SJTxx-C

DANGER

1326AB and 1326AS Motors

845H Encoder

Flex I/O

842A Encoder

Publication 1394-5.0 — May 2000

ODS Software

Overview 1-5

CNC Interface System

The 1394 9/Series CNC Interf ace system (1394-SJTxx-E) provides a digital servo system to be used with the 9/260 and 9/290 CNC. This system provides all power electronics and uses a cost-saving digital interface app roach. Servo control for this system is handled by th e 9/ Series CNC. A fiber optic I/O ring is provided to the 1394 and the system is completely interfaced with and programmed using ODS (Off-Line Development System) and the CNC operator panel. AllenBradley Remote I/O, MMS/Ethernet (9/260 and 9/290 only), and Data Highway Plus (9/260 and 9/290 only) communications are avai lable options with the 9/Series CNC interface system.

Figure 1.3 CNC Interface System

1746 I/O

Fiber Optic Ring

Operator Panel

MTB Panel

Fiber Optic Ring

RIO

PLC

9/230, 9/260, or 9/290 CNC

1394

Fiber Optic Ring

1326AB Motors

Fiber Optic Ring

Publication 1394-5.0 — May 2000

1-6 Overview

1756-M

SE Interface

SERCOS System

The 1394 SERCOS system module (1394C-SJTxx-D) provides a digital servo drive sy st em with a fiber-opti c di gi tal network interf ace. It can be used as a velocity or torque control system and is quickly commissioned with the Allen-Bradley SERCOS Interface Module (Bulletin 1756 with 1756-MxxSE), which provides access to auto tuning and start-up prompti ng. The 13 94 als o pro vide s a SCANp ort interface as a standard feature.

For specific installation and wiring information refer to the 1394 SERCOS Multi-Axis Motion Control System User Manual (publication 1394 -5.20).

Figure 1.4 SERCOS System

ControlLogix Chassis

SERCOS

SERCOS System Module

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394 SERCOS System

DANGER

1326AB, 1326AS, and MP Series Motors

SERCOS System Module

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

DANGER

1394 SERCOS System

1326AB, 1326AS, and MP Series Motors

SERCOS

Publication 1394-5.0 — May 2000

SLC 500

Overview 1-7

Analog Servo System

The 1394 Analog Servo system (1394x-SJTxx-A) provides a digital servo drive system with a traditional ±10V DC analog interface. It can be used as a velocity or torque control system and is quickly commissioned with the Allen-Bradley universal Bulletin 1201 HIM (Human Interface Module), which provides access to auto tuning and start-up prompting. The 13 94 also pro vides a SCANport interfa ce as a standard feature.

Figure 1.5 Analog Servo System

Bulletin 1201 HIM

RIO

(purchased separately)

PanelView 550

GML

RS-232/-422

Discrete Outputs

Discrete Inputs

Analog Outputs

Analog Inputs

DH-485

Flex I/O

IMC S Class Compact, Control Logix (or other customer supplied motion controller)

SCANport

Optional Bulletin 1201

HIM or other remote

SCANport interface

Optional Bulletin 1203

Communication Module

1394

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1326AB and 1326AS Motors

To RIO, Serial, DeviceNET,

SLC, etc.

Publication 1394-5.0 — May 2000

1-8 Overview

9/440 CNC System

The 9/440 CNC system module gives you all the power and programming capabilities of a 9/Series CNC, integrated into the compact packaging of the 1394 System Module. The 9/440 CNC System Module provides ter m inating points for:

•Resolvers

• Encoder feedback (for optional position feedback or spindle control)

• Two serial ports (for communicating with the 9/Series ODS or other peripherals such as printers or tape readers)

• E-STOP string and status

• Spindle outputs

• 9/Series fiber optic ring connection

• Touch probe interface

• Remote I/O connection

There are three versions of the 9/440 CNC System:

Number of

Resolver

Catalog

Version:

1 Axis 9/440 8520-1S 3 Axis 9/440 8520-3S

4 Axis 9/440 8520-4Sx4

You can connect a total of three feedback devices. If you use three resolvers, the encoder port (J11) is

not available. If you use the encoder feedback port (J11), the third resolver feedback (J3) is disabled.

You can connect a total of six feedback devices. If you use four resolvers, the last encoder port (J11) is

not available. If you use all three encoder feedback ports, the third resolver feedback (J3) is disabled.

Number:

Axis modules:

1 1 2 0

feedback ports:

Analog outputs:

2 2

Encoder feedback ports:

For more in fo rmation on the 9 / 440, refer to th e 9/Series Integration and Maintenance Manual (publication 8520-6.2).

Publication 1394-5.0 — May 2000

Figure 1.6 9/440 System

Overview 1-9

What is a 1394 System?

Optical signal cable

Terminal type connection

The 1394 system consists of the follo wing components (catalog number appears in parenthesis ):

• One System Module (1394x-SJTxx-x)

• One to four Axis Modules (1394x-AMxx-xx)

• One to four servo m oto rs (1326Ax-Bxxxx)

• One to four power and feedback cables Also available are the DC Link Mod ule (1394-DCL M ) and Drive

Interface Module (1394-DIM).

The: Is used:

1394-DCLM In addition to the axis module(s) 1394-DIM In place of an axis module.

Publication 1394-5.0 — May 2000

1-10 Overview

ANGER

RISK OF ELECTRICAL SHOCK.

HIGH

VOL

AGE MA

EXIST UP

TO FIVE MINUTES

AFTER REMOVING POWER.

Axis modules are connected to system modules using slide-and-lock, module-to-module conn ections. For information on mot ors and cables, refer to the 1326AB 460V , T orque Plus Series, A C Servo Motors Pro duct

Data (publication 1326A-2.9), 1326AS Series 460V, Low Inertia, Brushless Servo Motor s Product Data (publication 1326A-2.10), and 1326 Cables for 460V AC Servo Motors Product Data (publication

1326A-2.11). In addition to the equi pment sho wn abov e, you will nee d to supply the

following:

• Three phase input contactor

• Three phase input fusing

• 24V AC or DC logic power for system module and contactor enable (Analog Servo only)/DRIVEOK power (all modul es)

Refer to Appendix A for inform ation on these top ics.

Note: An externa l shunt resistor kit (1394-SR10A) is a va ilable for 5

and 10 kW systems with regenerative loads that exceed the capacity of the inter nal 2 00W shunt res istor pro vi ded. Most 5 and 10 kW systems will not r equire a shunt res istor kit. All 22 kW 1394 based products require an external shunt module (1394-SR9Ax or 1394-SR36Ax). This includes b oth 1394 and 8520 catalog items.

System Modules

System modules, av ail able with r atings of 5, 10 and 22 kW (at 460V), house the system control PCB and convert 360 to 480VAC, threephase, 50/60 Hz input power to a 530 - 680VDC link voltage. The 5 and 10 kW system modules have an internal shunt resistor with a 200W continuous rating and a peak rating of 40,000W. The 22 kW system module requires an external shunt module.

Figure 1.7 1394 System module

Y A M

G TA L

O V

H G I H

K C O

H S

L A C

R T C E

R E

N I V

M E R

R E T F

A S E

U N I

M E V I

F O

T P U

T S I

X E

Publication 1394-5.0 — May 2000

Overview 1-11

Axis Modules

Axis modules, with continu ous out put cur rents (RMS) of 3.0 , 4.5, 7 .5

23.3 and 35.0A, con vert the DC power suppl ied by the sys tem module to a variable AC voltage. You will require one axis module for every 1326Ax-Bxxxx servo motor you plan to run using the 1394. Choose each axis module based on t he current requirements of the servo motor .

Figure 1.8 1394 Axis Module

External Shunt Module (used with 22 kW System)

Shunt modules with (rms) po we r output of 300, 900, 1800 and 3600W continuous, 160,000W peak are available for use with the smart power 22 kW s ystem module. T he shunt module dissipates excess regenerative power from the Bulletin 1394 system. You must use one shunt module with each 22 kW smart power system module. Available in two sizes, each package contains an integral fuse and terminal block. The 3600 W p ackage is a vailable with a 115 /230V AC cooling fan. Choose your shunt module based on the shunt requirements of the 1326Ax-Bxxxx servo motors you plan to run using the 1394.

Note: 5 and 10 kW system modules can use an optional 1400W shun t

module kit to dissipate excess regenerative energy (unpackaged components).

Figure 1.9 1394 External Shunt Module

Publication 1394-5.0 — May 2000

1-12 Overview

1326AB Motors

This family of high-p erfor mance, medi um inert ia, fe rrit e, thre e-phas e servo motors feature a specially designed housing that reduces motor length. They are a vailab le with continuous t orque ratings of 2.3 to 53 .0 N-m (20.7 to 469.0 lb-in.). Refer to the 1326AB 460V, Torque Plus Series, AC Servo Motors Prod uct Data (publication 1326A-2.9) for more information on features and options. IP65 protection rating is standard when used with the shaf t oil seal kit. IP67 pr otection r ating is avai lable (specify -L in the ca talog number, refer to Appendix D).

Figure 1.10 1326AB Motor

1326AS Motors

This family of high-performance servo motors feature neodymiumiron-boro n pe rm anent magne t rotors that provide low inertias, hi gh accelerations and high peak torques. They are available with continuous torque ratings of 0.49 to 49.3 N-m (4.33 to 436 lb-in.). Refer to the 1326AS Series 460V, Low Inertia, Brushless Servo Motors Product Data (public ati on 1326A-2. 10) fo r more infor mat ion on features and options. IP65 pr otection rating is standard when used with the shaft oil seal.

Important: 1326AS-Bxxxx motors cannot be used with the 9/Series

and 9/440 controllers.

Figure 1.11 1326AS Motor

Publication 1394-5.0 — May 2000

Overview 1-13

1326AH Motors

This family of hazardous duty motors are UL recognized AC brushless servo motors. Construction of the motor is a totally enclosed non-ventilated (TENV) square frame design utilizing a permanent magnet rotor and a fixed stator winding. Rare earth magnets, long life ball bearings, and brushless construction also assures maximum performance. The y are available wit h conti nuou s torque ratings of 2.97 to 16.9 N-m (26.3 to 149.8 lb-in.). Refer to the 1326AH Hazardous Duty Motors Product Data (publication 1326AH-TD001B-US-P) for more information.

Figure 1.12 1326AH Motor

Publication 1394-5.0 — May 2000

1-14 Overview

Drive Inter face Module

The 1394-DIM (Drive Interface Module) provides four channels of analog output, four drive enable outputs, and four drive fault inputs. The 1394-DIM allows the 139 4x-SJTxx-C, -T, or -L system module to be used to cont rol any external driv e with a ±10V velocity torque reference command and quadrature encoder output. Each 1394-DIM can support up to four drives . However , the maximum number of axe s (1394-DIM controlled dri ves pl us 139 4x-AMxx axis modules) cannot exceed four per 1394x-SJTxx-C or -T system module and one per 1394C-SJTxx-L system module. The 1394-DIM is not compatible with the 1394x-SJTxx-A syste m module.

Figure 1.13 Drive Interface Module

DC Link Module

The 1394-DCLM (DC Link Module) provides additional load leveling and energy storage (capacitance) for 1394 systems. This allows additi ona l re gene rative ener gy to b e stor ed duri ng the mac hine cycle, increasing system capacity, lowering cycle time, and avoiding resistive heat loss. The module can be used alone or two modules can be used to interconnect two 1394 systems using the DC Link cable.

Figure 1.14 DC Link Module

Publication 1394-5.0 — May 2000

Overview 1-15

Standard Features of the 1394

The 1394 provides the following standard features:

• UL Listed a n d CUL Certified

•CE Marked

Control

• Supports Standard GMC (1394x-SJTxx-C and -L) and GMC Turbo , CNC Interface, SERCOS, and Analog Servo configurations with a standard array of hardware.

• Digitally-adjus ted veloc ity and current loop compensati on, which accommodates a wide range of system inertias.

• Two configurable analog test outputs that can be li nked t o crit ical system parameters for troubleshooting (GMC and Analog Servo system modules).

• All systems provide digital fault and diagnostic utilities (including a current monitor, thermal overload detection, and a feedback signal monitor).

• Status LEDs for system and axis modules.

• Status LEDs for motion board, Axislink, and RIO (GMC system only).

• Highly-integrated surface mount circuitry.

• Encoder signal output (A QUAD B) for encoder emulation (Analog Servo system modules only).

• DSP assisted processing.

• Smart Power contro l, a v ail able on al l 22 kW system modul es and 5 and 10 kW system modules (Series C or later), allows poweruse monitoring for process optimization.

• Smart Power system mod ules, available on all 22 kW system modules and 5 and 10 kW system modules (Series C or later), include active Soft Start inrush current limiting for DC link charging.

• Electrical Noise Protection included on GMC, GMC Turbo, SERCOS, and Analog Servo system modules (Series C or later) and axis modules (Series C or later).

• Improved grounding terminations on GMC, GMC Turbo, SERCOS, and Analog Servo system modules (Series C or later) and axis modules (Series C or later).

Note: To determine the series of your module, refer to Figure P.1 in

the Preface.

Publication 1394-5.0 — May 2000

1-16 Overview

Power

• IGBT technology for efficient, quiet operation.

• Transie nt (MOV) voltage, phase loss, and ground fault protected input.

• An integral 200W shunt resistor is available (5 and 10 kW only). An external 1400W shunt kit is available (5 and 10 kW only). Other external shunt kits and modules from 300 to 3600W continuous.

• Current ratings of 3.0, 4.5, and 7.5A continuous, a t 50°C (122°F) (inside cabinet) and 23.3 and 35A continuous, at 40°C (104°F) (with heat sinks out the back) with up to 300% motor ratings for high duty-cycle oper at ion producing continuous to rque ranges of

0.7 to 53.0 N-m (6 to 469 lb-in.).

• 324-528V AC, three-phase, 50/60 Hz direct line operation.

• No isolation transformer or inductors are required (360/480VAC Hz direct line operation) for most applications.

• Advanced protective features, such as software-based current foldback, which provides overload tolerant operation and soft current limiting.

Integration

• Hinged system module front cover for easy access to control and power wiring.

• System and axis modules that can be quickly removed and easily interchanged for troubleshooting and diagnostics.

• Standard widths of 50 mm (1394x-AM03, -04, and -07) and 75 mm (1394x-AM50-xx and -AM75-xx) ax is modules are available.

• Mass termination plugs and reliable, contact-type, terminal blocks are used for easy install ation and service.

• Plug interconnects for auxiliary, encoder input (GMC), encoder output and motor resolver input (all).

• Slide-and-lock, module-to-module connection, which eliminates bus bars and wiring harnesses.

• Advanced communicat ions and I/O capabi lities help inte grate the 1394 to standard plant floor networks.

Publication 1394-5.0 — May 2000

Installing Your 1394

(applies to all systems)

Chapter

Chapter Objectives

This chapter covers the following to pi cs:

• Complying with European Union directives

• Before mounting your system

• Unpacking your modules

• System mounting requirements

• Bonding your system

• Mounting your 1394 system

• Mounting your 1394-DCLM

• Mounting the external shunt resistor for 5 and 10 kW system modules

• Mounting external shunt modules for 22 kW system modules

• Mounting considerations for GMC and GMC Turbo systems

ATTENTIO N: The following information is a guideline for proper installation. The National

Electrical Code and any other governing regional or local codes overrule this informa tion. The AllenBradley Compan y cannot assume responsibility fo r the compliance or the noncompliance with any code, national, local or otherwis e, for the proper inst allation of this system or associate d equipment. If you ignore codes during installation, hazard of personal injury and/or equipment damage exists.

Complying With European Union Directives

If this product is ins ta ll ed wi thin the European Union or EEC r e gions and has the CE mark, the following regulations apply.

EMC Directive

This unit is tested to meet Counc il Directive 89/336 Electromagnetic Compatibility (EMC) using a technical construction file and the following standards, in whole or in part:

• EN 5008x-2 EMC - Emission Standard, Part 2 - Indust rial Environment

• EN 5008x-2 EMC - Immunity Standard, Part 2 - Industrial Environment

Publication 1394-5.0 — May 2000

2-2 Installing Your 1394 (applies to al l systems)

The product described in this manu al is intended for use in an industrial environment.

To meet CE requirements, the following additions are required:

• You must run three-phase in put wiring in a conduit that is

• You must install a power line filter (Allen-Bradley catalog

• You must terminate the shields of t he moto r po we r cable s and the

Low Voltage Directive

These units are tested to meet Council Dir ect ive 73/23/EEC Low Voltage Directive. The EN 60204-1 Safety of Machinery-Electrical

Equipment of Machines, Part 1-Specificati on for General Requirements standard applies in whole or in part.

grounded to the enclosure.

number SP-74102-006-01, SP-7 4102 -006 -02, SP-74102-006-03 or equivalent based on system current) between the three-phase input line and the system module input.

motor feedback cables to the enc los ure at the point of entry.

Before Mounting Your System

Refer to Appendix B for interconnect information.

Before you mount your 1394 system make sure you understand the following:

• how to store your 1 39 4 before insta llation

• how to unpack the system and axis modules

• the minimum mounting requirements

• how to determine your mounting hole layout

Storing Your 1394 Before Installation

The 1394 System module and Axis modules should remain in their shipping containers prior to installation. If the equipment is not to be used for a period of time, store it as follows:

• Store the equipment in a clean, dry locati on that is not ex posed to a corrosive atmosphere.

• Do not store equipment in a construction area.

• Store within an ambient temperature range of 0 to 65° C (32 to 149° F).

Publication 1394-5.0 — May 2000

• Store with in a relative humidity rang e of 5 to 95%, noncondensing.

Installing Your 1394 (app lies to all systems) 2-3

Unpacking Modules

Each 1394 System module ships with the following:

• One system module

• One system terminator

• One terminal operat ing tool (part number 1394-194)

• One user manual (publication 1394-5.0)

• One appl ic ation program loc k key (G MC and GMC Turbo only)

• Mating power conne ctors (5 and 10 kW Series C only)

• Cable shie ld grounding c lamps (5, 10, and 22 kW Series C only) Note: To determine the series of your module, refer to Figure P.1 in

the Preface.

Each 1394 Axis Module ships with the following:

• One 1394 Axis module

• TB1 and TB2 connectors

• One 1394 Axis module information sheet (publication 1394 -5.5)

Remove all packing material, wedges, and braces from within and around the components. After unpacking, check the item(s) nameplate catalog number against the purchase order. Refer to Appendix D for more information on catalog numbers.

System Mounting Requirements

There are several things that you need to take into account when preparing to mount the 1394:

• The ambient te mperature of the l oc ation in which y o u will install the 1394 must not exceed 50° C (122° F).

• You must install the panel on a flat, rigid, vertical sur face that won’t be subje cted to shock, vib ration, mois ture, oil mist , dust, or corrosive vapors.

• You have to mount the system vertically.

• You need to maintain minimum clearances (see Figur e 2.1) for proper airflow , easy module access, and proper cable bend radius.

Refer to Appendix A for mounting dimensions, po wer d issipation , and envir onmental specificat ions for the 1394.

Publication 1394-5.0 — May 2000

2-4 Installing Your 1394 (applies to al l systems)

Figure 2.1 Minimum System and Axis Module Mounting Requirements

Allow 50.8 mm (2.00 in.) clearance

for airflow and installation.

ATTENTIO N: This driv e contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are

required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD contro l procedures, components can be damaged. If you are not f amiliar with static control procedures, refer to Allen-Bradley publication 8000-

4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook.

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY

EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Allow 10.0 mm (0.4 in.) side clearance.

Allow 25.4 mm (1.00 in.) clearance

at cover tab for opening and closing. (See ATTENTION: statement below)

Wire entry area for cable ground clamps and

Allow additional clearance below the system module to provide the recommended cable bend radius.

Refer to

1326 Cables for 460V AC Servo Motors

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

signal, power, and motor connections.

(publication 1326A-2.11) for more information.

Allow 10.0 mm (0.4 in.) side clearance.

Allow 76.2 mm (3.00 in.) clearance

ATTENTIO N: If you are mounting a 1394x-SJTxx- T system module, and using the SLC Interface, you

will need an additional 101.6 mm (4 in.) of cl ear ance to the left of the system module to allow for connecting the SLC interface cable (1746-C7 or -C9).

Determining Your System Mounting Hole Layout

for depth of terminator.

Publication 1394-5.0 — May 2000

To prepare your subpanel for mounting:

1. Before you mount your 1394 System, use the illustration and

table on the next page to identify your axis module combination.

Installing Your 1394 (app lies to all systems) 2-5

Figure 2.2 1394 Mounting Hole Layout

Axis Module Combination

Dimensions are in millimeters and (inches)

(1.97)

(0.00)

System module mounting holes

System

62.5

(2.46)

(1.97)

AAA

C D E

100

(3.94)

125

(4.92)

137.5 (5.41)

(5.91)

D E

150

175

(6.89)

(7.87)

200

212.5 (8.37)

(8.86)

225

250

(9.84)

275

(10.83)

outline

385

(15.16)

33.5 TYP (1.32)

Heat sink

cutout for the

AM50/75

module

only

67 TYP

(2.64)

Heat sink

cutout for the

AM50/75

module

only

Heat sink

cutout for the

AM50/75

module

only

8 TYP

(0.32)

Type of Axis Module Number of Axes Cutout Needed?

287.5

(11.32)

Heat sink

cutout for the

AM50/75

module

only

19.5

(0.768)

348

(13.70)

M6 tapped hole or 1/4-20 UNC - 2B

1394x-AM50, or -AM75, and

1394C-AM50-IH, or -AM75-IH

0no

1394x-AM03, AM04, or AM07 up to 4 no 1394x-AM50, or -A M75, and

1394C-AM50-IH, or -AM75-IH

1 yes (1394x-AM50 or -AM7 5)

no (1394C-AM50-IH or -AM75-IH) 1394x-AM03, AM04, or AM07 up to 3 no 1394x-AM50, or -A M75, and

1394C-AM50-IH, or -AM75-IH

2 yes (1394x-AM50 or -AM75)

no (1394C-AM50-IH or -AM75-IH) 1394x-AM03, AM04, or AM07 up to 2 no 1394x-AM50, or -A M75, and

1394C-AM50-IH, or -AM75-IH

3 yes (1394x-AM50 or -AM75)

no (1394C-AM50-IH or -AM75-IH) 1394x-AM03, AM04, or AM07 up to 1 no

Note: When mounting axis module combinations, you must mount the 1394x-AM50, -AM75, -AM50-IH, and -AM75-IH closest to the system

module and ahead of the 1394x-AM03, -AM04, and -AM07 axis modules.

1394x-AM50, or -A M75, and 1394C-AM50-IH, or -AM75-IH

4 yes (1394x-AM50 or -AM75)

no (1394C-AM50-IH or -AM75-IH)

2. Once you have identified your axis module combination, modify

your subpanel using the dimensions that correspond with the combination you chose in step one.

3. Go to Bonding Your System.

Publication 1394-5.0 — May 2000

2-6 Installing Your 1394 (applies to al l systems)

Mounting Your 1394 Through the Back of the Cabinet

The figure below shows an example of the typical mounting of a 1394 system with 1394x-AM50 or -AM75 axis modu les. The 13 94x-AM50 and -AM75 have heatsinks that mount through the back of the electrical cabinet.

Figure 2.3 Mounting the 1394 with heatsinks through the back of the cabinet

This configuration requires a gasket between

Note:

the 1394

-AM50 or -AM75 and the inside of

the enclosure. Use the gasket provided.

Customer-supplied

enclosure

Bonding Your System

After you have established your panel layout, you need to understand how to bond your system and subpanels. Bonding is the practice of connecting metal chassis, assemblies, frames, shields and enclosures to reduce the effects of electromagnetic interference (EMI).

Bonding Modules

Unless specifi ed, most pa ints a re not conduct i v e and a ct as i nsulat ors. To achiev e a good bond bet ween mo dul es and the subpanel, the surfaces need to be paint-free or plated. Bonding metal surfaces creates a low impedance exit path for high frequency energy. Improper bonding blocks tha t dir ect exit path and allo ws hi gh frequency energy to travel elsewhere in the cabinet. Excessive high frequency ene rgy can effect the operation of other microp rocessor controlled equipment. The illustrations below show details of recommended bonding practices for painted panels, enclosures and mounting brackets.

Publication 1394-5.0 — May 2000

Installing Your 1394 (app lies to all systems) 2-7

Figure 2.4 Bonding Examples

Subpanel

Star washer

Nut

Stud-mounting the subpanel

to the enclosure back wall

Back wall of enclosure

Welded stud

Use a wire brush to remove paint from threads to maximize ground connection.

Use plated panels or scrape paint on front of panel

Bolt-mounting a ground bus or chassis to the back-panel

Ground bus or

mounting bracket

Flat washer

Nut

Mounting bracket or

Flat washer

Nut

Stud-mounting a ground bus

or chassis to the subpanel

ground bus

Star washer

Subpanel

Tapped hole

Scrape paint on both sides of panel and use star washers.

Star washer

Flat washer

Subpanel

Welded stud

Scrape paint

Flat washer

If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole.

Bolt

Star washer

If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around each mounting hole.

Publication 1394-5.0 — May 2000

2-8 Installing Your 1394 (applies to al l systems)

Bonding Multiple Subpanels

Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span mu ltiple panels. R efer to the illustration below for recommended bonding pra ct ices.

Figure 2.5 Bonding Multiple Subpanels

Recommended:

Bond the top and bottom of each subpanel to the cabinet using 25.4 mm (1.0 in.) by 6.35 mm (.25 in.) (minimum) wire braid

Mounting Your 1394 System

Bonded cabinet ground bus to subpanel

Scrape the paint around each fastener to maximize metal-to-metal contact

The procedures in this section assume you have prepared your panel and unders tand how to bond your system. To mount your 1394 system:

1. Install the top mount ing fasteners on the subpanel for the syst em

module and all axis modules. The heads of the fa steners shou ld be at least 0.25 in. from the panel. Make sure all fasteners are properly bonded to the subpanel. Refer to Bonding Your System for more information.

2. Hang the 1394 System Module on the two fasteners on the left

side of the subpanel.

Publication 1394-5.0 — May 2000

Important: If you are mounting a GMC Turbo system module

(1394x-SJTxx-T), and using the SLC interface, you will need an additional 101.6 mm (4 in.) of clear ance to the left of the system module to allow for connecting the SLC interf ace cable (1746-C7 or -C9).

Installing Your 1394 (app lies to all systems) 2-9

3. If you are mounting a: Do this:

1394x-AM03, -AM04 or

-AM07; 1394C-AM50IH, or -AM75-IH axis module

1394x-AM50 or -AM75 axis module with the heat sink through the back of the enclosure (refer to Figure 2.3)

1. Hang the axis module on the ne xt mounting fastener.

2. Go to main step 5.

1. Remove th e paper backing from the gasket that came wi th the AM50/75 axis module.

2. Position the gasket so that the sticky side faces the axis module and the small hole side is on top.

3. Slide the gasket over the heat sink and attach it to t he back of the axi s module.

Figure 2.6 Gasket Position

gasket

4. Go to main step 4.

1394-DCLM or 1394-DIM

1. Hang the DCLM or the DIM as the last (right-most) module.

Note: If both DCLM and DIM are

mounted on the same system, the DIM should be the last mod ul e.

2. Go to main step 5.

4. Hang the AM50/75 axis module on the next mounting fastener.

5. Engage the alignment tab (re f er to Figure 2.7).

Figure 2.7 Alignment Tab

Engaged alignment tab

Publication 1394-5.0 — May 2000

2-10 Installing Your 1394 (applies to all systems)

6. Slide the slide -and-l ock mech anism on th e axis module to the left

Figure 2.8 Slide-and Lock Mechanism

until it locks into place.

Slide-and-Lock Mechanism

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

If you: Do this:

Have more axis modules for this system module

Do not have more axis modules for this system module

Go to main step 3.

Go to main ste p 8.

8. Install the lower fasteners for the system module and all axis

modules.

9. Attach the terminator to the last axis module. Slide it to the left

until it locks in place.

Figure 2.9 Attaching the Terminator

Attach the Terminator

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

Important:The terminator terminates the serial ring and provides

protection for the DC Link. The 13 94 system wi ll not operate without the terminator.

Publication 1394-5.0 — May 2000

10. Tighten al l mounting fasteners.

Installing Your 1394 (app lies to all systems) 2-11

Mounting Your 1394-DCLM

Two 1394 system power buses can be linked by connecting two DCLMs together. This procedure is application specific and requires proper implementation. Please contact your Allen-Bradley sales representative for mo re information.

When using the 1394-DCLM for ener gy st orage, the po wer plug must be installed (r efer to Figure 2.10 for location).

Figure 2.10 Locating the P o wer Plug

Allen-Bradley

DC Link Module

1394 Digital Servo Controller

System Module

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

DC Link Module

Power Plug

Mounting the External Shunt Resisto r for 5 and 10 kW System Modules

Mounting External Shunt Modules for 22 kW System Modules

If your 5 or 10 kW 1394 system module requires a means of dissipating regenerative energy that exceeds the capacity of the internal shunt resistor, install a 1394 External Shunt Resistor Kit (catalog number 1394-SR10A).

ATTENTIO N: T o a v oid the haza rd of shock or b urn and ignition of flammable material, appropriate

guarding must be provide d. These resistors can reach temperatures in excess of 350° C (662° F). Install per local codes.

To install the 1394-SR10A Shunt Resistor Kit use two M10 (3/8 in.) bolts and mount the external shunt resistor assembly vertically on a flat rigid metal surface that will not be subjected to shock, vibration, moisture, oil mist, dust or corrosive vapors.

Note: To extend the leadwire length up to 15 m (49 ft total overall

length), use MTW, 105° C, (302° F) Class H insulated wire (UL styles 3349, 3374, or equivalent).

If you are using a 22 kW system module, you must use a shunt module (1394-SR9A, -SR9AF, -SR36A or -SR36AF). An external shunt module is required for 22 kW system modules because there is no internal shunt resistor.

Publication 1394-5.0 — May 2000

2-12 Installing Your 1394 (applies to all systems)

Shunt Module Mounting Orientation

Because the shunt module d is sipat es e xcess re gener ati ve power in th e form of heat, you need to consider the following guidelines. Refer to Figure 2.11 and Figure 2.12 for shunt module spacing requirements.

Figure 2.11 Shunt Module Spacing Requirements Within an Enclosure

Temperature sensitive component

(mounted above shunt module)

Incorrect Shunt Placement

Top of cabinet

3600W Shunt Module

1394 Digital Servo Controller

ALLEN-BRADLEY

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

INPUT DC INPUT AC

CAT. PART SER.

BULLETIN 1394 3600W SHUNT MODULE

FOR FUSE REPLACEMENT USE:

BUSSMAN CAT. NO.

254 mm (10.0 in.) clearance

for airflow and installation

1394 Digital Servo Controller

3600W Shunt Module

155 mm (6.1 in.) clearance

for airflow and installation

ALLEN-BRADLEY

BULLETIN 1394 3600W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

155 mm (6.1 in.) clearance

for airflow and installation

Wire entry area

for signal, power and motor connections

155 mm (6.1 in.) clearance

for airflow and installation

Figure 2.12 Shunt Module Spacing Requirements Outside of an Enclosure

Solid protective plate

254 mm (10.0 in.) clearance

for airflow and installation

Publication 1394-5.0 — May 2000

155 mm (6.1 in.) clearance

for airflow and installation

for signal, power and motor connections

155 mm (6.1 in.) clearance

1394 Digital Servo Controller

3600W Shunt Module

155 mm (6.1 in.) clearance

for airflow and installation

ALLEN-BRADLEY

BULLETIN 1394 3600W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

Wire entry area

for airflow and installation

Enclosure

Low voltage

Communications

Control I/O wiring

Motor feedback cables

155 mm (6.1 in.) of

clearance on all sides

of the shunt module

minimum

Installing Your 1394 (app lies to all systems) 2-13

Shunt Module Mounted Outside the Cabinet

The illustration below details the proper position and cable routes for mounting the shunt module outside the cabinet.

Figure 2.13 Shunt Module Mounted Outside of the Cabinet

Customer-supplied

metal enclosure (optional)

1394 Digital Servo Controller

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

300W Shunt Module

Metal

conduit

1394 Digital Servo Controller

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE

CAT. PART SER.

INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

300W Shunt Module

Motor power

cables

360/480V AC power

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Always separate all low voltage signal

wiring from high voltage power wiring to

reduce affects of EMI and RFI.

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

8 AWG (8.4 mm2), 105 C, 600V wire

Max. Length 3.05 m (10 ft) for each wire

Twisted conductors (2 twists per foot) min. or a shielded twisted pair

Shielding is recommended for reducing the effects of EMI and RFI.

Publication 1394-5.0 — May 2000

2-14 Installing Your 1394 (applies to all systems)

Shunt Module Mounted Inside the Cabinet

The illustration below details the proper position and cable routes for mounting the shunt module inside the cabinet.

Figure 2.14 Shunt Module Mounted Inside of the Cabinet

Low voltage Communications Control I/O wiring Motor feedback cables

Always separate all low voltage signal

wiring from high voltage power wiring to

reduce affects of EMI and RFI.

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Motor power cables

360/480V

AC power

155 mm (6.1 in.) of clearance on all sides of the shunt module minimum

1394 Digital Servo Controller

300W Shunt Module

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

Status

8 AWG (8.4 mm

105 C, 600V wire Max. Length 3.05 m

(10 ft) for each wire

Use twisted conductors (2 twists per foot) min. or a shielded twisted pair.

Shielding is recommended for reducing the effects of EMI and RFI.

Publication 1394-5.0 — May 2000

ATTENTIO N: If you choose to mount the shunt module inside your cabinet, you must make sure that

the ambient temperature inside the cabinet does not exceed 50° C (122° F).

Installing Your 1394 (app lies to all systems) 2-15

Mounting the Shunt Module

The procedures in this section assume you have prepared your panel and understand ho w to bond your system. To mount your 1394 Shunt Module:

1. Install the top mounting fasteners on the subpanel for the shunt

module. The heads of both fasteners should be at least 6.35 mm (0.25 in.) fro m the panel. Make su re the fasteners ar e properly bonded to the subpanel. Refer to Bonding Your System for more information.

2. Hang the 1394 Shunt Module on the two fasteners.

3. Install the lo wer f asteners for the shunt module.

4. Tighten all mounting fasteners.

Publication 1394-5.0 — May 2000

2-16 Installing Your 1394 (applies to all systems)

Mounting Considerations for GMC and GMC Turbo Systems

Consider the following when mounting 1394 GMC and GMC Turbo Systems.

Mounting GMC and GMC Turbo Systems Next to Flex I/O



Separating low voltage communication wiring from high voltage power cable s reduces the levels of EMI and RFI. Because high voltage motor wi ring is present at the bottom of each axis module we recommend that you mount your Flex I/O modules to the left of the system module .

Figure 2.15 Mounting GMC and GMC Turbo Systems Next to Flex I/O

Preferred

Install Flex I/O to the left of the axis modules

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

DANGER

Bond DIN rail to sub panel

Preferred

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

DANGER

Screw Flex I/O connector to tapped hole in sub panel. This grounds flex cable shields.

Important: You must separate low voltage I/O from

all exposed high voltage conductors to avoid the affects of EMI and RFI.

Publication 1394-5.0 — May 2000

Chapter

Wiring System, Axis, and Shunt Modules, and Motors

(for all systems)

Chapter Objectives

Finding Additional Wiring Information for 1394 Systems

This chapter covers the following to pi cs:

• Understanding basic wiring requirements

• Determining your type of i nput power

• Grounding your 1394 system

• Connectin g system module power

• Connecting motor power to axis modules

• Connecting feedback to system modules

• Connecting your motor cables to motors

• Connecting your external shunt resistor

• Connecting your shunt module (required for 22 kW system)

The information and procedures included in this chapter apply to the following 1394 systems; GMC Turbo, GMC, 9/440 CNC, CNC Interface, and Analog Servo.

For additional wiring information on:

GMC or GMC Turbo system modules

1394 Analog Servo system modules

CNC Interface or 9/440 system modules

1394 SERCOS system modules

Refer to the following:

Chapter 4 (Wiring 1394 GMC and GMC Turbo Systems)

manual.

Chapter 5 (Wiring Your 1394 Analog Servo System)

manual.

9/Series CNC Hardware Integration and Maintenance Manual

(publication 8520-6.2).

1394 SERCOS Multi-Axis Motion Control System User Manual

(publication 1394-5.20)

in this

Publication 1394-5.0 — May 2000

3-2 Wiring System, Axis, and Shunt Modules, and Motors (for all systems)

Understanding Basic Wiring Requirements

This section contains basic wiring information for the 1394.

ATTENTIO N: Plan the installation of your system so that you ca n perform all cutting, drilling, tapping,

Important: This section contains common PWM servo system

and welding with the system removed from the enclosure. Because the system is of the open type construction, be car eful to k eep an y metal debris f rom falling into it . Metal debris or ot her foreign matte r can become lod ge d in the circuitry, which can result in damage to components.

wiring configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system confi gurations take precedence over the values and methods provided.

Publication 1394-5.0 — May 2000

Low voltage

Communications

Control I/O wiring

Motor feedback cables

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-3

Routing High and Low Voltage Cables

Be aware that when you connect and route power and signal wiring on a machine or sy stem, radiat ed noise from n earby relays (relay coils should have surge suppressors), transformers, and other electronic drives can be induced into motor or encoder feedback, communications, or other sensitiv e, low voltage signals. This can cause system faults and communication problems. To minimize the levels of radiated noise, route machine power and signal lines separately.

Figure 3.1 Routing Cables Inside Your Cabinet

Always separate all low voltage signal wiring

from high voltage power wiring to reduce affects

of EMI and RFI.

Motor power

cables

460/380V

AC power

Always cross high and low voltage conductors at 90 degree angles.

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Maximize

distance

between high

and low voltage

cables on

parallel runs

Do not run low

and high voltage

wires in the

same wire way

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Unshielded conductors

Status

Unshielded lead length

less than or equal to

76.2 mm (3.0 in.)

Publication 1394-5.0 — May 2000

3-4 Wiring System, Axis, and Shunt Modules, and Motors (for all systems)

System Module Wire Sizes

All wire sizes in this manual ar e rec omme nded minimums. Assume that wires are type MTW copper wire (machine tool wire, 75° C, minimum) per NFPA 79 unless otherwise noted . Consul t the Natio nal (or local) Electrical Code for factors related to ambient conditions, length, etc. See your Allen-Bradl ey Sales Representative for more information.

Shielding

To minimize radiated and induced noise problems or ground loops, separate feedback, command, and other shields from each other and connect them at a common machine or sys tem eart h gr ound. Connect all shields to a single earth ground point. Refer to Grounding Your 1394 System in this chapter and Appendix B for additional information.

Insulate the open-ended shields (resolver feedback cable at the resolver and velocity command cable at the servo drive) so that they do not cause ground loops.

EMI/RFI Shielding

The 1394 has an inverter carrier frequency of 5000 Hz. The drive’s output inverter switching sequence produces a carrier frequency of 10,000 Hz when measured at the motor. This can induce noise into sensitive equipment lines adjacent to it.

ATTENTIO N: This system can produce electromagnetic radiation that can cause industrial or

radio-controlled equipment to operate erratically and cause possible in jury to personnel. The 1394 system is designed to be interconnected with Allen-Bradley EMI shielded motor cables only. Do not substitute cables. The EMI shield of the motor power cabl e m u st be grounded at both ends to function properly.

EMI/RFI Bonding

The metal chassis of electrical components should be bonded to the subpanel in an electrical cabinet with metal to metal contact . The purpose of a high frequency (HF) bond is to provide HF noise currents a pa th of least impeda nce to return to the i r source.

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-5

Input Power Conditioning

You can directly connect the 1394 to a three-phase, AC power li ne. However, if certain power line conditions exist, the input power component can malfunction. If either of the foll o wing is true , you can use a line reactor or isolation-type transformer to reduce the possibility of thi s type of malfunction:

• The AC line supplying the drive has power factor correction capacitors.

• The AC line frequently experiences transient power interruptions or significant voltage spikes.

Important: Line conditioning is not typically requ ired. If you have

experienced power problems in the past on a power distribution line, you may need to consider input power conditioning.

ATTENTIO N: The 1394 does not supply line fuses or a circuit break er. They are customer -supplied items.

Branch circuit break ers or disconnect switc hes cannot provide the level of protection required by drive components. Refer to Appendix A for size and type recommendations.

Publication 1394-5.0 — May 2000

3-6 Wiring System, Axis, and Shunt Modules, and Motors (for all systems)

Determining Your Type of Input Power

Before you ground or wire y our 1394 system you must determine the type of 360/480V input power you will be connecting to. The 1394 system is designed to operate in both grounded and ungrounded environments.

Grounded Power Configuration

As shown in the figure below, the grounded power configuration allows you to ground your 3-phase power at a neutral point. Each 1394 system module has a factory-installed jumper configured for grounded power di stribution. If you det ermine that you have grounded power di stribution in your plant you do not need to modify your system.

Figure 3.2 Grounded Power Configuration

Conduit/4-Wire Cable

Ground grid or

Power distribution ground

PE1

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

PE3 (drain/shield) PE2 (wire 8) W1 (wire 3) V1 (wire 2) U1 (wire 1)

1326 motor power cable

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-7

Ungrounded Power Configuration

As shown in the figure below, the ungrounded power configuration does not allow for a neutral ground point. If you determine that you have ungr ounded power distribution in your plant, you need to move the factory-installed jumper to the ungrounded power distribution position to prevent electrostatic buildup inside the 1394. Refer to the ground jumper procedures for the system module you need to configure.

Figure 3.3 Ungrounded Power Configuration

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Conduit/4-Wire Cable

Ground grid or

Power distribution ground

PE1

PE3 (drain/shield) PE2 (wire 8) W1 (wire 3) V1 (wire 2) U1 (wire 1)

1326 motor power cable

ATTENTIO N: Ungrounded systems do not refere nce each phase potential to a power distribution ground. This can result in an unkn own potential to earth ground.

Publication 1394-5.0 — May 2000

3-8 Wiring System, Axis, and Shunt Modules, and Motors (for all systems)

Setting the Ground Jumper in a 5 or 10 kW System Module for Ungrounded Power Configurations

This procedure assumes that you have bonded and mounted your 1394x-SJT05-x or 1394x-SJT10-x system module to the su bpanel and that there is no power applied to the sy stem. To set the ground jumper for an ungrounded system:

Important: If you have grounded power distribution, you do not

need to set the ground jumper. Go to Grounding Your

1394 System.

1. Verify that all 24V control and 360/480V power has been

removed from th e syst em.

2. Open the system module door.

3. For gro und jumper

settings on this system module:

Do this:

Series A and B

Series C

1. Locate the ju mper connected to J 26 and J27 on the circuit board behind the Danger label in the upper right hand corner of the syste m module (refer to Figure 3.4 for the jumper’s location).

2. Unplug the jumper from J26.

3. Plug the jumper in GND3.

4. Go to main step 4.

1. Unplug the ri bbon c able from t he i nput wiring board (refer to Figure 3.4 for location).

2. Remove the three control board screws.

3. Remove the control board (pull it straight out from system module).

4. Locate the jump er connecting J4 and J5, and move one en d of the jumper from J5 to J6.

5. Re-install the control board. Align the guide pins in the rear of the enclosure with holes in the con tr o l boar d.

Publication 1394-5.0 — May 2000

6. Re-install the three control board screws and re-connect the ribbon cable.

7. Go to main step 4.

Note: To determine the series of your module, refer to Figure P.1

in the Preface.

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-9

4. Close the system module door.

5. Go to Grounding Your 1394 System.

Figure 3.4 Ground Jumper Locations for the 5 and 10 kW System Modules

1394-SJT

1394C-SJT (5 and 10 kW Series C)

xx-x

Upper Control Board Screw

Ribbon Cable Connector

(5 and 10 kW Series A and B)

J26

GND3

xx-x

J27

Side

Control Board

Screw

Lower Control Board Screw

J5 J6

Setting the Ground Jumper in a 22 kW System Module for Ungrounded Power Configurations

This procedure assumes that you have bonded and mounted your 1394x-SJT22-x system module to the subpanel and that there is no power applied to the system. To set the ground jumper:

Important: If you have grounded power distribution, you do not

need to set the ground jumper. Go to Grounding Your

1394 System.

1. Verify that all 24V control and 360/480V power has been

removed from th e syst em.

2. Open the system module door.

3. Disconnect both ends of the input wiring board ribbon cable.

Refer to Figure 3.5 for the location of the ribbon cable.

4. Remove the upper and lower input wiring board screws. Refer to

Figure 3.5 for the location of the screw s.

5. Remove the input wiring board.

Publication 1394-5.0 — May 2000

3-10 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Figure 3.5 Removing the Input Wiring Board in a 22 kW System Module

Disconnect both sides of the ribbon cable

Remove both input wiring board screws and remove the input wiring board

6. Locate the ground jumpe r inside the system module. Refer to the

figure below for jum p er location.

Figure 3.6 Location of the 22 kW System Module Ground Jumper

Ground Jumper

Publication 1394-5.0 — May 2000

Front edge of board

Factory default jumper position for a grounded configuration

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-11

7. Without removi ng the circu it board, unplug the jumper and mo v e

it to the ungrounded power distribution position. Refer to the figure below for the jumper positions.

Figure 3.7 22 kW System Module Jumper Positions

DO NOT REMOVE CIRCUIT BOARD FROM 1394

Jumper position for an ungrounded power configuration

Front edge of board

8. Re-install th e input wiring board.

9. Re-install the upper and lower input wiring board screws. Refer

to Figure 3.5 for the location of the screws.

10. Re-connect both ends of the input wiring board ribbon cable.

Refer to Figure 3.5 for the location of the ribbon cable.

11. Close the system module door.

12. Go to Gr ounding Your 1394 System.

Publication 1394-5.0 — May 2000

3-12 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Grounding Your 1394 System

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

We recommend that all equipment and components of a machine or process system have a common earth ground point connected to their chassis. A grounded system provides a safety ground path for short circuit protection. Ground ing your modules and panels mini mizes shock hazards to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.

Grounding your System to the Subpanel

The National Electri cal Code contains grounding req uirements, conventions, and definitions. Follo w all applicable local codes and regulations to safely ground your system. Refer to the illustration below for details on grounding your system and axis modules. Refer to Appendix B for interconnect information.

Figure 3.8 PE Safety Ground Configuration with Multiple 1394 Systems on One Panel

22 kW or

Status

DANGER

5 and 10 kW

System Modules

(Series A and B)

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

DANGER

Connect the system

module's PE and each axis

module's PE1 to the PE bar

System module

ground bar

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

DANGER

Bonded PE ground bar

comply with local codes

22 kW or

5 and 10 kW

System Modules

(Series C or later)

System module

ground bar

Bonded cabinet ground bus

All ground wiring must

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Always follow NEC and applicable local codes

Ground grid or power distribution ground

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-13

Grounding Multiple Subpanels

To ground multiple subpanels, refer to the figure below.

Figure 3.9 Subpanels Connected to a Single Ground Point

Always follow NEC and applicable local codes

Wiring System Module Power

Ground grid or power

distribution ground

The system module provides terminating points for the AC power input, logic power, feedback, and various other control signals. The slide-and-lock mechanism transfers power and commutation signals to each axis module.

Each individual application requires different wiring. This section provides guidelines for wiring your system. Because of the diversity of applications and systems, no single method of wiring is applicable in all cases.

Publication 1394-5.0 — May 2000

3-14 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Terminal Block Locations for 5 and 10 kW System Module (Series A and B)

The 5 and 10 kW system module (Series A and B) components use IEC terminals for power connections. You will wire the system and axis modules using the po we r ter mi nal block conveniently located at the bottom front of the system and a xis modules. The maximum wire size allo wed in the terminal blocks is 3.3 mm access to the i nput po wer t erminals, open th e syste m module door and look in the lower right corner. Refer to Figure 3.10 for terminal block details.

ATTENTIO N: To avoid personal injury and/or equipment damage ensure installation complies with

specifications regarding wire types, conductor sizes, branch circuit prote ction, and discon nect devi ces. The National Electrical Code (NEC) and local codes outline provi sions for safely install ing electrical equipment.

(12 AWG). To gain

Figure 3.10 Terminal Block for a 5 or 10 kW System Module (Series A and B)

Wire: Descrip ti on: Connects to terminal(s): Required (Y / N):

24V Logic A user-supplied 24V AC rms or 24V DC power source. Refer to

Appendix A

360/480V AC Input Power

Input Power Neutral

PE Ground The 1394’s ground connection to the bonded system ground

External Shunt Resistor

360/480V AC, three-phase power input Refer to system specifications for rated AC input voltage, tolerance, and source impedance.

Three-phase input neutral (present only on grounded power configurations).

bar on the subpanel. Optional 1400W external shunt resistor used to dissipate

excess regenerative energy from the system module.

for 24V input power specifications.

Appendix A

W1 and W2 Y

for

U, V, and W Y

System ground bar N

PE Y

DC+ and COL N

Publication 1394-5.0 — May 2000

Note: Refer to Appendic es A and B for information about three-phase

input fusing and circuit breaker information as related to the power input. Refer to the sec tion Connecting Your External Shunt Resistor for information about wiring the optional shunt resistor to the 5 and 10 kW system modules.

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-15

Connector Locations for 5 and 10 kW System Module (Series C)

The 5 and 10 kW system module (Series C) uses connectors instead of IEC terminals for connecting power. You will wire the system using power connectors (J1, J10, and J11) that mate with plugs (P1, P10, and P11) conveniently located on the bottom of the system module. Figure 3.11 details the location of the connectors.

ATTENTIO N: To avoid personal injury and/or equipment damage ensure installation complies with

Figure 3.11 Connectors for 5 and 10 kW System Module (Series C)

1 2

J10

1 2 3 4

1394 bottom view

Wire: Description: Maximum wire size:

24V Logic A user-supplied 24V AC rms or 24V DC power source. Refer to

Appendix A

360/480V AC Input Power

Input Power Neutral Three-phase input neutral (present only on grounded power

PE Ground The1394’s ground connection to the bonded system ground bar

External Shunt Resistor O pti onal 1400W external shunt resistor used to dissipate

360/480V AC, three-phase power input Refer to syste m specifications for rated AC input voltage, tolerance, and source impedance.

configurations).

on the subpanel.

excess regenerative energy from the system module.

for 24V input power specifications.

Appendix A

J11

1 2 3

for

System module

ground bar

3.3 mm2 (12 AWG)

(10 AWG)

5.3 mm

(10 AWG)

5.3 mm

8.4 mm

(8 AWG)

5.3 mm

(10 AWG)

Connects to

terminal(s):

J1-1 and J1-2

J10-1 (U) J10-2 (V) and J10-3 (W)

J10-4 N

System module ground bar

J11-3 and J11-1

1394 front view

Required

(Y/N):

Note: Refer to Appendic es A and B for information about three-phase

input fusing and circuit breaker information as related to the power input . Refer to the section Connecting Your External Shunt Resistor for information ab out wiring the opt ional shunt resistor to the 5 and 10 kW system modules.

Publication 1394-5.0 — May 2000

3-16 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Terminal Block Locations for a 22 kW System Module

All 22 kW system module components use IEC terminals for power connections. You will wire the system and axis modules using the power termin al block conv eniently located at the bottom front of the system and axis m odules. To gain access to the input po wer t erminals , open the system module door and look in the lower right corner. Figure 3.12 details the order of the terminal blocks.

ATTENTIO N: To avoid personal injury and/or equipment damage, ensure installa tion complie s with

Figure 3.12 Terminal Block for 22 kW System Module

Wire: Description: Maximum wire size:

3.3 mm

24V Logic A user-supplied 24V AC rms or 24V DC power source. Refer to

Appendix A

360/480V AC power input 360/480V AC , three-phase power input. Refer to

system specifications for rated AC input voltage, tolerance, and source impedance.

Input Power Neutral Three-phase input neutral (present only on grounded power

configurations).

PE Ground The1394’s ground connection to the bonded system ground bar

on the subpanel.

External Shunt Module Used to dissipate excess rege nerative energy from the system

module.

for 24V input power specifications.

Appendix A

for

(12 AWG) W1 and W2 Y

(8 AWG)

8.4 mm

(8 AWG)

8.4 mm

8.4 mm2 (8 AWG)

8.4 mm

(8 AWG)

Note: Refer to Appendic es A and B for information about thr ee-phase

input fusing and circuit breaker information as related to the power input . Refer to the section Connecting Your Shunt Module for information about wiring the shunt module to the 22 kW system module.

Publication 1394-5.0 — May 2000

Connects to terminal(s):

U, V, and W Y

System ground bar (Series A and B)

PE (Series C) N PE (Series A and B) Y System module ground

bar (Series C) DC+ and COL Y

Required (Y/N):

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-17

Required Tools and Equipment

Before you begin to connect power wiring, be sure to have the following:

• A small, flathead screwdriver

• User-supplied contactor

• User-suppli ed wiring for input power

Connecting Power Wiring for 5 and 10 kW (Series A and B) and 22 kW System Modules

To connect power wiring:

1. Connect the ground wire for the system module to the bonded

ground bus bar on the subpanel. For more information on bonding, refer to the chapter Installing Your 1394.

2. Open the front door of the system module.

3. Connect the system ground bar wire as follows: If your system m o dule is: Then:

5 and 10 kW or 22 kW (Series A and B)

22 kW (Series C)

Insert the syst em ground bar wire in the termin al block labeled PE.

Connect the system ground bar wire to the system module ground bar.

4. Connect the three-phase incoming power wires as follows: Insert the w ire la beled: Into this term inal block:

UU VV WW

5. Connect the three-phase input neutral wire as follows:

If your system m o dule is: Then:

5 and 10 kW or 22 kW (Series A and B)

Connect the three-phase input neutral wire to the bonde d system ground bar . For more inf ormation on bonding, refer to the chapter Installing Your 1394.

22 kW (Series C)

Insert the three-phase input neutral wire in the terminal block labeled PE.

Note: The three-phase input neut ral connect ion is presen t only on

grounded power configurations.

Publication 1394-5.0 — May 2000

3-18 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

6. Insert one of the 24V control power wire s into the terminal block

labeled W1.

7. Insert the other 24V control power wire into the terminal block

labeled W2.

8. Tighten and torque all six screw terminals to the values in the

following table.

System Module: Terminal Block

Designator:

Terminal Block Torque:

5 and 10 kW All 0.56 - 0.62 N-m

(5.0 - 5.6 lb-in.)

22 kW W1, W2 0.56 - 0.62 N-m

(5.0 - 5.6 lb-in.)

DC+, COL, U, V, W, PE 2.21 - 2.66 N-m

(20.0 - 24.0 lb-in.)

9. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

10. Go to the section Connecting Motor Power to Axis Modules.

Connecting Power Wiring for 5 and 10 kW System Modules (Series C)

To connect power wiring:

1. Connect the system module ground wi re from th e syste m module

ground bar to the bonded ground bus bar on the subpanel. For more information on b ondi ng, refer to the chapter Installing Your

1394.

Publication 1394-5.0 — May 2000

2. Insert the three- phase input neutral wire into connector terminal

J10-4 and tighten the J10-4 connector screw (torque value =

0.56-0.62 N-m, 5.0-5.6 lb-in.). Note: The three-phase input neut ral connect ion is presen t only on

grounded power configurations.

3. Insert the thr ee -phase incom in g power wires as follows and

tighten the three J10 connector screws.

Insert the wire labeled:

Into connector terminal:

Tighten to thi s torque value:

U J10-1 V J10-2

0.56-0.62 N-m (5.0-5.6 lb-in.)

W J10-3

4. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-19

5. Plug J10 into P10.

6. Insert one of the 24V c ontrol po wer wi res into c onnector t erminal

J1-1 and tighten the J1-1 connector screw (torque value =

0.56-0.62 N-m, 5.0-5.6 lb-in.).

7. Insert the other 24V control power wire into connector terminal

J1-2 and tighten the J1-2 connector screw (torque value =

0.56-0.62 N-m, 5.0-5.6 lb-in.).

8. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

9. Plug J1 into P1.

10. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

11. Go to Connecting Motor Power to Axis Modules.

Connecting Motor Power to Axis Modules

The procedures in this section detail how to connect motor cable flying leads to the terminals on the front of each axis mo dul e. You must use one 1326-CPx1-xxx motor power ca ble for each of your 1326Ax servo motors. Refer to the interconnect drawings in Appendix B for more in formation. The table below describes each of the terminals.

Te rmin al: Description:

U1 Motor Power A V1 Motor Power B W1 Motor Power C PE1 Axis Ground PE2 Motor Ground PE3 Overall Shield

Publication 1394-5.0 — May 2000

3-20 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Connecting Thermal and Brake Leads to Axis Modules

Axis modules provide terminating points for the motor power, thermal sensor, and brake. Axis module wiring is identical for all avai lable axis module ratings .

Figure 3.13 Locating TB1 and TB2

U1V1W1

PE1

PE2

PE3

Important: Noise filters on the mo tor thermal sensor and brake

connectors (TB1 and TB2) add capacitance (1.0

µF) from each leg of the thermal switch and motor brake leads to ground. This should be considered when selecting ground fault circuits.

Connect the motor thermal sensor and brak e l ead to the Axis Module at TB1 and TB2. Each axis module comes with a brake and thermal connector kit. Refer to Appendix D for more information.

Te rmin al: Description:

TB1-1, 2 Thermal Sensor Input from Motor Cable TB1-3, 4 Brake 24V DC from Motor Cable TB2-1, 2 Brake 24V DC from Fault System TB2-3, 4 Thermal Sensor Output to Fault System

Required Tools and Equipment

• A small, fl athead screwdriver

• One 1326-CPx1-xxx motor power cable for each axis

• One axis module connector kit (catalog number 1394-199) for thermal switch and brake inputs. You will need one kit per axis module as each kit contains two connectors.

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-21

Wiring Motor Power, Thermals and Brakes

The procedures in this section assume that your system and axis modules are already mounted. We recommend that you start at eith er the first or last axis m o dule, wire it co m p letely, and then wire the module next to it completely, and so on until they are all wired.

To wire your 1394 axis modules:

1. If your system

module is:

Then do this:

Series A or B 1. Bond one end of the axis modul e groun d

wire to the subpanel .

2. Connect the other e nd o f the ground wire to terminal block PE1.

3. Go to main step 7.

Series C 1. Connect one end of the axis module

ground wire to the syst em module ground bar.

2. Connect the other e nd o f the ground wire to terminal block PE1.

3. Go to main step 2. Refer to F igure 3.14 for main steps 2-6.

Note: For more information on bonding, refer to the chapter

Installing Your 1394.

Publication 1394-5.0 — May 2000

3-22 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Important: T o impr ov e the bo nd betwe en the mo tor cabl e shiel d

and the axis module PE ground, a cabl e shield cl amp is included with the Series C axis modules.

Figure 3.14 Series C Axis Module Cable Clamp

Cable wires

51 mm

(2.0 in.)

Bracket

screw

22 mm

(.875 in.)

Motor

cable

Braided shield exposed

Dimensions given are approximate and will vary depending on the specific installation. Keep wires as short as possible while maintaining adequate stress relief.

Clamp

screw

Cable shield clamp

Feedback

cable clamps

System module

ground bar

Axis cable clamp

1394 front view

Cable Preparation

Clamp Attachment

Wiring to Axis Module

2. Prepare one end of the motor cable for attachment to the cable

shield clamp by removing the outer insulation and braided shield from the motor cable. Ensure approximately 51 mm (2.0 in.) of the insulated cable wires are exposed (refe r to Figure 3.14).

3. Remove another 22 mm (.875 in.) of insulation to expose the

braided shield underneath for clamp attachment. Important: When cutting into the insul ation use care not to cut

into the braided shield underneath.

4. Position the cable shield clamp over the exposed braided shield

(ensure clam p screw is behind clamp and not braided shield).

5. Tighten the clamp screw. Important: Do not overtighten the clamp screw or damage to

the braided shield may result.

6. Thread the bracket screw into the bottom of the axis module and tighten.

7. Connect an axis module conn ector kit (c atalog number 1394 -199) to each motor cable that you will use. Refer to instructions that come with the kit for the specific connections.

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-23

8. On one axis, connect the wires as follows:

Insert the wire labeled: Into this terminal block:

1U1 2V1 3W1 8PE2 bare wire (no label) PE3 (Series A and B modules)

N/A (Series C) The bare wire is replaced by the ca ble shield clamp on the motor cable.

9. Tighten and torque all five screw terminals to the values in the

following table.

Axis Module: Terminal Block

Terminal Block Torque:

Designator:

2 kW, 3 kW, 5 kW All

10 kW, 15 kW All

0.56 - 0.62 N-m (5.0 - 5.6 lb-i n. )

1.55 - 2.0 N-m (14.0 - 18.0 lb-in.)

10. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten each loose wire.

11. Connect the brak e and ther mal swit ch connect or to the front-most

mating half (TB1) under its axi s modul e. Refer to Fig ure 3.13 for location of TB1. Refer to Appendix B for thermal s witch interconnect inf ormation.

12. If your motor: Do the following:

Has the brake option

1. Connect the ap propriate contro l wires to the second connector in the axis module connector kit to the appropriate cable.

2. Insert the co nnector in the rear-most mating half (TB2) for its ax is.

Does not have the brake option

3. Go to main step 13.

Go to main step 13.

Publication 1394-5.0 — May 2000

3-24 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

13. Wire yo ur thermal s witch into t he approp riate cont rol circuitr y for

monitoring purposes. Refer to Appendix B for thermal switch interconnect inf ormation.

ATTENTION: To avoid damage to your motor, monitor the thermal switch for overheat conditions.

14. If you: Do this:

Have more axis modules to wire

Have wired all of your axis modules

1. Move to the ne xt axis module.

2. Go to the main step 2. Go to Connecting Feedback to

System Modules.

Connecting Feedback to System Modules

The procedure in this section assumes that your system and axis modules are already mounted and your power is wired. Wire the commutation resolver (integral to the 1326 motor) to the system at the connectors sho wn i n the f ollowing table. You must use Allen-Bradley 1326-CCU-xxx shielded ca bles for proper operation. Refer to Appendix D for more information on connectors and accessories.

ATTENTIO N: To guard against hazard of personal injury or damage to equipment, the interconnections

between the motor a nd resolv er must be made e xactl y as shown in Appendix B. Failure to do so could c aus e loss of motor control and/or severe oscillation of the motor shaft.

Note: All CCU cables are shi pped wit h pre-p inned co nnecti ons and

loose connector housings for the system end.

If you are using this system module:

GMC Turbo or GMC J5 (axis 0), J6 (axis 1), J7 (axis 2), and J10 (axis 3).

9/440 CNC or CNC Interface

Analog Servo FB0 (axis 0), FB1 (axis 1), FB2 (axis 2), and FB3

M = mandatory, O = optional, and N/A = non applicable

Connect it to terminal(s):

Wiring 1394 GMC and GMC Turbo Systems

Refer to for locations.

FB0 (axis 0) through FB3 (axis 3). Refer to the

9/Series Integration and Maintenance Manual

(publication 8520-6.2) for more information.

(axis 3). Refer to

for locations.

System

Wiring Your 1394 Analog Servo

M, O, or N/A:

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-25

T o i mpro ve t he bond between th e motor fe edback cable sh ield and the system module PE ground, a cable shield clamp is included with the Series C system modules.

Ensure an appropriate amount of the cable insulation and braided shield is removed from the feedback cable. Place the cable wires and exposed braided shield into the cable shield clamp and tighten the clamp screw. Then thread the bracket screw into the bott om of the system module and tighten. Refer to Figure 3.14 for an illustration.

The table below provides pin-outs for the resolver connection.

Terminal: Wire Number: Color: Function:

1 1 Black Axis x R1 2 1 Shield Shield 3 2 Black Axis x S1 4 3 Green Axis x S2 5 3 Shield Shield 6 1 White Axis x R2 7 2 Shield Shield 8 2 Red Axis x S3 9 3 Black Axis x S4 10 Overall Shield Overall Shield Overall Shield

To connect motor feedback:

1. Connect the connector shells to the resolver feedback cables.

2. For each axis/motor you will use, connect one motor resolver

feedback cable to the appropriate feedback connector on the bottom of the system module control board. For the location of those connectors, refer to the drawing on the inside of t he system module door or the section Finding Additional Wiring Information for 1394 Sys tems.

3. If you are: Do th is:

Using the A QuadB option (for Analog Servo system only)

1. Connect the connec tor shells to the 1394SA15 cables. Refer to the instructions that came with the cables for more information.

2. For each AQuadB output you will use, connect one 1394-SA15 cable to the AQuadB mating slot under the system module.

3. Go to step 4.

Not using the AQuadB option

Go to step 4.

Publication 1394-5.0 — May 2000

3-26 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

4. If you have: Do this :

More motors to wire 1. Move to th e next motor.

Wired all of your motors Go to Connecting Your Motor

2. Go to the main step 1.

Cables to Motors.

Connecting Your Motor Cables to Motors

Connecting Your External Shunt Resistor

This procedure assumes that your system and axis modules are already mounted and wired. To connect your motor cables:

1. Orient the motor end of the resolver cable so that the flat on the

connector is facing the shaft of the motor .

2. Push the cable onto the appropriate mating half until it clicks.

3. Orient the motor end of the power cable so that the flat on the

connector is facing the shaft of the motor.

4. Push the cable onto the appropriate mating half until it clicks.

5. If you have: Do this :

More motors to wire 1. Move to th e next motor.

2. Repeat the steps above.

Wired all of your motors Go to the Commissioning

chapter for your specific system.

These procedures assume that your external shunt resistor is already mounted.

Publication 1394-5.0 — May 2000

To connect your external shunt resistor:

1. Remove all 24V control power, contactor enable power, and 360/

480V AC input power from the system.

2. If your system module is: Do this:

Series A and B Go to Connecting Your External

Shunt Resistor (Series A and B).

Series C Go to Connecting Your External

Shunt Resistor (Series C).

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-27

Connecting Your External Shunt Resistor (Series A and B)

1. Open the front door of the 1394 system module.

2. Remove and discard the COL/INT jumper wire from the power

terminal block in the lower right corner, as shown in the figure below.

Figure 3.15 1394 System Module Jumper Removal (Series A and B)

Jumper

3. Install the jumper block in the P1 position, which is loca ted

directly behind the Status LED, as shown in the figure below.

Figure 3.16 1394 System Module Jumper Installation (Series A and B)

Jumper block to P1

4. Install and ti ghten the resistor wire with th e fuse in the DC+

terminal on the power te rm inal block in the lower right cor ne r.

5. Install and tighten the oth er resistor wire in the COL termin al on

the power terminal block in the lower right corner.

Publication 1394-5.0 — May 2000

3-28 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Connecting Your External Shunt Resistor (Series C)

1. Locate and unplug the J11 connector on the bottom of the system

module.

2. Remove and disca rd the jumper wi re between J11 -1 and J11-2, as

shown in the f igure below.

Figure 3.17 1394 System Module Jumper Removal (Series C)

Remove jumper

J11

1 2 3

Connecting Your Shunt Mo dul e (required for 22 kW system)

1394 bottom view

3. Install the shunt resistor wire leading to the fuse in connector

J11-1.

4. Install the other shunt resistor wire in connector J11-3.

5. Tighten th e J11 connector scre ws (torque value = 0.56-0.62 N-m,

5.0-5.6 lb-in.).

The procedures in this section assume that y our shunt module is already mounted. Wiring the shunt module consists of connecting power from the system module and, depending on the shunt module you ordered, connecting power to the fan inside the module.

Required Tools and Equipment

The required tools an d equipment are:

• A small, fl athead screwdriver

• User-supplied power wiring

• The two fan jumpers that came with your 1394-SR36AF shunt

module.

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-29

Wiring the Shunt Module Power

There are three types of cable that can be used to connect the 1394 shunt module to your 1394 system module. All shunt power wiring should meet the following general specifications:

•8 AWG (8.4 mm

)

•105° C

•600V

• Maximum length of each wire is 3.05 m (10 ft.).

• If you mount the shunt module outside the cabinet, the shunt power cables and fan wiring must be inside metal conduit to minimize the levels of EMI and RFI.

To minimize the levels of EMI and RFI inside your cabinet, we recommend you:

• Use a single cable that contains a twisted pair with an overall shield. The shunt module is des igned to accept a metal conduit which will also act as an overall shield.

• Route your shunt power cables with motor power cables.

• Separate shunt po wer cables from other sensitive, low voltage signal lines.

The table belo w details your shunt powe r wiring options.

For this Type of Cable: Twist Conductors (Y/N):

Twisted pair with overall shield N Twisted pair (no shield) N Discrete conductors

Twisting cancels most of the RFI noise for the two conductors. Refer to Figure 3.18 and Figure 3.19 for

more infor mation.

Y (2 twists per foot)

To connect the shunt mod ule to the 22 kW syst e m m odule:

1. Verify that there is no 24V control or 360/480V power applied to the system.

2. Open the front door of the system module.

3. Insert one end of one user-supplied 8.4 mm

(8 AWG), 105° C

(221° F), 600V, shielded wire in the terminal block labeled COL.

4. Insert one end of the other user-supplied 8.4 mm

(8 AWG),

105° C (221° F), 600V, shielded wire in the terminal block labeled DC +.

5. Tighten both screw terminals (torque = 2.5 N-m, 22.1 lb-in.).

6. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

Publication 1394-5.0 — May 2000

3-30 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Figure 3.18 Routing Shunt Module Wiring When the Module is Outside the Cabinet

Customer-supplied

metal enclosure (optional)

155 mm (6.1 in.) of

Low voltage

Communications

Control I/O wiring

Motor feedback cables

clearance on all sides

of the shunt module

minimum

1394 Digital Servo Controller

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

300W Shunt Module

Metal

conduit

1394 Digital Servo Controller

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE

CAT. PART SER.

INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

300W Shunt Module

Motor power

cables

360/480V AC power

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Always separate all low voltage signal

wiring from high voltage power wiring to

reduce affects of EMI and RFI.

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

8 AWG (8.4 mm2), 105 C, 600V wire

Max. Length 3.05 m (10 ft) for each wire

Twisted conductors (2 twists per foot) min. or a shielded twisted pair

Shielding is recommended for reducing the effects of EMI and RFI.

Publication 1394-5.0 — May 2000

ATTENTIO N: The resistors inside the 1394 shunt module can reach temperatures in excess of 350° C

(662° F). Be sure to provide appropriate guarding to avoid hazard of shock or bur n and ignition of flammable material. Install per local codes.

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-31

Figure 3.19 Routing Shunt Module Wiring When Module is Inside the Cabinet

Low voltage Communications Control I/O wiring Motor feedback cables

Always separate all low voltage signal

wiring from high voltage power wiring to

reduce affects of EMI and RFI.

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Motor power cables

360/480V

AC power

155 mm (6.1 in.) of clearance on all sides of the shunt module minimum

1394 Digital Servo Controller

300W Shunt Module

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE

CAT. PART SER.

INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

8 AWG (8.4 mm

105 C, 600V wire Max. Length 3.05 m

(10 ft) for each wire

Use twisted conductors (2 twists per foot) min. or a shielded twisted pair.

Shielding is recommended for reducing the effects of EMI and RFI.

ATTENTIO N: To avoid burn hazard and ignition of flammable material, be sure to provide appropriate

guarding. The resistors inside the 1394 shunt module can reach temperatures in excess of 350° C (662° F). Install per local codes.

7. Open the front door of the shunt module.

8. Insert the wi re from the system module term in al block labeled

COL in the to p terminal on the left side of the shunt module. Refer to Figure 3.20 for the terminal’s location.

9. Insert the wi re from the system module term in al block labeled

DC+ in the bottom terminal on the left side of the shunt module. Refer to Figure 3.20 for the terminal’s location.

Publication 1394-5.0 — May 2000

3-32 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

Figure 3.20 Terminating Wir es at the Shunt Module

Connected to COL on the 22 kW System Module

Connected to DC + on the 22 kW System Module

10. Tighten both screw terminals (torque = 2.5 N-m, 22.1 lb-in.).

11. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten each loose wire.

12. If your shunt module: Then:

Has a Fan Go to Wiring the Shunt

Module Fan Power.

Does not hav e a fan Finish installing your system.

Publication 1394-5.0 — May 2000

Wiring System, Axis, and Shunt Modules, and Motors (for all systems) 3-33

Wiring Shunt Module Fan Power

This procedure assumes that you ha ve bonded, mou nt ed, and wired the power to your shun t module. The shunt f an can be wired for 115V or 230V input. Use 16 AWG 1.3 mm copper wire for all fan power wiring. The current draw of each shunt module fan is s h own in the table bel ow.

For this input power: The current draw is:

115V AC .2A 230V AC .1A

Important: If you mount the shunt module outside the cabinet, the

shunt fan power wiring must be inside metal conduit to minimize the levels of EMI and RFI.

To wire the shunt fan for 115V:

1. Verify that all 24V control or 360/480V input power is removed

from the system.

[machine tool, 75° C (167° F)]

2. Open the front door of the shunt module.

3. Using a flat scre w dri ver , r emove t he plate that cov ers the fa n wire

access hole located on t he bo ttom right side of the module.

4. Insert one wire from the 115V AC power supply into terminal 1.

5. Insert the other wire fro m the 115V AC power supply into

terminal 4.

6. Insert one of the ju mp er wires that came with your shunt module

into terminals 1 and 3. Refer to Figure 3.21 for the jumper’s location.

7. Insert the other jumper wire that came with your shunt module

into terminals 2 and 4. Refer to Figure 3.21 for the jumper’s location.

8. Tighten all screw terminals.

9. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

To wire the shunt fan for 230V:

1. Verify that all 24V control or 360/480V input power is removed

from the system.

2. Open the front door of the shunt module.

3. Using a flat scre w dri ver , r emove t he plate that cov ers the fa n wire

access hole located on t he bo ttom right side of the module.

4. Insert one wire from the 230V AC power supply into terminal 1.

Publication 1394-5.0 — May 2000

3-34 Wir ing System, Axis, and Shunt Modules, and Motor s (for all systems)

5. Insert the other wire fro m the 230V AC power supply into

terminal 4.

6. Insert the jumper wire that came with your shunt module into

terminals 2 and 3. Refer to Figure 3.21 for the jumper’s location.

7. Tighten all screw terminals.

8. Gently pull on each wire to make sure it does not come out of its

terminal. Re-insert and tighten any loose wires.

Figure 3.21 Wire Locations for the Shunt Module Fan

Wiring the fan for 115V

To power supply

Wiring the fan for 230V

Publication 1394-5.0 — May 2000

Chapter

Wiring 1394 GMC and GMC Turbo Systems

Chapter Objectives

Finding Additional Wiring Information for 1394 Systems

This chapter covers the following to pi cs:

• Understanding GMC and GMC Tu rbo wiring and connections

• Understanding input wiring board layout

• Connecting your communication cables

• Connecting a GMC and GMC Turbo to a 1394-DIM

• Understanding DIM signals

• Wiring and Configuring an External Drive to the 1394-DIM

This chapter provide s signal wiring and connectio n information required for the 1394 GMC and GMC Turbo system modules only.

For additional wiring information on:

1394 Analog Servo system modules

CNC Interface or 9/440 system modules

1394 SERCOS system modules

Refer to the following:

Chapter 5 (Wiring Your 1394 Analog Servo System)

manual.

9/Series CNC Hardware Integration and Maintenance Manual

(publication 8520-6.2).

1394 SERCOS Multi-Axis Motion Control System User Manual

(publication 1394-5.20)

in this

Understanding GMC and GMC Turbo Wiring and Connec ti ons

The 1394 GMC and GMC turbo contain an integrated IMC S Class motion controller that is functionally equivalent to the IMC S Class Compact. GMC and GMC T urbo system modules provide c onnections fo r the following:

• Motor feedback (resolvers)

• Auxiliary encoders (optional)

• RS-232 and RS-422 serial communications

• Remote I/O

• Flex I/O

• DH-485

• AxisLink

• SLC Interface (Direct connection) (Turbo only)

Publication 1394-5.0 — May 2000

4-2 Wiring 1394 GMC and GMC Turbo Systems

Understanding Input Wiring Board Layout

The input wiring board provides terminating points at TB1 and TB2 for the various control signals. The figure below shows the locations of the various signal ter m inations.

Figure 4.1 Input Wiring Board for 1394

SYS ENABLE

24V INPUT COM

CHASSIS

HOME0

POS 0TRAV0

NEG 0TRAV0 THERM FLT0

24V INPUT COM

CHASSIS

HOME2 POS 0TRAV2 NEG 0TRAV2

THERM FLT2

24V INPUT COM

CHASSIS REG0 5V REG0 24V

REG COM

CHASSIS

REG2 5V

REG2 24V

REG COM

CHASSIS A TEST 0 A TEST 1

A TEST COM

CHASSIS

-SJTxx-C, -C-RL and -T, -T-RL

SYS ENABLE

24V INPUT COM

CHASSIS HOME1 POS 0TRAV1

NEG 0TRAV1

THERM FLT1

24V INPUT COM CHASSIS

HOME3

POS 0TRAV3 NEG 0TRAV3

THERM FLT3

24V INPUT COM

CHASSIS REG1 5V REG1 24V REG COM CHASSIS REG3 5V

REG3 24V

REG COM CHASSIS

CHASSIS

C16

DRIVE OK1

TP2 TP3

TP1

DRIVE OK2

TB3

B16

A16

Publication 1394-5.0 — May 2000

C6 C5

Important: Use the terminal operating tool, as shown in Figure 4.3

(supplied with the system module), to help you insert and remove wires on the input wiring board.

Wiring 1394 GMC and G MC Turbo Systems 4-3

Figure 4.2 Input Wiring Board for 1394C-SJT

-L and -L-RL

SYS ENABLE

24V_INPUT_COM

CHASSIS

HOME0 POS_0TRAV0 NEG_0TRAV0

THERM_FLT0

24V_INPUT_COM

CHASSIS

NOT USED

REG0_5V

REG0_24V

REG_COM

CHASSIS

SYS ENABLE 24V_INPUT_COM

CHASSIS

NOT USED

REG1_5V REG1_24V

REG_COM CHASSIS

C16

NOT USED

TB3

B16

A16

NOT USED

DRIVE_OK1

TP3

A_TEST_0

A_TEST_1

A_TEST_COM

CHASSIS

TP2

TP1

DRIVE_OK2 CHASSIS

Important: Use the terminal operating tool, as shown in Figure 4.3

(supplied w ith the system module) , to help you i nsert and remove wires on the input wiring board.

Publication 1394-5.0 — May 2000

4-4 Wiring 1394 GMC and GMC Turbo Systems

Using the T erm inal Operating Tool to Insert Wires

Each system module you order comes with a terminal operating tool that allo ws you to easily insert your wir es in to the terminals. Refer to Appendix D for the part number.

Figure 4.3 Terminal Operating Tool

Insert wire

here

Hook

Flat tab

To use the terminal operating tool with TB1:

1. Put the hook into the hook slot with tab end of the tool to your

left.

2. Gently push the tool to the right to open the wire slot.

3. Insert the wire.

4. Gently release the tool by moving it to the left.

5. Reverse directions for TB2.

Publication 1394-5.0 — May 2000

Wiring 1394 GMC and G MC Turbo Systems 4-5

Input Wiring Board Signal Descriptions

The following tables provide descriptions of the various control signals shown in Figure 4.1. Terminate the signals you need for your applicatio n using the termi nal operatin g to ol.

Terminal connections for

Wire: Description:

SYS ENABLE

24V INPUT COM

CHASSIS Common chassis ground point. TB1 terminals 3, 9, 15,

HOME0 Home switch inputs for each axis require

POS OTRAV0

NEG OTRAV0

THERM FLT0

A 24V DC input is applied to these terminals to enable the system.

Common grounding point for 24V signals. TB1 and TB2 terminals 2,

24V DC (each), 13 mA to energize. Each input is optically isolated and filtered to minimize switch bounce. Refer to Figure 4.4.

The positive limit switch inputs for each axis require 24V DC (each), 13 mA to energize. Each input is optically isolated and filtered to minimize switch bounce. Refer to Figure 4.4.

The negative limit switch inputs for each axis require 24V DC (each), 12 mA to energize. Each input is optically isolated and filtered to minimize switch bounce. Refer to Figure 4.4.

The thermal fault switch inputs for each axis require 24V DC (each), 12 mA to energize. Each input is optically isolated and filtered to minimize switch bounce. Refer to Figure 4.4.

1394x-SJTxx-C, -C-RL and -T, -T-R L sys tems:

Either TB1 or TB2, terminal 1

8, and 14

19, 23, and 27 TB2 terminals 3, 9, 15, 19, 23, 26, and 27

TB1 - 4 (axis 0), TB2 - 4 (axis 1), TB1 - 10 (axis 2), TB2 - 10 (axis 3)

TB1 - 5 (axis 0), TB2 - 5 (axis 1), TB1 - 11 (axis 2), TB2 - 11 (axis 3)

TB1 - 6 (axis 0), TB2 - 6 (axis 1), TB1 - 12 (axis 2), TB2 - 12 (axis 3)

TB1 - 7 (axis 0), TB2 - 7 (axis1), TB1 - 13 (axis 2), TB2 - 13 (axis 3)

Terminal connections for 1394C-SJTxx-L and

-L-RL systems:

Either TB1 or TB2, terminal 1

TB1 terminals 2 and 8

TB1 terminals 3,9,19 and 27 TB2 terminals 3,19,26 and 27

TB1 - 4 (axis 0)

TB1 - 5 (axis 0)

TB1 - 6 (axis 0)

TB1 - 7 (axis 0)

Mandatory or Optional:

Mandatory

Optional

Figure 4.4 Home, Travel and Thermal Fault Inputs

Publication 1394-5.0 — May 2000

4-6 Wiring 1394 GMC and GMC Turbo Systems

Wire: Description:

REG 5V, 24V, COM

High-speed, optically-isolated filtered registration input for each axis. Inputs can be either 5 or 24V DC. Refer to Figure 4.5 for typical registration device inputs.

Note: To further reduce electrical noise, a dedicated power supply may be required for the registration sensors.

You can disable the registration input filters by removing jumpers P0-P3 on the input wiring board.

A TEST 1 A TEST 2 A TEST COM

Two software-programmable outputs are available:

A voltage corresponding to the motor

•

velocity and direction of rotation will be

1.0V/

present between these terminals.

krpm is available. Minimum impedance that can be placed across this output is 10k ohm. A voltage corresponding to positive and

•

negative current will be present between these terminals. ±2.5V DC equals 100% of motor continuous current rating.

5.0V DC

equals 200%. Minimum impedance that can

be placed across this output is 10k ohms. Any axis analog current/voltage output may be linked to either analog output using internal software parameters. By default Axis 0 velocity is linked to A TEST 0 and Axis 0 current is linked to A TEST 1.

DRIVE OK 1/2 When you apply 24V AC/DC control power

to the system and no system faults are detected, the Drive OK relay contact closes. The contact remains closed until a drive fault occurs, the DC bus voltage is lost, or you remove 360/480V input power from the system module. If a drive fault is detected or the DC bus voltage is lost, the relay contact opens. You can wire the Drive OK contacts into the Estop string to open the main power contactor if a fault occurs. The contact rating is 115V AC or 24V DC, 1A.

Te rminal connections for

-SJTxx-C, -C-RL

1394 and -T, -T-RL systems:

For 5V TB1 16 (axis 0) TB2 16 (axis 1)

Terminal connections for 1394C-SJTxx-L and

-L-RL systems:

For 5V TB1 16 (axis 0)

TB2 16 (axis 1) TB1 20 (axis 2) TB2 20 (axis 3)

For 24V TB1 17 - 18 (axis 0) TB2 17 - 18 (axis 1)

For 24V

TB1 17 - 18 (axis 0)

TB2 17 - 18 (axis 1) TB1 21 - 22 (axis 2) TB2 21 - 22 (axis 3)

For CO M (used with 5V and 24V) TB1-18 (axis 0) TB2-18 (axis 1)

For CO M

(used with 5V and 24V)

TB1-18 (axis 0)

TB2-18 (axis 1) TB1-22 (axis 2) TB2-22 (axis 3)

TB1-24 (A TEST 0) TB1-25 (A TEST 1) TB1-26 (A TEST COM)

TB1-24 (A TEST 0)

TB1-25 (A TEST 1)

TB1-26 (A TEST COM)

TB2 terminals 24 and 25 TB2 terminals 24 and 25

Mandatory or Optional:

Optional

Mandatory

Publication 1394-5.0 — May 2000

Wiring 1394 GMC and G MC Turbo Systems 4-7

Figure 4.5

Typical Registration Inputs

Important: Connections shown ar e typical on ly. Some input devices

vary in their specific connections. Consult the wiring diagram for your device.

Important: If you are using current sinking, you can only use one

device per con tr o ll er.

Connecting Your Communication Cables

The 1394 GMC and GMC Turbo system modules provide the following communication options:

• Encoder feedback

• RS-232 and RS-422 serial communications

• DH-485

• AxisLink

• Remote I/O

• Flex I/O

• SLC Interface (Direct connection) (Turbo only)

Figures 4.6, 4.7, and 4.8 show the locations of the various communication connect io ns.

Publication 1394-5.0 — May 2000

4-8 Wiring 1394 GMC and GMC Turbo Systems

Figure 4.6 Inside the 1394 GMC and GMC Turbo (catalog number 1394-SJT22)

Motion Board

Screw

Control

Status

Axislink and RS-422

Multi Drop Addresses

Remote I/O (2)

SLC IN

(Turbo Only)

Control Reset

Input Wiring

Board Screw

Control Init

SLC OUT

(Turbo Only)

Input Wiring

Board Screw

AxisLink

SW1-SW6

Switches

Application Program Lock

DH-485 (2)

Status

Board

Status

Remote I/O

Control

Reset

AxisLink

Status

Application

Program Lock

Control

Status 0 1 2

AxisLink &

RS422 Multi Drop

Control Address

Control

Init

Serial

Port

Config.

DH-485

(J1)

DH-485

(J2)

Publication 1394-5.0 — May 2000

Motion Board

Screw

Wiring 1394 GMC and G MC Turbo Systems 4-9

Figure 4.7 Bottom View of the 1394-SJT

-C and -T

1394-SJT22-T-RL System Module

AxisLink

Extended Axis Link Switch

(Turbo only)

Flex I/O

Auxillary Encoder Input Auxillary Encoder Input Auxillary Encoder Input Auxillary Encoder Input

Axis 0 (J3) Axis 1 (J4) Axis 2 (J5)

Axis 3 (J10)

Figure 4.8 Bottom View of the 1394C-SJT

AxisLink

Flex I/O

-C, -L, and -T

RS-232 and RS-422

RS-232, RS-422 and DH-485

Axis 0 (J5) Resolver Feedback Input

Axis 1 (J6) Resolver Feedback Input

Axis 2 (J7) Resolver Feedback Input

Axis 3 (J10) Resolver Feedback Input

1394C-SJT

RS-232 and RS-422

RS-232, RS-422 and DH-485

-L-RL System Module

Auxillary Encoder Input Auxillary Encoder Input

Axis 0 (J3) Axis 1 (J4)

Axis 0 (J5) Resolver Feedback Input

Publication 1394-5.0 — May 2000

4-10 Wiring 1394 GMC and G MC Turbo Systems

Encoder Feedback Wiring

These connectors accept encoder feedback signals from an optional encoder. Terminal 10 requires a user -supplied, regulated +5V DC (±5%). We recommend Belden #9728 wire or equivalent. When you use a 5 volt power supply, there is a maximum distance between the encoder and 1394 of 12.2 meters (40 feet).

The 1394 interface circuitry requires 0.325A to oper at e. Any additional devices connected to the 1394, such as incremental encoders, may require an additiona l 0.2A per device to operate. Check your device for operational requirem ents.

Make the encoder feed back connect ions ac cordin g to th e tabl e belo w. Connectors are locate d on the bottom of your sys tem module (refe r to Figure 4.7 for 1394x-SJTxx-C and -T systems and Figure 4.8 for 1394C-SJTxx-L systems).

For this axis: Connect to this terminal:

0J3 1J4 2J5 3J10

51 mm

(2.0 in.)

22 mm

(.875 in.)

Motor

cable

Cable Preparation

T o i mpro ve t he bond between th e motor fe edback ca ble sh ield and the system module PE ground, a cable shield clamp is included with the Series C system modules.

Ensure an appropriate am ount of the cable insulation and braided shield is removed from the feedback cable. Place the cable wires and exposed braided shield into the cable shield clamp and tighten the clamp screw. Then thread the bracket screw into the bottom of the system module and tighten . Refer to the figure below for an illustration.

Figure 4.9 Series C System Module Cable Clamps

Cable wires

Bracket

screw

Braided shield exposed

Dimensions given are approximate and will vary depending on the specific installation. Keep wires as short as possible while maintaining adequate stress relief.

Clamp

screw

Cable shield

clamp

Clamp Attachment

Feedback

cable clamps

System module

ground bar

1394 front view

Wiring to System Module

Publication 1394-5.0 — May 2000

Wiring 1394 GMC and G MC Turbo Systems 4-11

The following cables are available to connect auxiliary encoder feedback to the 1394 GMC and GMC Turbo:

• 1394-GE15 (from the auxiliary incremental encoder to the 139 4)

• 1394-GR04 (from the 4100-REC and -AEC to the 1394)

Refer to Appendix D for connectors and accessory part numbers. Refer to the table below for interconnection information.

Pin: Description:

1 Channel A High 2 Channel A Low 3 Channel B High 4 Channel B Low 5 Channel Z High 6 Channel Z Low 7 Strobe x 8+5V Out 9 Common Output 10 +5V Input (user supplied) 11 Common Input (user

supplied)

12 Shield

Refer to Appendix B for 1326-CEU-xxx Encoder Feedback Cable information.

Serial Communications

The 1394 provides two optically-isolated RS-232/RS-4 22 s erial ports (CHAN A/J3 and CHAN B/J4). These ports are located on the bottom of the system m odule. Refer to Figure 4.7 for 1 394-SJTxx-C and -T (Series A and B) systems and Figure 4.8 for 1394C-SJTxx-C, -L, and

-T (Series C) systems. Both ports use 9-pin, A T compatible, DB-9 connectors and are id entically wired.

You can configure CHAN A/port J3 for RS-232(C) or RS-422, and you can configure CHAN B/port J4 independently for RS-232, RS422, or DH-485. In addition, if you select RS-422 or DH-485, you can configure the port to use a termination resistor (if required). If you select DH-485, port J4 is disc onnected. You configure both ports using switches on the system module. Refer to Figure 4.10 for switch settings and Figure 4.6 f or location. Both port s are configured for RS 232 operation when they are shipped from the factory.

Publication 1394-5.0 — May 2000

4-12 Wiring 1394 GMC and G MC Turbo Systems

Figure 4.10 SW1 - SW6 (RS-232/RS-422) Switch Settings

SW1 Port J1, J2

Left No DH-485 Terminal No RS-422 Terminal No RS-422 Terminal RS-232/422 RS-232 RS-232 Right DH-485 Terminal (220Ω) RS-422 Terminal (220Ω) RS-422 Terminal (220Ω) DH-485 RS-422 RS-422

SW2 Port J4

SW3 Port J3

SW4 Port J1, J2/J4

SW5 Port J4

SW6 Port J3

When a port is configured for RS-232 operation, you can connect compatib le serial communication devices using common RS-232 cables. Refer to the table below for signal designations and Figur e

4.11 for cable recommendations. Refer to the IMC S Class Motion Control Installation and Setup Manual (publication 999-122) for multidrop a pp lication instru ctions.

RS-232 RS-422 Pin Signal Description Pin Signal Description

1 NC No Connection 1 TxD+ Transmitted Data (+) 2 TxD Transmitted Data 2 TxD- Transmitted Data (-) 3 RxD Received Data 3 RxD- Received Data (-) 4 DTR Data Terminal Ready 4 TxD+ T ransmitted Data (+) 5 Com Signal Common 5 Com Signal Common 6 DSR Data Set Ready 6 TxD+ Transmitted Data (+) 7 RTS Ready To sent 7 RxD+ Received Data (+) 8 CTS Clear To Send 8 RxD+ Received Data (+) 9 NC No Connection 9 NC No Connection

Refer to

Data Highway Connection

for DH-485 signal designations.

Publication 1394-5.0 — May 2000

Important: The RTS/ CTS and DSR/DTR signal s are int er nal ly

jumpered to allow you to use standard RS-232 cables with serial devices requiring hardware handshaking.

Wiring 1394 GMC and G MC Turbo Systems 4-13

Figure 4.11 RS-232/422 Cable Signals

RS-232C RS-422

J3/CHAN A

Serial Device

Com RxD

TxD

Shield

Recommended Cable -

Belden #9533 or Equivalent

1394 connector is 9 pin, AMP #205204-1 or equivalent.

J4/CHAN B

Serial Device

5 2 3

RxD+ RxDTxD+ TxDCom

Recommended Cable -

Belden #9503 or Equivalent

Data Highway Connection

The 1394 provides two optically-isolated ports (J1 and J2) for Data Highway 485 (DH-485) communication. Both connectors are wired identically (you can use either one). A telephone-type connector provides the interface with the following signal designations.

Pin: Signal: Description:

1 Data A Da ta A Transmi t 2 Data B Da ta B Transmi t 3 NC No Connection 4 NC No Connection 5 Tx Enab Transmitted Data Enable 6 Shield Signal Shield 7 Com Signal Common 8 NC No Connection

J3/CHAN A J4/CHAN B

4 2 7 3 5

Publication 1394-5.0 — May 2000

4-14 Wiring 1394 GMC and G MC Turbo Systems

AxisLink

AxisLink provides a net work to transfer data be twee n mu lt ipl e nodes (up to eight standard ) that a llo ws yo u to syn chroni ze complex motion applications. For example, these nodes can be eight GMC system modules, one ALEC and 7 GMC system modules, or some other combinatio n. AxisLink allows one 1394 to be u sed as a mas ter ax is for electronic gearing, camming, etc. on other systems. Using the Extended Node option in GML version 3.9.1 (or higher) with firmware v ersi on 3.5 (or hi gher) you ca n link up to 1 6 nodes. Connec t the AxisLink cable to J1 with a three pin connector as shown in Figure 4.12. The maximum end-to-end length for Daisy-Chain cabling configurations is 25 m (82 ft). The minimum distance between AxisLink nodes is 0.9 m (3 ft). Refer to Figures 4.7 and 4.8 for the AxisLink connector ’s location.

Figure 4.12 AxisLink Connections for a GMC System

Connects to J1

AxisLink Connector

Blue

Shield

Required cable

AB 1770-CD

(Belden 9463 or equivalent)

Clear

150 ohm

Install a 150 ohm termination resistor across 1 and 2 if this is the first or last module on the line.

Important: All nodes on the same AxisLink network should be

operated at the same servo update rate.

Important: Select your AxisLink node address (0-7) using the front

panel switch (see Figure 4.6 for the switch’s location) (standard mode only). Do not use positions 8 or 9.

Publication 1394-5.0 — May 2000

Wiring 1394 GMC and G MC Turbo Systems 4-15

GMC Turbo System

For those appli ca ti ons that require longer AxisLink cable lengths, the GMC Turbo offers the AxisLink Extended Length option. The Extended Length option allows the user to support up to eigh t nodes for a maximum end-to-end cable length of 125 m (410 ft) (user supplied cable). To enable the Extended Length optio n , set the switch located between the Flex I/O and AxisLink connectors on the bottom of the GMC Turbo system module. See Figure 4.7 for the switch’s location and Figure 4.14 for switch settings.

The Extended Node option allows the user to support up to 16 nodes for a maximum end-to-end cable length of 25 m (82 ft). This feature is enabled in G M L version 3.9.1 (or higher) with Firmware version

3.5 (or higher).

Important: You cannot use the Extended node option if the

Extended Length option is enabled.

Figure 4.13 AxisLink Connections for a GMC Turbo with Extended Length Option Enabled

Connects to J1

Extended Length AxisLink Connector

Yellow

Shield

Recommended cable

(Belden 9182, Carol C8014

or equivalent)

Black

Figure 4.14 AxisLink Extend Length Switch Setting

AxisLink Extended

Length Enabled

Flex I/O connector

AxisLink connector

300 ohm

Install a 300 ohm termination resistor across 1 and 2 if this is the first or last module on the line.

AxisLink Extended

Length Disabled

Bottom Edge of the1394 GMC Turbo Board

Publication 1394-5.0 — May 2000

4-16 Wiring 1394 GMC and G MC Turbo Systems

Remote I/O

The Remote I/O (RIO) interface allows the 1394 to comm unicate with Allen-Bradley position controllers or other RIO devices. Two identical connectors (CHAN A/P3 and CHAN B/P4) are provided at the top of the Moti on Dri ve Module. A thr ee-pin co nnector i s used for the interface. R efer to the Installation Guidelines for the T winaxial Cable (publication 92-D1770-BCO) for more information.

Figure 4.15 Remote I/O Connections

Remote I/O Connects to P3 or P4

Remote I/O Cable

Blue

Shield

Clear

Required cable AB 1770-CD (Belden 9463 or equivalent)

Terminal

Clamping screws

Flex I/O

Flex I/O provides general purpose discrete inputs, discrete outputs, analog inputs and analog outputs (J2). The Flex I/O Module is connected to the 1394 with a 4100-CCF1 (maximum cable length is 305 mm (12 in.) or 4100-CCF3 cable (maxi m um cable length is

0.91m (3 ft). Up to eight modules of the following types can be connected in any order.

• 1794-IB16 16 Discrete Inputs (24V DC)

• 1794-OB16 16 Discrete Outputs (24V DC)

• 1794-IE8 8 Analog Inputs

• 1794-OE4 4 Analog Outputs

150 or 82

ohm

Install a 150 or 82 ohm termination resistor across 1 and 2 if this is the first or last module on the line.

Publication 1394-5.0 — May 2000

• 1794-IA8 8 115AC Discrete Inputs

• 1794-OA8 8 115V AC Outputs

• 1794-IE 4XOE 2 Analog combination module

• 1794-IB10XOB6 Discrete combinatio n module

• 1794-OW8 Relay output module

• 1794-IF4I Isolated analog input module

• 1794-OB16P Discrete output (protected)

A 1794-ASB adapter is not required. Use a 4100-CCF1 or 4100CCF3 cable to connect the 1394 to Flex I/O modules.

Wiring 1394 GMC and G MC Turbo Systems 4-17

SLC Interface

The GMC Turbo (catalog number 1394x-SJTxx-T) can connect directly to an SLC 5/03, 5/04, or 5/05 back plane using a 1746-C7 or -C9 cable. The SLC processor recognizes the GMC Turbo as an intelligent SLC module.

The GMC Turbo supports the transfer of input/output image f i les and M0/M1 files.

If you are using: Refer to: Publication number: For this information:

GML Commander Reference

GML Commander 4.

x.x

Manual

GMLC-5.2 Programming

GML 3.

x.x

GML Programming Manual, Document Update

999-104-DU1 Programming

999-104-DU1.1 1394 SLC Interface

The figure below shows the location of the GMC Turbo to SLC connectors.

Figure 4.16 Connecting a GMC Turbo to an SLC

SLC right side connector

SLC IN connector

1746 Rack with SLC 5/03, 5/04, or 5/05

SLC OUT connector

1746-C7 or -C9 cable

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394 GMC Turbo System

ATTENTIO N: T o avoid in jury or damage to equipment do not install SLC interface cables (catalog numbers

1746-C7 and 1746-C9) while the unit(s) is powered up. ATTENTIO N: SLC Interface faults will not

automatically shut do wn or stop the axes or applic ation program operating in the 1394 GMC Turbo. These conditions must be han dle d i n a safe manner with the user’s application program.

Publication 1394-5.0 — May 2000

4-18 Wiring 1394 GMC and G MC Turbo Systems

Figure 4.17 Configurations for Connecting a GMC Turbo to an SLC

SLC right side connector

1746 Rack with SLC 5/03, 5/04, or 5/05

1394 SLC OUT connector

1746 Rack with SLC 5/03, 5/04, or 5/05

SLC left side connector

1394 SLC IN connectors

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394 GMC Turbo System

SLC right side connectors

1746 Rack

1394 SLC IN connector

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394 GMC Turbo System

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394 GMC Turbo System

SLC right side connector

1746 Rack with

DANGER

SLC 5/03, 5/04, or 5/05

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

1394 SLC IN connector

1394 GMC Turbo System

Use cable 1746-C7 or 1746-C9 to connect the 1394x-SJTxx-T to the SLC.

Important: The figure above shows connection informati on only

and does not imply a specific mounting configuration.

Publication 1394-5.0 — May 2000

Wiring 1394 GMC and G MC Turbo Systems 4-19

Connecting a GMC and GMC Turbo to a 1394-DIM

1394 Axis Modules

1394 GMC or GMC Turbo System Module

GML

RS-232/-422

See Figure 4.32 for Auxiliary Encoder input pin-outs and Figure B-1

Appendix B

( Encoder Connectors on a bottom view of the 1394 GMC/GMC Turbo system module.

) to view the Auxiliary

The 1394-DIM acts as an interface between one 1394 GMC/GMC Turbo system module and the external axis dr ive(s).

On the 1394x-SJTxx-C, -C-RL, -T, and -T-RL, the 1394-DIM acts in place of one to four axis modul es. On the 1 394C-SJTxx-L and -L-RL the 1394-DIM acts in place of one axis module. The 1394-DIM passes a standard servo out put sign al from th e system module to each external drive connected to the 1394-DIM. Using a 1394-DIM as part of a 1394 system lets you control ext ernal drives and motors of any size.

1394-DIM System Example

The figure below shows an exa mp le of a 139 4 GMC/GMC T urbo System after connecting a 1394-DIM.

Figure 4.18 A 1394-DIM Connected to a GMC or GMC Turbo

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Status

DANGER

Axis 1

Axis 0

1394-DIM

Axis connections

located on the

underside of DIM

1326AB

1394-DIM ground connector

+/- 10V reference Drive Enable Drive OK (see Figure 4.29)

DIM A axis connector

DIM B axis connector

Servo Amplifier

Encoder

Servo Amplifier

Encoder

Motor

1394-GE15

Encoder Feedback Cable

1326-CEU-xxx (if A-B 845H)

Figure 4.18 shows the 1394-DIM connected to a 1394 GMC Turbo with two 1394 axis modules. A 1326AB-Bxxxx motor is directly connected to each of the 1394 axis modules. Two servo amplifiers with motors are connected to the 1394-DIM. It can accept two because there are two axis modules connected to the 1394 GMC Turbo. The encoders attached to the motors have encoder feedback cables connected to the system module.

Publication 1394-5.0 — May 2000

4-20 Wiring 1394 GMC and G MC Turbo Systems

1394 Axis Modules

1394 GMC or GMC

Turbo System Module

1394-DIM with 1398-DDM-

xxx

System Example

Figure 4.19 shows the 1394-DIM connected to a 1394 GMC Turbo with two 1394 axis modules and a 1398-DDM-xxx servo controller. A 1326AB-Bxxxx motor is directly connected to each of the 1394 axis modules. One servo amplifier with motor is connected to the 1394-DIM.

Figure 4.19 1394-DIM with 1398-DDM-

Status

DANGER

RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.

Axis 0

Axis 1

Axis 2

Encoder

xxx

System Example

1394-DIM

J1 Breakout Board

(Refer to Figure 4.20)

1326AB

1326-CEU-

xxx

(If A-B 845H)

9101-1391

Encoder

Motor

Power

1398-DDM-

TB1

H, F, Y, or N Series Motor

xxx

1394-GE15

Encoder

1326AB

1326-CEU-

xxx

J2 Breakout

Board

9101-1392

(If A-B 845H)

Figure 4.20 shows the J1 breako ut board intercon nect detail s between the 1394-DIM and the 1398-DDM-xxx. Refer to ULTRA 200 User Manual (publication 1398-5.0) and ULTRA 100 User Manual (publication 1398 -5.2) for more information.

Publication 1394-5.0 — May 2000

Rockwell Automation 1326 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Preface

Who Should Use this Manual

Purpose of this Manual

Contents of this Manual

Related Documentation

Conventions Used in this Manual

Module Series Designator

1394 Product Receiving and Storage Responsibility

Allen-Bradley Support

Local Product Support

Technical Product Assistance

The 1394 System

Series Note

Safety Precautions

1394 System Overview

GMC System

CNC Interface System

SERCOS System

Analog Servo System

9/440 CNC System

What is a 1394 System?

System Modules

Axis Modules

External Shunt Module (used with 22 kW System)

1326AB Motors

1326AS Motors

1326AH Motors

Drive Inter face Module

DC Link Module

Standard Features of the 1394

Control

Power

Integration

Chapter Objectives

Complying With European Union Directives

EMC Directive

Low Voltage Directive

Before Mounting Your System

Storing Your 1394 Before Installation

Unpacking Modules

System Mounting Requirements

Determining Your System Mounting Hole Layout

Mounting Your 1394 Through the Back of the Cabinet

Bonding Your System

Bonding Modules

Bonding Multiple Subpanels

Mounting Your 1394 System

Mounting Your 1394-DCLM

Mounting the External Shunt Resisto r for 5 and 10 kW System Modules

Mounting External Shunt Modules for 22 kW System Modules

Shunt Module Mounting Orientation

Shunt Module Mounted Outside the Cabinet

Shunt Module Mounted Inside the Cabinet

Mounting the Shunt Module

Mounting Considerations for GMC and GMC Turbo Systems

Chapter Objectives

Finding Additional Wiring Information for 1394 Systems

Understanding Basic Wiring Requirements

Routing High and Low Voltage Cables

System Module Wire Sizes

Shielding

EMI/RFI Shielding

EMI/RFI Bonding

Input Power Conditioning

Determining Your Type of Input Power

Grounded Power Configuration

Ungrounded Power Configuration

Setting the Ground Jumper in a 5 or 10 kW System Module for Ungrounded Power Configurations

Setting the Ground Jumper in a 22 kW System Module for Ungrounded Power Configurations

Grounding Your 1394 System

Grounding your System to the Subpanel

Grounding Multiple Subpanels

Wiring System Module Power

Terminal Block Locations for 5 and 10 kW System Module (Series A and B)