Rockwell Automation 1326 User Manual

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

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