Rockwell Automation 1394 User Manual

1394 SERCOS Interface Multi-Axis Motion Control System

(Catalog Numbers 1394C-SJT05-D, 1394C-SJT10-D, 1394C-SJT22-D)

Installation Manual

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley or liability (to include intellectual property liability) 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

(available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.



does not assume responsibility

Throughout this manual we use notes to make you aware of safety considerations:

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

IMPORTANT

Allen-Bradley is a registered trademark of Rockwell Automation. ControlLogix, Logix, RSLogix, SoftLogix, and SCANport are trademarks of Rockwell Automation. Bussmann is a registered trademark of Cooper Industries, Inc. Hiperface is a registered trademark of Stegmann, Inc. SERCOS interface is a trademark of the Interests Group SERCOS interface e.V. (IGS). Windows is a registered trademark of Microsoft Corporation. UL is a registered trademark of Underwriters Laboratories.

Identifies information that is critical for successful application and understanding of the product.

Preface

Installing Your 1394 SERCOS Interface System

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

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

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

Product Receiving and Storage Responsibility . . . . . . . . . . . P-2

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

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

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

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

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

Comments Regarding this Manual . . . . . . . . . . . . . . . . . P-4

Chapter 1

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

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

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

Meeting CE Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-2

Low Voltage Directive. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

Before Mounting Your System . . . . . . . . . . . . . . . . . . . . . . 1-5

Unpacking Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

System Mounting Requirements. . . . . . . . . . . . . . . . . . . 1-6

Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-7

Determining Your System Mounting Hole Layout. . . . . . 1-8

Mounting Your 1394 Through the Back of the Cabinet. . 1-9

HF Bonding Your System. . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . 1-11

Planning Your Panel Layout . . . . . . . . . . . . . . . . . . . . . . . 1-12

Establishing Noise Zones . . . . . . . . . . . . . . . . . . . . . . 1-12

Cable Categories for the 1394 . . . . . . . . . . . . . . . . . . . 1-14

Mounting Guidelines to Reduce Electrical Noise . . . . . 1-15

Mounting Your 1394 SERCOS interface System . . . . . . . . . 1-18

Mounting Your External Shunt Resistor Kit . . . . . . . . . . . . 1-21

Chapter 2

1394 SERCOS Interface Connector Data

i Publication 1394-IN002B-EN-P — February 2004

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

Locating System Module Connectors and Indicators . . . . . . 2-2

System Module Connector Pin-outs . . . . . . . . . . . . . . . . . . 2-4

System Module Connectors . . . . . . . . . . . . . . . . . . . . . . 2-4

Discrete Input Connector Pin-out . . . . . . . . . . . . . . . . . 2-5

Relay Output Connector Pin-out . . . . . . . . . . . . . . . . . . 2-6

Analog Output Connector . . . . . . . . . . . . . . . . . . . . . . . 2-7

Motor Feedback Connector Pin-outs . . . . . . . . . . . . . . . 2-8

Auxiliary Feedback Connector Pin-outs . . . . . . . . . . . . . 2-9

System Module Input Power Pin-outs . . . . . . . . . . . . . 2-11

SCANport Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Locating Axis Module Connectors and Indicators . . . . . . . 2-12

ii Table of Contents

Connecting Your 1394 SERCOS Interface System

Axis Module Connector Pin-outs. . . . . . . . . . . . . . . . . . . . 2-13

Axis Module Connectors . . . . . . . . . . . . . . . . . . . . . . . 2-13

Motor Power and Brake Connector Pin-outs. . . . . . . . . 2-13

Understanding I/O Specifications . . . . . . . . . . . . . . . . . . . 2-15

Discrete Input Specifications . . . . . . . . . . . . . . . . . . . . 2-15

Analog Output Specifications. . . . . . . . . . . . . . . . . . . . 2-17

Drive System OK Relay Specifications . . . . . . . . . . . . . 2-18

Motor Brake Relay Specifications. . . . . . . . . . . . . . . . . 2-19

SERCOS Connection Specifications . . . . . . . . . . . . . . . 2-20

Logic Power Input Specifications . . . . . . . . . . . . . . . . . 2-20

Understanding Feedback Specifications. . . . . . . . . . . . . . . 2-21

Motor and Auxiliary Feedback Specifications . . . . . . . . 2-21

Chapter 3

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

Understanding Basic Wiring Requirements . . . . . . . . . . . . . 3-1

Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . 3-2

Routing Power and Signal Wiring . . . . . . . . . . . . . . . . . 3-2

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

Determining Your Type of Input Power . . . . . . . . . . . . . . . 3-4

Grounded Power Configuration. . . . . . . . . . . . . . . . . . . 3-4

Ungrounded Power Configuration . . . . . . . . . . . . . . . . . 3-5

Setting the Ground Jumper in Ungrounded Power

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Setting the Ground Jumper in 5 and 10 kW

System Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Setting the Ground Jumper in 22 kW System Modules . . 3-7

Grounding Your 1394 SERCOS Interface System . . . . . . . . . 3-9

Grounding Your System to the Subpanel . . . . . . . . . . . . 3-9

Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . 3-10

Motor Power Cable Shield Termination . . . . . . . . . . . . 3-11

Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . 3-13

1394 Power Wiring Requirements . . . . . . . . . . . . . . . . 3-13

Connecting Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Connecting Power Wiring for 5 and 10 kW

System Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Connecting Power Wiring for 22 kW System Modules . 3-17

Connecting Motor Power, Thermal Switch, and Brake . . . . 3-20

Connecting the Ground Wire and Cable Clamp . . . . . . 3-20

Wiring the Motor Power Connector . . . . . . . . . . . . . . . 3-22

Wiring the TB1/TB2 Connectors (1326AB/AS Motors). . 3-23

Wiring the Relay Outputs Connector . . . . . . . . . . . . . . 3-25

Understanding Feedback and I/O Cable Connections . . . . 3-26

Motor Feedback Connector Pin-outs . . . . . . . . . . . . . . 3-26

Wiring Feedback Connectors. . . . . . . . . . . . . . . . . . . . 3-29

Attaching the Cable Shield Clamp . . . . . . . . . . . . . . . . 3-31

Wiring Discrete Input Connectors . . . . . . . . . . . . . . . . 3-32

Publication 1394-IN002B-EN-P — February 2004

Troubleshooting Status Indicators

Specifications and Dimensions

Table of Contents iii

Understanding External Shunt Connections. . . . . . . . . . . . 3-34

Connecting Your SERCOS Fiber-Optic Cables . . . . . . . . . . 3-35

Chapter 4

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

Understanding How to Detect a Problem . . . . . . . . . . . . . . 4-1

Troubleshooting System and Axis Module LEDs . . . . . . . . . 4-2

Troubleshooting the SERCOS Network Status LED. . . . . . . . 4-4

Troubleshooting System and Axis Module Faults. . . . . . . . . 4-5

System Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Axis Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Troubleshooting General System Problems . . . . . . . . . . . . 4-11

Appendix A

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

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

System Module Power Specifications . . . . . . . . . . . . . . . A-2

Axis Module Power Specifications . . . . . . . . . . . . . . . . . A-3

Axis Module Series Information. . . . . . . . . . . . . . . . . . . A-3

Circuit Breaker Specifications . . . . . . . . . . . . . . . . . . . . A-4

Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Contactor (M1) Specifications . . . . . . . . . . . . . . . . . . . . A-5

Relay Contact Specifications . . . . . . . . . . . . . . . . . . . . . A-6

24V Logic Input Power Specifications . . . . . . . . . . . . . . A-6

Input Transformer Specifications for 24V Logic Power . . A-6

1394 System Power Dissipation Specifications . . . . . . . . A-7

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Environmental Specifications. . . . . . . . . . . . . . . . . . . . . A-8

AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . A-9

External Shunt Module/Resistor Specifications . . . . . . . . A-9

Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . A-10

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

1394 System Module Dimensions . . . . . . . . . . . . . . . . A-11

Axis Module Dimensions . . . . . . . . . . . . . . . . . . . . . . A-12

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iv Table of Contents

Interconnect Diagrams

Catalog Numbers and Accessories

Appendix B

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

1394 SERCOS Interface Interconnect Diagram Notes . . . . . . B-2

Power Interconnect Diagrams. . . . . . . . . . . . . . . . . . . . . . . B-3

Shunt Module Interconnect Diagrams . . . . . . . . . . . . . . . . . B-4

Axis Module/Motor Interconnect Diagrams . . . . . . . . . . . . . B-6

Thermal Switch and Brake Interconnect Diagrams. . . . . . . . B-9

Understanding Motor Thermal Switches . . . . . . . . . . . . . B-9

How Your Feedback Cable Affects Thermal Switch

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Thermal Switch Interconnect Diagrams . . . . . . . . . . . . . B-9

Brake Interconnect Diagrams . . . . . . . . . . . . . . . . . . . B-14

Appendix C

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

1394 System Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

1394 Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

RSLogix 5000 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

External Shunt Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Motor Feedback Cables. . . . . . . . . . . . . . . . . . . . . . . . . C-4

MP-Series Motor Brake Cable . . . . . . . . . . . . . . . . . . . . C-4

SERCOS Interface Fiber-Optic Cables . . . . . . . . . . . . . . . C-4

Motor End Connector Kits . . . . . . . . . . . . . . . . . . . . . . . C-5

1394 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Publication 1394-IN002B-EN-P — February 2004

Preface

Read this preface to familiarize yourself with the rest of the manual. The preface covers the following topics:

• Who Should Use this Manual

• Purpose of this Manual

• Contents of this Manual

• Product Receiving and Storage Responsibility

• Related Documentation

• Conventions Used in this Manual

• Allen-Bradley Support

Who Should Use this Manual

Purpose of this Manual

Use this manual for designing, installing, and wiring your 1394 SERCOS interface Multi-Axis Motion Control System. The manual is intended for engineers or technicians directly involved in the installation and wiring of the 1394.

If you do not have a basic understanding of the 1394, contact your local Allen-Bradley representative for information on available training courses before using this product.

This manual provides the mounting, wiring, and connecting procedures for the 1394 and standard Rockwell Automation/AllenBradley motors recommended for use with the 1394.

For power up procedures, troubleshooting, and system integration with the ControlLogix and SoftLogix SERCOS module/PCI card (see table below) refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN024x-EN-P). Manuals are available electronically (as a .pdf) or in hardcopy from www.theautomationbookstore.com.

Interface ControlLogix Module SoftLogix PCI Card

SERCOS interface 1756-MxxSE 1784-PM16SE

1 Publication 1394-IN002B-EN-P — February 2004

P-2 Preface

Contents of this Manual

Refer to the following listing for the descriptive contents of this installation manual.

Chapter Title Contents

Preface

Appendix A Specifications and Dimensions

Appendix B Interconnect Diagrams

Appendix C

Installing Your 1394 SERCOS Interface System

1394 SERCOS Interface Connector Data

Connecting Your 1394 SERCOS Interface System

Troubleshooting Status Indicators

Catalog Numbers and Accessories

Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended.

Provides system mounting information for the 1394 SERCOS interface components.

Provides system module and axis module connector locations, signal descriptions, and I/O specifications.

Provides connection and wiring information for the 1394 SERCOS interface components.

Provides troubleshooting tables that define the 1394 status LEDs and fault codes.

Provides mounting dimensions, and power, weight, environmental, and functional specifications for the 1394.

Provides power, shunt, and drive/motor interconnect diagrams for the 1394.

Provides catalog numbers and descriptions of the 1394 and related products.

Product Receiving and Storage Responsibility

You, the customer, are responsible for thoroughly inspecting the equipment before accepting 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 notifying the freight agent. Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment.

Store the product in its shipping container prior to installation. If you are not going to use the equipment for a period of time, store using the following guidelines.

• Use a clean, dry location

• Maintain an ambient temperature range of -40 to 70° C

(-40 to 158° F)

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

• Store it where it cannot be exposed to a corrosive atmosphere

• Store it in a non-construction area

Publication 1394-IN002B-EN-P — February 2004

Preface P-3

Conventions Used in this Manual

The conventions starting below are used throughout this manual.

• Bulleted lists such as this one provide information, 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

Publication 1394-IN002B-EN-P — February 2004

P-4 Preface

Allen-Bradley Support

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 Allen-Bradley representative for:

• Sales and order support

• Product technical training

• Warranty support

• Support service agreements

Technical Product Assistance

If you need technical assistance, contact your local Allen-Bradley representative or Rockwell Automation Technical Support at (440) 646-5800 / www.ab.com/support. Please have the catalog numbers of your products available when you call.

Comments Regarding this Manual

To offer comments regarding the contents of this manual, go to www.ab.com/manuals/gmc and download the Motion Control Problem Report form. Mail or fax your comments to the address/fax number given on the form.

Publication 1394-IN002B-EN-P — February 2004

Chapter

Installing Your 1394 SERCOS Interface System

Chapter Objectives

This chapter covers the following topics:

• Complying With European Union Directives

• Before Mounting Your System

• Unpacking Modules

• System Mounting Requirements

• HF Bonding Your System

• Planning Your Panel Layout

• Mounting Your 1394 SERCOS interface System

• Mounting Your External Shunt Resistor Kit

ATTENTION

The following information is a guideline for proper installation. The National Electrical Code and any other governing regional or local codes overrule this information. The Allen-Bradley Company cannot assume responsibility for the compliance or the noncompliance with any code, national, local or otherwise, for the proper installation of this system or associated equipment. If you ignore codes during installation, hazard of personal injury and/or equipment damage exists.

1 Publication 1394-IN002B-EN-P — February 2004

1-2 Installing Your 1394 SERCOS Interface System

Complying With European Union Directives

If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply.

For more information on the concept of electrical noise reduction, refer to System Design for Control of Electrical Noise Reference Manual (publication GMC-RM001x-EN-P).

EMC Directive

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

• EN 50081-2 EMC - Emission Standard, Part 2 - Industrial

Environment

• EN 50082-2 EMC - Immunity Standard, Part 2 - Industrial

Environment

• EN 61800-3 EMC - Adjustable Speed Electrical Power Drive

Systems - Second Environment, Restricted Distribution Class

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

Meeting CE Requirements

To meet CE requirements, the following components are required:

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

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

• For MP-Series and 1326AB (M2L/S2L) motors use 2090 series

motor power and feedback cables and terminate the cable shields to the chassis clamps provided (refer to Chapter 3 for wiring instructions).

• For 1326AB/AS (resolver) motors use 1326 series motor power

and feedback cables and terminate the cable shields to the chassis clamps provided (refer to Chapter 3 for wiring instructions).

• Combined motor power cable length for all (up to 4) axes must

not exceed 360 m (1181 ft).

Publication 1394-IN002B-EN-P — February 2004

Installing Your 1394 SERCOS Interface System 1-3

• Install the 1394 SERCOS interface system inside an enclosure. Run

input power wiring (grounded to the enclosure) in conduit

outside of the enclosure. Separate signal and power cables as

shown in Planning Your Panel Layout of this chapter.

Low Voltage Directive

These units are tested to meet Council Directive 73/23/EEC Low Voltage Directive. The EN 50178-1 Electronic Equipment for Use in

Power Installations and EN 60204-1 Safety of Machinery-Electrical Equipment of Machines, Part 1-Specification for General Requirements

standards apply in whole or in part.

Refer to Appendix B of this document for interconnect information.

1394 System Component

This section provides an overview of the 1394 system components and a typical installation.

Overview

1394 Component: Catalog Numbers: Description:

System Module 1394C-SJTxx-D

Axis Module 1394C-AMxx The 1394 Axis Modules are available with 2, 3, 5, 15.6, and 23.8 kW continuous output.

ControlLogix/ SoftLogix Platforms

RSLogix™ 5000 software

Servo Motors

Cables

AC Line Filters

External Shunt Modules

1756-MxxSE module 1784-PM16SE PCI card

9324-RLD300ENE

MP-Series, 1326AB, and 1326AS servo motors

Motor Power, Feedback, and Brake cables

Fiber-Optic cables

SP-74102-006-01 The SP-74102-006-01 three-phase AC line filter is suitable for 1394C-SJT05-D system modules. SP-74102-006-02 The SP-74102-006-02 three-phase AC line filter is suitable for 1394C-SJT10-D system modules. SP-74102-006-03 The SP-74102-006-03 three-phase AC line filter is suitable for 1394C-SJT22-D system modules.

1394-SR10A

1394-SR-xxxx One Bulletin 1394 external passive shunt module is required for each 1394C-SJT22-D system module.

The 1394 multi-axis System Modules are available with 5, 10, or 22 kW continuous output and 360V/ 480V ac input power. Each system module accommodates up to four axis modules.

The SERCOS interface module/PCI card serves as a link between the ControlLogix/SoftLogix platform and 1394 system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (SERCOS) protocol over a fiber-optic cable.

RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of controllers.

The MP-Series (low inertia) 460V, 1326AB (M2L/S2L), and 1326AB (resolver) motors are available for use with the 1394 SERCOS interface system.

Motor power, feedback, and brake cables include integral molded, bayonet style, quick connect/ quick-release connectors at the motor. Power and brake cables have flying leads on the drive end and straight connectors that connect to servo motors. Standard feedback cables have a straight connector on the motor end and flying leads that wire to a feedback connector on the drive end.

SERCOS fiber-optic cables are available in enclosure only, PVC, nylon, and glass with connectors at both ends.

The Bulletin 1394-SR10A external passive shunt resistor is available when the 1394C-SJT05/10-D internal shunt capability is exceeded.

Note: Refer to Appendix C for a complete list of catalog numbers for

the 1394 components listed above.

Publication 1394-IN002B-EN-P — February 2004

1-4 Installing Your 1394 SERCOS Interface System

The typical 1394 SERCOS interface system installation includes the following components.

Figure 1.1 Typical 1394 SERCOS interface System Installation

ControlLogix Chassis

1756-MxxSE Interface

SERCOS ring

ControlLogix Programming Network

SERCOS System Module

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

DANGER

1394C-SJT

Workstation with RSLogix 5000

-D

1326AB, 1326AS, and MPL-Bxxxx Motors

(Resolver-based or absolute high resolution feedback)

SERCOS System Module

1394C-SJTxx-D

SERCOS ring

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

DANGER

1326AB, 1326AS, and MPL-Bxxxx Motors

(Resolver-based or absolute high resolution feedback)

Publication 1394-IN002B-EN-P — February 2004

Installing Your 1394 SERCOS Interface System 1-5

Before Mounting Your System

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

• how to unpack the 1394 system and axis modules

• the system mounting requirements

• how to determine your mounting hole layout

Unpacking Modules

Each 1394 system module ships with the following:

• One system module

• One system terminator

• One installation manual (publication 1394-IN002x-EN-P)

• Mating power connectors (5 and 10 kW only)

• Mating I/O and feedback connectors

• Cable shield grounding clamps

Each 1394 axis module ships with the following:

• One 1394 axis module

• TB1 and TB2 connectors

• Cable shield grounding clamp

• 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 C for more information on catalog numbers.

Publication 1394-IN002B-EN-P — February 2004

1-6 Installing Your 1394 SERCOS Interface System

System Mounting Requirements

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

• The ambient temperature of the location in which you will install

the 1394 must not exceed Environmental Specifications as shown in Appendix A.

• You must install the panel on a flat, rigid, vertical surface that

won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors.

• You have to mount the system vertically.

• You need to maintain minimum clearances (see Figure 1.2) for

proper airflow, easy module access, and proper cable bend radius.

• The 1394 can operate at elevations to 1000 m (3300 ft) without

derating, however, the continuous current rating must be de-rated by 3% for each additional 300 m (1000 ft) up to 3000 m (10,000 ft). Consult your local Allen-Bradley representative prior to operating at over 3000 m (10,000 ft)

Refer to Appendix A for mounting dimensions, power dissipation, and environmental specifications for the 1394.

ATTENTION

Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

Publication 1394-IN002B-EN-P — February 2004

Installing Your 1394 SERCOS Interface System 1-7

Ventilation Requirements

This section provides information to assist you in sizing your cabinet and locating your 1394 system components. Refer to Figure 1.2 for minimum clearance requirements for power rail components mounted inside the cabinet.

Figure 1.2 Minimum System and Axis Module Mounting Requirements

50.8 mm (2.0 in.) clearance for airflow and installation

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 (1.0 in.) clearance

at cover tab for opening and closing.

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

to the Motion Control Selection Guide (publication GMC-SG001x-EN-P) for more information.

Status

DANGER

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

Wire entry area for cable ground clamps

and signal, power, and motor connections.

IMPORTANT

Refer to Appendix A for 1394 power dissipation specifications.

Allow 10.0 mm (0.4 in.) side clearance

Allow 76.2 mm (3.0 in.) clearance

for depth of terminator.

If the cabinet is ventilated, use filtered or conditioned air to prevent the accumulation of dust and dirt on electronic components. The air should be free of oil, corrosives, or electrically conductive contaminates.

Publication 1394-IN002B-EN-P — February 2004

1-8 Installing Your 1394 SERCOS Interface System

Determining Your System Mounting Hole Layout

Based on your actual axis module combination, use the following illustration and table to modify your subpanel using the dimensions that correspond to that specific combination.

Figure 1.3 1394 Mounting Hole Layout

Dimensions are in millimeters and (inches)

System

outline

385

(15.16)

Axis Module Combination

Type of Axis Module Number of Axes Cutout Needed?

1394x-AM50, or -AM75, and

1394C-AM50-IH, or -AM75-IH 1394x-AM03, AM04, or AM07 up to 4 no 1394x-AM50, or -AM75, and

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

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

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

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

(1.97)

(0.00)

System module mounting holes

33.5 TYP (1.32)

62.5

100

(2.46)

(3.94)

(1.97)

AAA

C D E

Heatsink

cutout for the

AM50/75

module

only

67 TYP

(2.64)

137.5 (5.41)

125

150

(4.92)

(5.91)

D E

Heatsink

cutout for the

AM50/75

module

only

175

(6.89)

200

(7.87)

cutout for the

AM50/75

212.5 (8.37)

225

(8.86)

Heatsink

module

only

8 TYP (0.32)

250

(9.84)

275

(10.83)

cutout for the

AM50/75

287.5

(11.32)

Heatsink

module

only

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

0no

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

19.5

(0.768)

348

(13.70)

Publication 1394-IN002B-EN-P — February 2004

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.

Installing Your 1394 SERCOS Interface System 1-9

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 modules. The 1394x-AM50 and -AM75 have heatsinks that mount through the back of the electrical cabinet.

Figure 1.4 Mounting the 1394 with heatsinks through the back of the cabinet

Note: This configuration requires a gasket between

the 1394x-AM50 or -AM75 and the inside of the enclosure. use the gasket provided.

Customer-supplied enclosure

HF Bonding Your System

Bonding is the practice of connecting metal chassis, assemblies, frames, shields and enclosures to reduce the effects of electromagnetic interference (EMI). For more information on the concept of highfrequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to System Design for Control of Electrical Noise (publication GMC-RM001x-EN-P).

Bonding Modules

Unless specified, most paints are not conductive and they act as insulators. To achieve a good bond between power rail and the subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance return path for high-frequency energy.

IMPORTANT

To improve the bond between the 1394 SERCOS interface system and subpanel, construct your subpanel out of zinc plated (paint-free) steel.

Improper bonding blocks the direct return path and allows highfrequency energy to travel elsewhere in the cabinet. Excessive highfrequency energy can effect the operation of other microprocessor controlled equipment.

Publication 1394-IN002B-EN-P — February 2004

1-10 Installing Your 1394 SERCOS Interface System

The illustrations that follow (Figure 1.5) show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Figure 1.5 Recommended Bonding Practices for Painted Panels

Stud-mounting the subpanel

to the enclosure back wall

Back wall of enclosure

Subpanel Welded stud

Star washer

Nut

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

Use plated panels or scrape paint on front of panel.

Welded stud

Mounting bracket or

Flat washer

Nut

Stud-mounting a ground bus

or chassis to the subpanel

ground bus

Flat washer

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

Star washer

around the mounting hole.

Subpanel

Scrape paint

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

Ground bus or

mounting bracket

Flat washer

Nut

Subpanel

Tapped hole

Nut

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

Star washer

Flat washer

Bolt

Star washer

Publication 1394-IN002B-EN-P — February 2004

Star washer

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

Installing Your 1394 SERCOS Interface System 1-11

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 multiple panels.

Figure 1.6 Bonding Multiple Subpanels

ecommended:

Bond the top and bottom of each subpanel to the cabinet using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid

Bonded cabinet

ground bus to

subpanel

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

Publication 1394-IN002B-EN-P — February 2004

1-12 Installing Your 1394 SERCOS Interface System

Planning Your Panel Layout

This section outlines the practices which minimize the possibility of noise-related failures as they apply specifically to 1394 installations. For more information on the concept of electrical noise reduction, refer to System Design for Control of Electrical Noise Reference Manual (publication GMC-RM001x-EN-P).

Establishing Noise Zones

Observe the following guidelines when laying out your panel (refer to Figure 1.7 for zone locations).

• The clean zone (C) is to the left of the 1394 and includes the

I/O wiring, feedback cable, and DC filter (grey wireway).

• The dirty zone (D) is beneath and to the right of the 1394 (black

wireway) and includes the circuit breakers, transformer, 24V dc power supply, contactors, AC line filter, and motor power cables.

• The very dirty zone (VD) is limited to where the AC line (EMC)

filter VAC output jumpers over to the 1394. Shielded cable is required only if the very dirty cables enter a wireway.

• The SERCOS fiber-optic cables are immune to electrical noise, but

are relatively fragile and best run with other light weight cables.

Figure 1.7 Establishing Noise Zones

Dirty Wireway

Circuit

Breaker

XFMR

Clean Wireway

and

I/O

Feedback Cables

Route Encoder/Analog/Registration Shielded Cable

(1)

1394 SERCOS interface System

SERCOS System Module

Status

DANGER

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

Very dirty unshielded power connections segregated (not in wireway)

Filter

Line Filter

24V Motor

Brake PS

Contactors

Route 24V dc I/O

Shielded Cable

Publication 1394-IN002B-EN-P — February 2004

If I/O cable contains (dirty) relay wires, route wires in dirty wireway.

This is a clean 24V dc available for any device that may require it. The 24V enters the clean wireway and exits to the left.

This is a dirty 24V dc available for motor brakes and contactors. The 24V enters the dirty wireway and exits to the right.

Installing Your 1394 SERCOS Interface System 1-13

Observe the following guidelines when installing your 1756-MxxSE SERCOS interface module (refer to Figure 1.8 for zone locations).

• The clean zone (C) is beneath the less noisy modules (I/O, analog,

encoder, registration, etc. (grey wireway).

• The dirty zone (D) is above the chassis and below the noisy

modules (black wireway).

• The SERCOS fiber-optic cables are immune to electrical noise, but

are relatively fragile and best run with other light weight cables.

Figure 1.8 Establishing Noise Zones (ControlLogix)

Clean Wireway

(1)

EMC

Filter

EMC filter/power supply connections segregated (not in clean wireway)

Route dirty wireways directly above the ControlLogix rack

(shielded by the chassis)

Clean I/O

(Analog, Encoder

Registration, etc.)

Dirty Wireway

Spare Slot(s)

Dirty I/O

(24V dc I/O, AC I/O)

Publication 1394-IN002B-EN-P — February 2004

1-14 Installing Your 1394 SERCOS Interface System

Cable Categories for the 1394

The table below indicates the zoning requirements of cables connecting to the 1394.

Wire/Cable Connections

AC input power from filter to system module (unshielded option)

AC input power from filter to system module (shielded option)

Motor Power (must be shielded) U1, V1, W1, PE2 X X Thermal wires Brake wires (requires suppression) X 24V dc logic power W1, W2 X COM, PWR (24V dc), filtered COM, PWR (24V dc), unfiltered

Feedback

Registration Inputs Discrete Inputs X X Enable, Overtravel, and Home inputs Discrete Inputs X Analog Outputs Analog Outputs X X Relay Outputs Relay Outputs X

Zone Method

Very Dirty

U, V, W, PE

TB1/TB2

Discrete Inputs X

Motor X X

Auxiliary X X

Dirty Clean

Ferrite Sleeve

Shielded Cable

DPI/SCANport Fiber-Optic Rx and Tx No Restrictions



Refer to Footnote 2 on page 1-12.

Refer to Footnote 3 on page 1-12.

DPI/SCANport X X

The table below indicates the zoning requirements of cables connecting to the External Shunt Resistor Kit.

Zone Method

Wire/Cable Connections

Shunt Power (shielded option) Shunt Power (unshielded option) X Thermal Switch N/A X X Fan (if present) N/A X

COL, INT, DC+

Very Dirty

Dirty Clean

Ferrite Sleeve

Shielded Cable

Publication 1394-IN002B-EN-P — February 2004

Installing Your 1394 SERCOS Interface System 1-15

Mounting Guidelines to Reduce Electrical Noise

When mounting an AC line (EMC) filter, external shunt resistor, or wiring the motor brake and thermal switch, refer to the sections below for guidelines designed to reduce system failures caused by excessive electrical noise.

AC Line Filters

Observe the following guidelines when mounting your AC line (EMC) filter (refer to Figure 1.7 for an example).

• Mount the AC line filter on the same panel as the 1394 along the

right side of the right-most axis module.

• Good HF bonding to the panel is critical. For painted panels, refer

to Figure 1.5.

• Segregate input and output wiring as far as possible.

IMPORTANT

CE test certification applies only to AC line filter and single 1394 drive. Multiple drive loads may perform satisfactorily, but the user takes legal responsibility.

Publication 1394-IN002B-EN-P — February 2004

1-16 Installing Your 1394 SERCOS Interface System

External Shunt Modules

Observe the following guidelines when mounting your external shunt module (refer to Figure 1.9 and for an example).

• Mount circuit components and wiring in the very dirty zone or in

an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI.

• Mount resistors (other than metal-clad) in a shielded and

ventilated enclosure outside the cabinet.

• Keep unshielded wiring as short as possible. Keep shunt wiring as

flat to the cabinet as possible.

• Route thermal switch and fan wires separate from shunt power.

Figure 1.9 External Shunt Module Outside the Enclosure

Customer-supplied

metal enclosure

Clean Wireway

I/O and

Feedback Cables

150 mm (6.0 in.) of

clearance on all sides

of the shunt module

(minimum)

Metal conduit

(where required

by local code)

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice)

Shielded twisted pair (2nd choice)

Twisted pair, 2 twists per foot min. (3rd choice)

(1)

1394 SERCOS interface System

SERCOS System Module

Status

DANGER

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

Filter

Line Filter

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

Shunt thermal switch and fan wires (when exist)

Enclosure

Dirty Wireway

24V Motor

Brake PS

Contactors

Circuit

Breaker

XFMR

Publication 1394-IN002B-EN-P — February 2004

Very dirty shunt connections segregated (not in wireway)

Route Encoder/Analog/Registration Shielded Cable

Route 24V dc I/O

Shielded Cable

Enclosure

Installing Your 1394 SERCOS Interface System 1-17

When mounting your shunt module inside the enclosure, follow these additional guidelines (refer to Figure 1.10 and for an example).

• Metal-clad modules can be mounted anywhere in the dirty zone,

but as close to the 1394 as possible.

• Shunt power wires can be run with motor power cables.

• Keep unshielded wiring as short as possible. Keep shunt wiring as

flat to the cabinet as possible.

• Separate shunt power cables from other sensitive, low voltage

signal cables.

Figure 1.10 External Shunt Module Inside the Enclosure

Clean Wireway

Twisted pair, 2 twists per foot min. (3rd choice)

I/O and

Feedback Cables

Route Encoder/Analog/Registration Shielded Cable

150 mm (6.0 in.) of clearance

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice)

Shielded twisted pair (2nd choice)

1394 SERCOS interface System

SERCOS System Module

Status

DANGER

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

Very dirty shunt connections segregated (not in wireway)

on all sides of the

shunt module (minimum)

Filter

Line Filter

Enclosure

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

Enclosure

Dirty Wireway

Shunt thermal switch and fan wires (when exist)

24V Motor

Brake PS

Contactors

Circuit

Breaker

XFMR

Route 24V dc I/O

Shielded Cable

Motor Brake and Thermal Switch

The thermal switch and brake are mounted inside the motor, but how you connect to the axis module depends on the motor series. Refer to Connecting Motor Power, Thermal Switch, and Brake in Chapter 3 for wiring guidelines specific to your drive/motor combination. Refer to Axis Module/Motor Interconnect Diagrams in Appendix B for the interconnect diagram for your drive/motor combination.

Publication 1394-IN002B-EN-P — February 2004

1-18 Installing Your 1394 SERCOS Interface System

Mounting Your 1394 SERCOS interface System

The procedures in this section assume you have prepared your panel and understand how to bond your system. For installation instructions regarding equipment and accessories not included here, refer to the instructions that came with those items.

ATTENTION

1. Layout the position for your 1394 in the enclosure (refer to

Establishing Noise Zones for panel layout recommendations). Mounting hole dimensions for the 1394 are shown in Appendix A.

Note: For help with the mounting hole layout for any combination

of axis modules, refer to Determining Your System Mounting Hole Layout on page 1-8.

This drive 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 control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-

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

2. Install the top mounting fasteners on the subpanel for the system

module and all axis modules. The heads of the fasteners should be at least 6.35 mm (0.25 in.) from the panel. Make sure the 1394 is properly bonded to the subpanel. Refer to the section HF Bonding Your System for proper bonding techniques.

IMPORTANT

3. Hang the 1394 system module on the two fasteners on the left side

of the subpanel.

To improve the bond between the 1394 and subpanel, construct your subpanel out of zinc plated (paint-free) steel.

Publication 1394-IN002B-EN-P — February 2004

Installing Your 1394 SERCOS Interface System 1-19

4. If you are mounting a: Do this:

1394x-AM03, -AM04 or AM07; 1394C-AM50-IH, or -AM75-IH axis module

1394x-AM50 or -AM75 axis module with the heat sink through the back of the enclosure (refer to Figure 1.4)

1. Hang the axis module on the next mounting fastener.

2. Go to main step 6.

1. Remove the paper backing from the gasket that came with 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 the back of the axis module.

Figure 1.11 Gasket Position

gasket

4. Go to main step 5.

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

6. Engage the alignment tab (refer to Figure 1.12).

Figure 1.12 Alignment Tab

Engaged alignment tab

Publication 1394-IN002B-EN-P — February 2004

1-20 Installing Your 1394 SERCOS Interface System

7. Slide the slide-and-lock mechanism on the axis module to the left

until it locks into place.

Figure 1.13 Slide-and Lock Mechanism

8. If you: Do this:

SERCOS System Module

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

Slide-and-Lock

Status

DANGER

mechanism

Have more axis modules for this system module

Do not have more axis modules for this system module

Go to step 4.

Go to step 9.

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

modules.

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

until it locks in place.

Figure 1.14 Attaching the Terminator

SERCOS System Module

Attach the terminator

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

Status

DANGER

Publication 1394-IN002B-EN-P — February 2004

IMPORTANT

The terminator terminates the serial ring. The 1394 system will not operate without the terminator.

11. Tighten all mounting fasteners.

Installing Your 1394 SERCOS Interface System 1-21

Mounting Your External Shunt Resistor Kit

If your 1394 requires a means of dissipating regenerative energy that exceeds the capacity of the shunt module, install an External Shunt Resistor Kit (refer to Appendix C for catalog numbers).

ATTENTION

To avoid the hazard of shock or burn and ignition of flammable material, appropriate guarding must be provided. These resistors can reach temperatures in excess of 350° C (662° F). Install per local codes.

To install your External Shunt Resistor Kit:

1. Layout the position for your shunt resistor in the enclosure (refer

to Establishing Noise Zones for panel layout recommendations).

2. Attach the shunt resistor to the cabinet. The recommended

mounting hardware is M6 metric (1/4 in.) bolts. Make sure all fasteners are properly bonded to the subpanel. Refer to the section HF Bonding Your System for proper bonding techniques.

3. Tighten all mounting fasteners.

For mounting dimensions, refer to the Motion Control Selection Guide (publication GMC-SG001x-EN-P).

Publication 1394-IN002B-EN-P — February 2004

1-22 Installing Your 1394 SERCOS Interface System

Publication 1394-IN002B-EN-P — February 2004

Chapter

1394 SERCOS Interface Connector Data

Chapter Objectives

This chapter provides power, feedback, and I/O connector locations and signal descriptions for your 1394 SERCOS interface system. This chapter includes:

• Locating System Module Connectors and Indicators

• System Module Connector Pin-outs

• Locating Axis Module Connectors and Indicators

• Axis Module Connector Pin-outs

• Understanding I/O Specifications

• Understanding Feedback Specifications

Switch and LED locations are shown, however for switch and LED configuration, refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN024x-EN-P).

1 Publication 1394-IN002B-EN-P — February 2004

2-2 1394 SERCOS Interface Connector Data

Locating System Module Connectors and Indicators

(1394C-SJT05-D and -SJT10-D is shown)

1394 System Module

Front Cover

SERCOS System Module

System Module

Status LED

Status

DANGER

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

SERCOS Receive (Rx) Connector

SERCOS Transmit (Tx) Connector

Use the figure below to locate the 1394C-SJT05-D and -SJT10-D System Module connectors and indicators.

Figure 2.1 1394 System Modules (1394C-SJT05-D and -SJT10-D)

System Module, front view

Analog Outputs

Connector

SERCOS Base Node

Address Switch

Relay Outputs

Connector

Discrete Input

Connectors (4)

Tie Down Anchor

SERCOS Baud Rate

and Optical Power Switches

1394 Digital Servo Controller

SERCOS interface

System Module

Enable3

Home3

Reg3_Com

Reg3_1

Enable2

Home2

Reg2_Com

Reg2_1

Enable1

Home1

Reg1_Com

Reg1_1

Enable0

Home0

Reg0_Com

Reg0_1

AXIS 0 AXIS 1 AXIS 2 AXIS 3 RELAY OUTPUTS

RELAY OUTPUTS

DRIVE SYSTEM OK

OUTPUT 3

OUTPUT 2

OUTPUT 1

OUTPUT 0

AXIS 3

Pos_Otrav3

Neg_Otrav3

I/O_Com

Reg3_2

AXIS 2

Pos_Otrav2

Neg_Otrav2

I/O_Com

Reg2_2

AXIS 1

Pos_Otrav1

Neg_Otrav1

I/O_Com

Reg1_2

AXIS 0

Pos_Otrav0

Neg_Otrav0

I/O_Com

Reg0_2

OFF ON

Single Point

Bond Bar

1 2 3

DANGER

RISK OF ELECTRICAL SHOCK.

MORE THAN ONE DISCONNECT SWITCH MAY BE REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICE.

DANGER

ELECTRICAL SHOCK HAZARD FROM ENERGY STROAGE CAPACITORS.

VERIFY LOW VOLTAGE DISCHARGE BEFORE SERVICING.

SEE INSTRUCTIONAL MANUAL.

- Analog_Out_1

- Analog_Out_2

- Analog_Out_3

- Analog_Out_4

- Common

- N/C

- SERCOS Receive

- SERCOS Transmit

Network Status LED

System Module, bottom view

(1394C-SJT05-D and -SJT10-D is shown)

Publication 1394-IN002B-EN-P — February 2004

Shunt Power Connector

DPI/SCANport Connector Axis 0 Auxiliary Feedback

Axis 3 Motor Feedback

(in four axis system) or

Axis 2 Auxiliary Feedback

(in three axis system)

Logic Power Connector

Input Power Connector

Axis 1 Auxiliary Feedback

Axis 2 Motor Feedback (in four axis system) or Axis 3 Auxiliary Feedback (in two axis system)

Axis 1 Motor Feedback

Axis 0 Motor Feedback

Cable Clamp Grounding Bracket (one clamp installed)

Note: Switch and LED locations are shown, however for switch and

LED configuration, refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN024x-EN-P).

1394 System Module

Front Cover

Use the figure below to locate the 1394C-SJT22-D System Module connectors and indicators.

Figure 2.2 1394 System Modules (1394C-SJT22-D)

System Module, front view

(1394C-SJT22-D is shown)

Analog Outputs

SERCOS System Module

SERCOS Base Node

Address Switch

Connector

1394 Digital Servo Controller

SERCOS interface

System Module

RELAY OUTPUTS

AXIS 3

Enable3

Home3

Reg3_Com

Reg3_1

AXIS 2

Enable2

Home2

Reg2_Com

Reg2_1

AXIS 1

Enable1

Home1

Reg1_Com

Reg1_1

AXIS 0

Enable0

Home0

Reg0_Com

Reg0_1

DRIVE SYSTEM OK

OUTPUT 3

OUTPUT 2

OUTPUT 1

OUTPUT 0

Pos_Otrav3

Neg_Otrav3

I/O_Com

Reg3_2

Pos_Otrav2

Neg_Otrav2

I/O_Com

Reg2_2

Pos_Otrav1

Neg_Otrav1

I/O_Com

Reg1_2

Pos_Otrav0

Neg_Otrav0

I/O_Com

Reg0_2

1394 SERCOS Interface Connector Data 2-3

System Module

Status LED

Status

DANGER

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

Relay Outputs

Connector

Discrete Input

Connectors (4)

SERCOS Receive (Rx) Connector

Tie Down Anchor

SERCOS Transmit (Tx) Connector

SERCOS Baud Rate

and Optical Power Switches

System Module, bottom view

(1394C-SJT22-D is shown)

DPI/SCANport Connector Axis 0 Auxiliary Feedback

Axis 3 Motor Feedback (in four axis system) or

Axis 2 Auxiliary Feedback

(in three axis system)

Axis 1 Motor Feedback

Network Status LED

Terminal Block for Logic Power, Input Power, and External Shunt Connections

OFF ON

1 2 3

Single Point

Bond Bar

Axis 1 Auxiliary Feedback

Axis 2 Motor Feedback (in four axis system) or Axis 3 Auxiliary Feedback (in two axis system)

Cable Clamp Grounding Bracket (one clamp installed)

Axis 0 Motor Feedback

Note: Switch and LED locations are shown, however for switch and

LED configuration, refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN024x-EN-P).

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2-4 1394 SERCOS Interface Connector Data

System Module Connector Pin-outs

The System Module connectors are described in the table below. System Module connector pin-outs and signal descriptions follow.

System Module Connectors

Description Connector

Main Input Power 4-position connector housing Logic Power 2-position connector housing Shunt Power 3-position connector housing Logic, Shunt, and Main Input Power

Terminal Block Single Point Bond Bar 5-position grounding bar Motor/Auxiliary Feedback 13-position connector housing Relay Outputs 10-position connector housing Analog Outputs 9-position connector housing Discrete Input 8-position connector housing (4) SERCOS Transmit and Receive SERCOS fiber-optic (2) DPI/SCANport DPI/SCANport

8-position terminal block 1394C-SJT22-D

Present on this 1394 System Module

1394C-SJT05-D / 1394C-SJT10-D

1394C-SJT05-D, 1394C-SJT10-D, or 1394C-SJT22-D

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1394 SERCOS Interface Connector Data 2-5

Discrete Input Connector Pin-out

The following table and figure below provides the signal descriptions and pin-out for the Axis 0-3 (8-pin) discrete inputs connector. Refer to

Discrete Input Specifications on page 2-15 and Analog Output Specifications on page 2-17 for I/O signal specifications.

IMPORTANT

The 24V dc supplies for use with discrete inputs and registration inputs are user-supplied. Connect the 24V dc common (pins 3 and 7, not internally connected) as described in the table below.

Axis x Pin

Description Signal

1 Hardware Enable ENABLEx 5 Positive limit switch POS_OTRAVx 2 Home Switch Input HOMEx 6 Negative limit switch NEG_OTRAVx

3 Common for Registration REGx_COM 7

4 High Speed Registration 1 Input REGx_1 8 High Speed Registration 2 Input REGx_2

Figure 2.3 Pin Orientation for 8-pin Discrete Inputs Connector

Axis x Pin

Enable3

Home3

Reg3_Com

Reg3_1

Description Signal

Common for HOME, ENABLE, and POS/ NEG_OTRAV Signals

Axis 3

I/O_COM

Pos_Otrav3 Neg_Otrav3 I/O_Com Reg3_2

1394 SERCOS interface

Control Board

1394C-SJTxx-D

Enable2

Home2

Reg2_Com

Reg2_1

Enable1

Home1

Reg1_Com

Reg1_1

Enable0

Home0

Reg0_Com

Reg0_1

Axis 2

Axis 1

Axis 0

Pos_Otrav2 Neg_Otrav2 I/O_Com Reg2_2

Pos_Otrav1 Neg_Otrav1 I/O_Com Reg1_2

Pos_Otrav0 Neg_Otrav0 I/O_Com Reg0_2

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2-6 1394 SERCOS Interface Connector Data

Relay Output Connector Pin-out

The following table and figure below provides the signal descriptions and pin-out for the Relay Output (10-pin) connector. Refer to Drive

System OK Relay Specifications on page 2-18 and Motor Brake Relay Specifications on page 2-19 for relay signal specifications.

Pin Description Signal

1 When wired properly in the control string,

3 4 5 6 7 8 9 10

this relay opens the main power contactor if a drive system fault occurs. Refer to figures B.1 and B.2 for examples.

Allows control of motor brake using Enable/Disable parameters for Axis 3.

Allows control of motor brake using Enable/Disable parameters for Axis 2.

Allows control of motor brake using Enable/Disable parameters for Axis 1.

Allows control of motor brake using Enable/Disable parameters for Axis 0.

DRIVE SYSTEM OK

OUTPUT 3

OUTPUT 2

OUTPUT 1

OUTPUT 0

Figure 2.4 Pin Orientation for 10-pin Relay Output Connector

1 2 3

1394 SERCOS interface

Control Board

1394C-SJTxx-D

4 5 6 7 8 9

Drive System OK

Output 3

Output 2

Output 1

Output 0

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-7

Analog Output Connector

The following table provides the signal descriptions and pin-outs for the analog output (9-pin) connector. Refer to Analog Output Specifications on page 2-17 for analog output signal specifications.

Pin Description Signal

1 Test Point ANALOG_OUT_1 2 Test Point ANALOG_OUT_2 3 Test Point ANALOG_OUT_3 4 Test Point ANALOG_OUT_4 5 Common ANALOG_OUT_COM 6N/C — 7N/C — 8N/C — 9N/C —

Figure 2.5 Pin Orientation for 9-pin Analog Output Connector

Analog_Out_1 Analog_Out_2

1394 SERCOS interface

Control Board

1394C-SJTxx-D

Analog_Out_3 Analog_Out_4 Analog_Out_COM N/C N/C N/C

N/C

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2-8 1394 SERCOS Interface Connector Data

Motor Feedback Connector Pin-outs

The following table provides the signal descriptions and pin-out for the motor and auxiliary feedback (13-pin) connectors. Motor and Auxiliary Feedback Specifications begin on page 2-21.

Stegmann Hiperface (SRS/SRM)

Refer to Appendix B for interconnect drawings showing how to connect Stegmann Hiperface

feedback to MPL-Bxxxx-M and -S,

-Axxxx-M and -S, and 1326AB-Bxxxx-M2L and -S2L 460V motors.

Pin Description Signal Pin Description Signal

1 Sine Differential Input+ SINE+ 8 Hiperface data channel DATA+ 2 Sine Differential Input- SINE- 9 Hiperface data channel DATA3 Cosine Differential Input+ COS+ 10 Reserved — 4 Cosine Differential Input- COS- 11 Reserved —

5 Common ECOMM 12

6 Encoder Power (+9V) EPWR_9VM 13

7Reserved —

Motor Thermal Switch (normally closed)

TS+

TS-

Resolver Transmitter TR = 0.25

Note: TR=0.25 is an abbreviation for Transformation Ratio 0.25.

Refer to Appendix B for interconnect drawings showing how to connect resolver transmitter feedback to MPL-Bxxxx-R and 1326AB-Bxxxx-21 Series 460V motors.

Pin Description Signal Pin Description Signal

1 Sine Differential Input+ S2 8 Reserved — 2 Sine Differential Input- S4 9 Reserved — 3 Cosine Differential Input+ S1 10 Resolver Excitation R1 4 Cosine Differential Input- S3 11 Resolver Excitation R2

5 Reserved — 12

6 Reserved — 13

7Reserved —

When using 1326AB (resolver-based) motors, the thermal switch wires pass through the TB1/TB2 noise filter circuitry on the bottom of the axis module.

IMPORTANT

To meet CE requirements, combined motor power cable length for all (up to 4) axes must not exceed

Motor Thermal Switch (normally

closed) Motor Thermal Switch (normally

closed)

TS+

TS-

360 m (1181 ft).

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-9

Auxiliary Feedback Connector Pin-outs

The following tables provide the signal descriptions and pin-outs for the auxiliary feedback (13-pin) connectors when used with different feedback devices. Motor and Auxiliary Feedback Specifications begin on page 2-21.

Note: For TTL devices, the position count will increase when A leads

B. For sinusoidal devices, the position count will increase when cosine leads sine.

Stegmann Hiperface (SRS and SRM)

Pin Description Signal Pin Description Signal

1 Sine Differential Input+ SINE+ 8 Reserved — 2 Sine Differential Input- SINE- 9 Reserved — 3 Cosine Differential Input+ COS+ 10 Hiperface data channel DATA4 Cosine Differential Input- COS- 11 Reserved — 5 Hiperface data channel DATA+ 12 Reserved — 6 Common ECOM 13 Reserved — 7 Encoder Power (+5V) EPWR_5V

TTL or Sine/Cosine with Index Pulse

Pin Description Signal Pin Description Signal

1 A+ / Sine Differential Input+ A+ / SINE+ 8 Reserved — 2 A- / Sine Differential Input- A- / SINE- 9 Reserved — 3 B+ / Cosine Differential Input+ B+ / COS+ 10 Index Pulse- I4 B- / Cosine Differential Input- B- / COS- 11 Reserved — 5 Index Pulse+ I+ 12 Reserved — 6 Common ECOM 13 Reserved — 7 Encoder Power (+5V) EPWR_5V

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2-10 1394 SERCOS Interface Connector Data

Figure 2.6 Pin Orientation for 13-pin Motor/Auxiliary Feedback Connectors

Front

Axis 0 Auxiliary Feedback

Axis 3 Motor Feedback

(in four axis system) or

Axis 2 Auxiliary Feedback

(in three axis system)

Axis 1 Motor Feedback

Back

Axis 1 Auxiliary Feedback

Axis 2 Motor Feedback (in four axis system) or Axis 3 Auxiliary Feedback (in two axis system)

Axis 0 Motor Feedback

13 12 11 10

1394 System Module

Feedback Connectors

7 6 5 4 3 2 1

(bottom view)

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-11

System Module Input Power Pin-outs

The following table provide the signal descriptions and pin-outs for the system module input power connections.

For the location of 1394C-SJT05-D and -SJT10-D input connectors, refer to Figure 2.1 on page 2-2. For the location of 1394C-SJT22-D input terminal block, refer to Figure 2.2 on page 2-3. Refer to Logic Power Input Specifications on page 2-20 for signal specifications.

Pin Description Signal

W1 W2 W2 U VV WW

PE Chassis Ground

Logic power input

Three-phase main input power

DC+ INT INT COL COL

External Shunt Connections

Figure 2.7 1394C-SJTxx-D Input Power

W1 W2

U V W

1394C-SJT05-D and -SJT10-D

Input Power Connectors

COL INT DC+

SCANport Adapter

DC+

1394C-SJT22-D

Input Power Terminal Blocks

This port allows you to connect a SCANport device, such as a Human Interface Module (HIM), to the 1394 SERCOS Interface system. Refer to figures 2.1 and 2.2 for SCANport location. Refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN024x-EN-P) for information on using the HIM.

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2-12 1394 SERCOS Interface Connector Data

Locating Axis Module Connectors and Indicators

Use the figure below to locate the axis module connectors and indicators. Shown below are typical 1394C-AM03, -AM04, and -AM07 axis modules. Although the physical size of the 1394C-AM50-xx and AM75-xx model is larger, the location of the connectors and indicators is identical.

Figure 2.8 1394 Axis Modules (1394C-AMxx and -AMxx-IH)

Front View

(typical)

Axis Enabled LED

Te rm in a to r

Motor Power Connections

Bottom View

(typical)

Motor Brake and Thermal Connections

U1V1W1

TB1

TB2

PE1

PE2

PE3

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-13

Axis Module Connector Pin-outs

The Axis Module connectors are described in the table below. Axis Module connector pin-outs and signal descriptions follow.

Axis Module Connectors

Description Connector

Motor Power Terminal Block 6-position terminal block Motor Brake/Thermal (TB1/TB2) 4-position connector housing (2)

Motor Power and Brake Connector Pin-outs

The following tables provide the signal descriptions and pin-outs for the Axis Module motor power and brake connections. Refer to Motor Brake Relay Specifications on page 2-19 for signal specifications.

Motor Power Connections

The following table provides the signal descriptions and pin-outs for the motor power (6-position) terminal block.

Terminal Description Signal

U1 V1 V1 W1 W1

PE1 Axis Ground

PE2 Motor Ground

PE3 No Connection

Cable Clamp Overall Shield

IMPORTANT

Three-phase motor power

To meet CE requirements, combined motor power cable length for all (up to 4) axes must not exceed

360 m (1181 ft).

Publication 1394-IN002B-EN-P — February 2004

2-14 1394 SERCOS Interface Connector Data

Motor Brake/Thermal Connectors

The following table provides the signal descriptions and pin-outs for the motor brake and thermal (4-pin) TB1 and TB2 connectors.

TB1 Pin Description Signal

1 2TS3 4BR-

TB2 Pin Description Signal

1 2 Filtered TS3 4 Filtered BR-

Thermal Sensor Input from Motor Cable

Brake wires from Motor Power Cable

Filtered brake wires from Fault System or System Module

Filtered thermal sensor output to Fault System or System Module

TS+

BR+

Filtered TS+

Filtered BR+

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-15

Understanding I/O Specifications

A description of the 1394 discrete inputs, analog outputs, relay outputs, SERCOS connections, and logic power connections is provided on the following pages.

IMPORTANT

To improve registration input EMC performance, refer to the System Design for Control of Electrical Noise Reference Manual (GMC-RM001x-EN-P).

Discrete Input Specifications

Two fast registration inputs and four other inputs are available for the machine interface on the four discrete input connectors. These are sinking inputs that require a sourcing device.

IMPORTANT

The discrete input 24V dc power supply is user-supplied.

Overtravel limit input devices must be normally closed and configured in RSLogix 5000.

Discrete Input Pin: Signal: Description:

Axis 0-3 input pin 1 ENABLE A 24V dc input is applied to these terminals to enable each axis. 50 ms Level

The Home switch input is a normally open or normally closed contact

Axis 0-3 input pin 2 HOME

Axis 0-3 input pin 5 Axis 0-3 input pin 6

Axis 0-3 input pin 7 I/O_Com Common grounding point for input signals (Home, Enable, Pos/Neg_Otrav) N/A N/A Axis 0-3 input pin 3

Axis 0-3 input pin 4 Axis 0-3 input pin 8

POS_OTRAV NEG_OTRAV

REG_COM REG_1 REG_2

configured in RSLogix 5000. Inputs for each axis require 24V dc (nominal), 15 mA (max) to energize. Each input is optically isolated and filtered to minimize switch bounce. Refer to Figure 2.9.

The positive/negative limit switch input is a normally closed contact configured in RSLogix 5000. Inputs for each axis require 24V dc (nominal), 15 mA (max) to energize. Each input is optically isolated and filtered to minimize switch bounce. Refer to Figure 2.9.

24V dc high-speed, optically-isolated filtered registration input for each axis. Refer to Figure 2.10.

Capture Time

50 ms Level

500 ns Edge

Edge/Level Sensitive

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2-16 1394 SERCOS Interface Connector Data

Figure 2.9 Enable, Home, and Overtravel Digital Input Circuits

24V dc

I/O Supply

IO_COM

Customer-Supplied Input

+24V dc

Customer-Supplied Registration

Input

I/O Supply

Input

IO_COM

Discrete

Input Pins

1, 2, 5, 6

Discrete

Input Pin 7

Discrete

Input Pins

4 and 8

Discrete

Input Pin 3

3k Ω

1000 pF

1394 System Module

Figure 2.10 Registration Digital Input Circuits

3k Ω

1000 pF

1394 System Module

511 Ω

VCC

1k Ω

CTRL_INPUT

VCC

1k Ω

CTRL_INPUT

The following table provides a description of the digital input specifications, as shown in figures 2.9 and 2.10.

Parameter Description Minimum Maximum

ON State Voltage

ON State Current Current flow to guarantee an ON State 5.0 mA 15.0 mA

OFF State Voltage

Voltage applied to the input, with respect to IOCOM, to guarantee an ON state.

Voltage applied to the input, with respect to IOCOM, to guarantee an OFF state.

17.5V dc 38V dc

—6.9V dc

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-17

Analog Output Specifications

The 1394 SERCOS interface drive includes two analog outputs that can be configured through software to represent drive variables. Figure

2.11 shows the configuration of the analog outputs. The table below provides a description of the analog outputs.

Note: Refer to Analog Output Connector on page 2-7 for connector

pin-outs and figures 2.1 and 2.2 for the connector location.

Figure 2.11 Analog Output Configuration

Oscilloscope

0V = 0 ref

DAC

IMPORTANT

1394 System Module

(second channel not shown)

Output values can vary during power-up until the specified power supply voltage is reached.

CH1

CH2

The following table provides a description of the analog output specifications.

Parameter Description Minimum Maximum

Resolution

Output Current

Output Signal Range

Offset Error Deviation when the output should be at 0V. — 1 mV Bandwidth Frequency response of the analog output DC 3.6k Hz (3 db)

Number of states that the output signal is divided into, which is 2

Current capability of the output. 0 +2 mA

Range of the output voltage. -10V +10V

(to the number of bits)

— ±11 bits

For configuration/setup of the analog outputs, refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN024x-EN-P).

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2-18 1394 SERCOS Interface Connector Data

Drive System OK Relay Specifications

The Drive System OK output is intended to be wired into the drive’s start/stop string to open the main power contactor if a drive system fault occurs. This configuration will cause the Drive System OK contacts to close after 24V logic power is applied and no system faults are detected. It is capable of handling 120V ac at 1A or less. An active state indicates the drive is operational and does not have a fault.

Figure 2.12 Drive System OK Relay

Normally

Open Relay

1394 System Module

DRIVE SYSTEM OK_1

DRIVE SYSTEM OK_2

The following table provides a description of the relay output specifications.

Parameter Description Minimum Maximum

ON State Current

ON State Resistance

OFF State Voltage

Maximum switched load — 1A Inductive

Current flow when the relay is closed — 1A

Contact resistance when the relay is closed — 1Ω

Voltage across the contacts when the relay is open —

120V ac 24V dc

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-19

Motor Brake Relay Specifications

The connections are rated for +24V, 1A operation. An active signal releases the motor brake. The brake signal uses the turn-on and turn-off delays specified by the brake active delay and brake inactive delay. The delay times are software configurable in RSLogix 5000. For the list of motors rated for 1A operation, the delay times and example diagram, refer to Brake Interconnect Diagrams on page B-15.

IMPORTANT

For motors requiring more than 1A, a relay must be added. For the list of motors rated at greater than 1A operation, the delay times and example diagram, refer to Brake Interconnect Diagrams on page B-16.

Figure 2.13 Relay Outputs

Axis 1

Axis 0

Normally

Open

Relay

1394 System Module

Axis 3

Axis 2

The following table provides a description of the relay output specifications.

Parameter Description Minimum Maximum

ON State Current

ON State Resistance

OFF State Voltage

Maximum switched load — 1A Inductive

Current flow when the relay is closed — 1A

Contact resistance when the relay is closed — 1Ω

Voltage across the contacts when the relay is open — 30V

Refer to Brake Interconnect Diagrams beginning on page B-14 for wiring examples.

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2-20 1394 SERCOS Interface Connector Data

SERCOS Connection Specifications

Two fiber-optic connectors (transmit and receive) are provided on the 1394 system module. The table below lists SERCOS communication specifications.

Specification Description

Data Rates 2, 4, and 8 MBd

Node Addresses

Logic Power Input Specifications

The 1394 system module must be wired with a logic power input. Refer to figures 2.1 and 2.2 for the location of the logic power connector/terminal blocks and page A-6 for the 24V Logic Input Power Specifications.

Determined by hardware configuration. Refer to the 1394 SERCOS Interface Integration Manual (publication 1394-IN0024x-EN-P).

Publication 1394-IN002B-EN-P — February 2004

1394 SERCOS Interface Connector Data 2-21

Understanding Feedback Specifications

The 1394 SERCOS interface system module can accept motor feedback signals from the following types of encoders:

• Stegmann Hiperface

• Resolver Transmitter TR = 0.25

• TTL AQB or Sine/Cosine (Feedback Only axis configuration in

RSLogix 5000)

The 1394 SERCOS interface system module can accept auxiliary feedback signals from the following types of encoders:

• Stegmann Hiperface

• TTL AQB or Sine/Cosine with index pulse

Note: Auto-configuration in RSLogix 5000 software of intelligent

absolute or high-resolution is possible only with Allen-Bradley motors.

Motor and Auxiliary Feedback Specifications

The table below lists motor encoder feedback specifications.

Specification Description

Encoder Types Sine/Cosine, Intelligent, Resolver, and Absolute Maximum Input Frequency 200 kHz (Sine/Cosine input)

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2-22 1394 SERCOS Interface Connector Data

The following table provides a description of the AM, BM, and IM inputs for auxiliary (TTL) motor encoders.

Parameter Description Minimum Maximum

AM, BM, and IM ON State Input Voltage

AM, BM, and IM OFF State Input Voltage

Common Mode Input Voltage

DC Current Draw Current draw into the + or - input. -30 mA 30 mA

AM, BM Input Signal Frequency

IM Pulse Width

AM, BM Phase Error

2.5 MHz Line Frequency

AM, BM Phase Error 1 MHz Line Frequency

Input voltage difference between the + input and the - input that is detected as an ON state.

Input voltage difference between the + input and the - input that is detected as an OFF state.

Potential difference between any encoder signal and logic ground.

Frequency of the AM or BM signal inputs. The count frequency is 4 times this frequency, since the circuitry counts all four transitions.

Pulse width of the index input signal. Since the index is active for a percentage of a revolution, the speed will determine the pulse width.

Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.

+1.0V +7.0V

-1.0V -7.0V

-7.0V +12.0V

— 1.0 MHz

125 nS —

-22.5° +22.5°

-45° +45°

The following table provides a description of the AM and BM inputs for Sine/Cosine encoders when used as motor or auxiliary feedback.

Parameter Description Minimum Maximum

Sine/cosine Input Signal Frequency

Sine/cosine Input Voltage

Frequency of the Sine or Cosine signal inputs. — 200 kHz

Peak-to-peak input voltages of the Sine or Cosine inputs.

Feedback Power Supply

The 1394 system module generates the +5V and +9V dc for the motor and auxiliary feedback power supplies. Short circuit protection and separate common mode filtering for each channel is included. Refer to the table below for specifications.

Supply Reference

+5V dc EPWR_5V 5.13 5.4 5.67 10

+9V dc EPWR_9V 8.3 9.1 9.9 10

5 volt total for all axes.

9 volt total for all axes.

Minimum Nominal Maximum Minimum Maximum

Voltage Current mA

0.5V (p-p) 2.0V (p-p)

400

275

Publication 1394-IN002B-EN-P — February 2004

Chapter

Connecting Your 1394 SERCOS Interface System

Chapter Objectives

Understanding Basic Wiring Requirements

This chapter covers the following topics:

• Understanding Basic Wiring Requirements

• Determining Your Type of Input Power

• Setting the Ground Jumper in Ungrounded Power Configurations

• Grounding Your 1394 SERCOS Interface System

• Power Wiring Requirements

• Connecting Input Power

• Connecting Motor Power, Thermal Switch, and Brake

• Understanding Feedback and I/O Cable Connections

• Understanding External Shunt Connections

• Connecting Your SERCOS Fiber-Optic Cables

This section contains basic wiring information for the 1394.

ATTENTION

IMPORTANT

1 Publication 1394-IN002B-EN-P — February 2004

This section contains common PWM servo system 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 configurations take precedence over the values and methods provided.

3-2 Connecting Your 1394 SERCOS Interface System

Building Your Own Cables

IMPORTANT

When building your own cables, follow the guidelines listed below.

• Connect the cable shield to the motor end connector with a

complete 360° connection and the cable clamp on the drive end.

• Use a twisted pair cable whenever possible. Twist differential

signals with each other and twist single-ended signals with the appropriate ground return.

Refer to Appendix C for MP-Series and 1326AB (M2L/S2L) motor end connector kit descriptions and catalog numbers.

Factory made cables are designed to minimize EMI and are recommended over hand-built cables to ensure system performance.

Routing Power and Signal Wiring

Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic drives, can be induced into motor or encoder feedback, communications, or other sensitive low voltage signals. This can cause system faults and communication problems.

Refer to Chapter 1 for examples of routing high and low voltage cables in wireways. Refer to System Design for Control of Electrical Noise (publication GMC-RM001x-EN-P) for more information.

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-3

Input Power Conditioning

In most applications, you can connect the 1394 system module directly to a three-phase, AC power line. However, if certain power line conditions exist, the input power component can malfunction. If either of the following is true, you can use a line reactor or isolationtype transformer to reduce the possibility of this 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 required. If you have experienced power problems in the past on a power distribution line, you may need to consider input power conditioning.

Publication 1394-IN002B-EN-P — February 2004

3-4 Connecting Your 1394 SERCOS Interface System

Determining Your Type of Input Power

Before you ground or wire your 1394 system you must determine the type of power distribution system you will be connecting to for main input power. The 1394 system is designed to operate in both grounded and ungrounded environments.

Grounded Power Configuration

The grounded power configuration allows you to ground your threephase power at a neutral point. The 1394 system module has a factory installed jumper configured for grounded power distribution. If you determine that you have grounded power distribution in your plant you do not need to modify your system.

Figure 3.1 Grounded Power Configuration

SERCOS System Module

System module

single point bond bar

Conduit/4-Wire Cable

Ground grid or

power distribution ground

Status

DANGER

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

PE1

Bonded cabinet ground bus

Cable clamp around shield

PE2 W1 V1 U1

1326 or MP-Series motor power cable

Shield

Note: The input power terminal designated PE is electrically common

to the system module single point bond bar.

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-5

Ungrounded Power Configuration

The ungrounded power configuration does not allow for a neutral ground point. If you determine that you have ungrounded 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 instructions on page 3-6 for 5 and 10 kW system modules, and starting on page 3-7 for 22 kW system modules.

Figure 3.2 Ungrounded Power Configuration

SERCOS System Module

System module

single point bond bar

Conduit/4-Wire Cable

Ground grid or

power distribution ground

Status

DANGER

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

PE1

Bonded cabinet ground bus

Cable clamp around shield

PE2 W1 V1 U1

ATTENTION

1326 or MP-Series motor power cable

Shield

Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground.

Note: The input power terminal designated PE is electrically common

to the system module single point bond bar.

Publication 1394-IN002B-EN-P — February 2004

3-6 Connecting Your 1394 SERCOS Interface System

Setting the Ground Jumper in Ungrounded Power Configurations

These procedures assumes that you have bonded and mounted your system module to the subpanel and that there is no power applied to the system.

IMPORTANT

If you have grounded power distribution, you do not need to set the ground jumper. Go to Grounding

Your 1394 SERCOS Interface System.

Setting the Ground Jumper in 5 and 10 kW System Modules

This procedures applies to 1394C-SJT05-D and -SJT10-D system modules. To set the ground jumper for an ungrounded system:

1. Verify that all 24V logic and main input power has been removed

from the system.

2. Open the system module door.

3. Remove the three control board screws (refer to Figure 3.3 for

locations).

4. Remove ribbon cable from control board (refer to Figure 3.3 for

location).

Note: You should not find it necessary to remove both ends of the

ribbon cable. Remove only the control board end.

5. Remove the control board for easy access to ground jumpers (pull

it straight out from system module).

6. Locate the jumper connecting J4 and J5 on the assembly adjacent

to the control board, and move one end of the jumper from J5 to J6 (refer to Figure 3.3 for locations).

7. Re-install the control board. Align the guide pins in the rear of the

enclosure with the holes in the control board.

8. Re-install ribbon cable into the control board connector.

9. Re-install the three control board screws.

10. Close the system module door.

11. Go to Grounding Your 1394 SERCOS Interface System.

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-7

Figure 3.3 Ground Jumper Locations for the 5 and 10 kW System Modules

Ribbon

Cable

Connector

Side

Control Board

Screw

1394 Digital Servo Controller

SERCOS interface

System Module

RELAY OUTPUTS

DRIVE SYSTEM OK

OUTPUT 3

OUTPUT 2

OUTPUT 1

OUTPUT 0

AXIS 3

Enable3

Pos_Otrav3

Home3

Neg_Otrav3

Reg3_Com

I/O_Com

Reg3_2

Reg3_1

AXIS 2

Enable2

Pos_Otrav2

Home2

Neg_Otrav2

Reg2_Com

I/O_Com

Reg2_1

Reg2_2

AXIS 1

Enable1

Pos_Otrav1

Home1

Neg_Otrav1

Reg1_Com

I/O_Com

Reg1_2

Reg1_1

AXIS 0

Enable0

Pos_Otrav0

Home0

Neg_Otrav0

I/O_Com

Reg0_Com

Reg0_2

Reg0_1

AXIS 0 AXIS 1 AXIS 2 AXIS 3 RELAY OUTPUTS

OFF ON

SERCOS Network Status

1 2 3

DANGER

RISK OF ELECTRICAL SHOCK.

MORE THAN ONE DISCONNECT SWITCH MAY BE REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICE.

DANGER

ELECTRICAL SHOCK HAZARD FROM ENERGY STROAGE CAPACITORS.

VERIFY LOW VOLTAGE DISCHARGE BEFORE SERVICING.

SEE INSTRUCTIONAL MANUAL.

- Analog_Out_1

- Analog_Out_2

- Analog_Out_3

- Analog_Out_4

- Common

- N/C

- SERCOS Base Address x10

- SERCOS Receive

- SERCOS Transmit

1394C-SJTxx-D (5 and 10 kW)

Upper Control Board Screw

Lower Control Board Screw

Ground Jumper Terminals

Setting the Ground Jumper in 22 kW System Modules

This procedures applies to 1394C-SJT22-D system module. To set the ground jumper for an ungrounded system:

1. Verify that all 24V logic and main input power has been removed

from the system.

2. Open the system module door.

3. Locate the ground jumper inside the system module (refer to

Figure 3.4 for jumper location).

4. Without removing the circuit board, unplug the jumper and move

it to the ungrounded power distribution position. Refer to Figure

3.5 for the jumper positions.

IMPORTANT

Do not remove circuit board from 1394 system module.

Publication 1394-IN002B-EN-P — February 2004

3-8 Connecting Your 1394 SERCOS Interface System

Figure 3.4 Location of the 22 kW System Module Ground Jumper

Figure 3.5 22 kW System Module Jumper Positions

1394C-SJT22-D

Ground Jumper

Front edge

of board

Factory default jumper

position for a grounded

configuration

Front edge

of board

Jumper position on

ungrounded power

configuration

Publication 1394-IN002B-EN-P — February 2004

5. Close the system module door.

6. Go to Grounding Your 1394 SERCOS Interface System.

Connecting Your 1394 SERCOS Interface System 3-9

Grounding Your 1394 SERCOS Interface System

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. Grounding your modules and panels minimizes shock hazards to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis. For CE grounding requirements, refer to Chapter 1.

IMPORTANT

To improve the bond between your 1394 and the subpanel, construct your subpanel out of zinc plated (paint-free) steel.

Grounding Your System to the Subpanel

This section provides examples for connecting the chassis ground to your 1394 and the subpanel. The 1394 system module provides a grounding bar as a common point of chassis ground for the system and axis modules, as shown in Figure 3.6.

ATTENTION

The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system. Refer to Appendix B for the 1394 interconnect diagrams.

Figure 3.6 1394 Ground Wire Connections

1394 Front View

PE1

System module

single point bond bar

The system module single point bond bar wires to the bonded system ground bus on the sub-panel. Refer to Figure 3.7 for grounding configuration examples.

To bonded cabinet ground bus or power distribution ground

Publication 1394-IN002B-EN-P — February 2004

3-10 Connecting Your 1394 SERCOS Interface System

Figure 3.7 PE Safety Ground Configuration with Multiple 1394 Systems on One Panel

1394C-SJTxx-x System Modules

SERCOS System Module

Status

DANGER

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

Bonded ground bar

(optional)

SERCOS System Module

Status

DANGER

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

SERCOS System Module

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

All ground wiring must

comply with local codes

SERCOS System Module

DANGER

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

System module

single point

bond bar

Bonded cabinet ground bus

Status

DANGER

Status

Always follow NEC and

applicable local codes

Ground grid or power

distribution ground

Publication 1394-IN002B-EN-P — February 2004

Grounding Multiple Subpanels

To extend the chassis ground to multiple subpanels, refer to the figure below.

Figure 3.8 Subpanels Connected to a Single Ground Point

Always follow NEC and applicable local codes

Ground grid or power

distribution ground

Connecting Your 1394 SERCOS Interface System 3-11

Motor Power Cable Shield Termination

Factory supplied motor power cables for MP-Series and 1326AB/AS motors are shielded, and the braided cable shield must terminate at the drive during installation. A small portion of the cable jacket must be removed to expose the shield braid. The exposed area must be clamped (using the clamp provided) in front of the axis module, as shown in Figure 3.9, and the power wires terminated in the axis module terminal block.

ATTENTION

To avoid hazard of electrical shock, ensure shielded power cables are grounded at a minimum of one point for safety.

IMPORTANT

Connecting MP-Series (Low Inertia) and 1326AB Motor Power

When using MP-Series (low inertia) or 1326AB (M2L/S2L) motors, only the three-phase motor power wires are included in power cable, as shown in the figure below. These motors have a separate connector on the motor for brake connections and thermal switch wires are included in the feedback cable.

Cable clamps, designed to accommodate cables 1.5 to 6 mm each axis module. If your axis module (1394x-AM75) /motor combination requires 10 mm a larger cable clamp (catalog number 1394C-8AWGGCLAMP) is necessary to accommodate the larger diameter cable.

(16 to 10 AWG) in size, are shipped with

(8 AWG) cable,

Figure 3.9 Motor Power Cable (2090-XXNPMP-xxSxx or -CDNBPMP-xxSxx)

Motor Power

Cable Clamp

Publication 1394-IN002B-EN-P — February 2004

1394 Front View

3-12 Connecting Your 1394 SERCOS Interface System

Connecting 1326AB/AS (resolver) Motor Power

When using 1326AB/AS motors with resolver feedback, the thermal switch and brake wires are included in the motor power cable (1326CPx1-xxx). To improve the EMC performance of your system, route the motor brake and thermal switch wires to TB1 (as shown in Figure

3.10) and reference Thermal Switch and Brake Interconnect Diagrams

on page B-9 for the interconnect diagram.

Figure 3.10 Motor Power Cable (1326-CPx1-xxx)

SERCOS System Module

Status

DANGER

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

1326-CPx1-xxx Motor Power Cable

Motor Brake and

Thermal Switch Wires

TB1

TB2

TB1

TB2

1326-CPx1-xxx Motor Power Cable

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-13

Power Wiring Requirements

Power wiring requirements are given in the tables below. Wire should be copper with 75° C (167° F) minimum rating, per NFPA 79 unless otherwise noted. Phasing of main input power is arbitrary and earth ground connection is required for safe and proper operation.

IMPORTANT

The National Electrical Code and local electrical codes take precedence over the values and methods provided.

1394 Power Wiring Requirements

Module Description

Main Input Power U, V, W, PE

System Module 1394C-SJT05-D or 1394C-SJT10-D

System Module 1394C-SJT22-D

System Module 1394C-SJTxx-D

Axis Module 1394C-AM03,

-AM04, and -AM07

Axis Module 1394C-AM50,

-AM75, -AM50-IH, and -AM75-IH

Axis Module 1394C-AMxx and

-AMxx-IH

The input power terminal designated PE is electrically common to the system module single point bond bar, so the ground connection at PE is optional. However, the ground connection at the single point bond bar is mandatory.

105° C (221° F), 600V.

Input Logic Power W1, W2 4 (12) Shunt Resistor

Connections Main Input Power U, V, W, PE Input Logic Power W1, W2 4 (12) External Shunt Module

Connections

Ground

Drive System OK and Brake Relay Circuits

Motor Power

Ground PE1 6 (10)

Motor Power

Ground PE1 10 (8)

Thermal Switch and Brake Filter Circuits

Connects to Ter mi na ls

COL, INT, DC+ 6 (10)

DC+, COL 10 (8)

Single Point Bond Bar

Relay Outputs 0.2-4.0 (26-12)

U1, V1, W1, and PE2

TB1/TB2 0.2-4.0 (26-12)

Recommended Wire Size

(AWG)

6 (10)

10 (8)

10 (8) 1.6 (14)

Motor power cable depends on motor/drive combination, 6 (10) maximum

Motor power cable depends on motor/drive combination, 10 (8) maximum

Tor que Value

Nm (lb-in.)

0.56 - 0.62 (5.0 - 5.6)

2.21 - 2.66 (20.0 - 24.0)

0.56 - 0.62 (5.0 - 5.6)

1.55 - 2.0 (14.0 - 18.0)

0.56 - 0.62 (5.0 - 5.6)

Note: Refer to the section Understanding External Shunt Connections

on page 3-34 for more information regarding the COL, INT, and DC+ connections.

Publication 1394-IN002B-EN-P — February 2004

3-14 Connecting Your 1394 SERCOS Interface System

For additional information refer to Power Specifications in Appendix A. Refer to Appendix B for the 1394 interconnect diagrams.

ATTENTION

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

To avoid personal injury and/or equipment damage, ensure motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.

To avoid personal injury and/or equipment damage, ensure shielded power cables are grounded to prevent potentially high voltages on the shield.

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-15

Connecting Input Power

The system module provides terminating points for the main input power, logic power, feedback, and various other control signals. The slide-and-lock mechanism transfers power and commutation signals to each axis module. This procedure assumes you have the 1394 SERCOS interface system mounted on your panel and are ready to wire the input power.

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.

IMPORTANT

Refer to Appendix B for the 1394 interconnect diagrams.

If you have this System Module: Then Go To:

1394C-SJT05-D (5 kW) or 1394C-SJT10-D (10 kW)

1394C-SJT22-D (22 kW)

When tightening screws to secure the wires, refer to the tables beginning on page 3-13 for torque values.

To ensure system performance, run wires and cables in the wireways as established in Chapter 1.

Connecting Power Wiring for 5 and 10 kW System Modules beginning below.

Connecting Power Wiring for 22 kW System Modules beginning on page 3-17.

Connecting Power Wiring for 5 and 10 kW System Modules

The 1394C-SJT05-D and 1394C-SJT10-D system modules use connectors for wiring the main input power and logic power. You will wire the system using connector plugs that mate with connector housings. Refer to Figure 2.1 for the connector locations.

ATTENTION

To avoid personal injury and/or equipment damage ensure installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment.

Publication 1394-IN002B-EN-P — February 2004

3-16 Connecting Your 1394 SERCOS Interface System

Wiring Main Input Power

To wire the main input power connector:

1. Prepare the incoming three-phase power wires for attachment to

the input power connector by removing 10 mm (0.375 in.) of insulation.

IMPORTANT

2. Route the three-phase power wires (U, V, W, and PE) to your 1394

system module.

3. Connect the system module ground wire from the system module

single point bond bar to the bonded ground bar or bonded cabinet ground bus on the subpanel (as shown in Figure 3.7). For more information on bonding, refer to Chapter 1.

4. Insert the incoming power wires into the input power connector

plug as follows and tighten the four connector plug screws.

Insert the wires labeled: Into connector terminals

UU VV WW Ground PE

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

labeled:

Publication 1394-IN002B-EN-P — February 2004

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

terminal. Re-insert and tighten any loose wires.

ATTENTION

6. Insert the input power connector plug into the input power

connector on the bottom of the system module (refer to Figure 2.1 for the connector location).

To avoid personal injury or damage to equipment, verify that keys are inserted into the beveled slots above terminals V and W of the input power connector plug and PE and COL on the system module input and shunt power connectors, respectively. If the keys are missing, refer to Installing Your 1394C Power Connector Key Kit Installation Instructions (publication 1394-IN023x-EN-P).

Connecting Your 1394 SERCOS Interface System 3-17

Wiring Logic Power

To wire the logic power connector:

1. Prepare the incoming 24V dc logic power wires for attachment to

the logic power connector by removing 10 mm (0.375 in.) of insulation.

IMPORTANT

2. Route the 24V dc power wires (W1 and W2) to your 1394 system

module.

3. Insert the incoming 24V dc logic power wires into the logic power

connector plug as follows and tighten the connector plug screws.

Insert the wires labeled: Into the connector terminals

W1 W1 W2 W2

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

terminal. Re-insert and tighten any loose wires.

5. Insert the logic power connector plug into the logic power

connector on the bottom of the system module (refer to Figure 2.1 for the connector location).

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

labeled:

6. Go to Connecting Motor Power, Thermal Switch, and Brake.

Connecting Power Wiring for 22 kW System Modules

The 1394C-SJT22-D system module use IEC terminal blocks instead of connectors for making power connections. You will wire the system module using the power terminal blocks. Refer to Figure 2.2 for the terminal block location.

ATTENTION

To avoid personal injury and/or equipment damage, ensure installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment.

Publication 1394-IN002B-EN-P — February 2004

3-18 Connecting Your 1394 SERCOS Interface System

Wiring Main Input Power

To wire the main input power terminal block:

1. Prepare the incoming three-phase power wires for attachment to

the input power terminals by removing 10 mm (0.375 in.) of insulation.

IMPORTANT

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

2. Route the three-phase power wires (U, V, W, and PE) to your 1394

system module.

3. Connect the system module ground wire from the system module

single point bond bar to the bonded ground bar or bonded cabinet ground bus on the subpanel (as shown in Figure 3.7). For more information on bonding, refer to Chapter 1.

4. Open the front door of the system module and locate the 22 kW

system module terminal blocks (refer to Figure 2.2).

5. Insert the incoming power wires into the terminal blocks as

follows and tighten the four terminal block screws.

Insert the wires labeled: Into the terminal blocks labeled:

UU VV WW

Publication 1394-IN002B-EN-P — February 2004

Ground PE

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

terminal block. Re-insert and tighten any loose wires.

Connecting Your 1394 SERCOS Interface System 3-19

Wiring Logic Power

To wire the logic power terminal block:

1. Prepare the incoming 24V dc logic power wires for attachment to

the logic power terminals by removing 10 mm (0.375 in.) of insulation.

IMPORTANT

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

2. Route the 24V dc power wires (W1 and W2) to your 1394 system

module.

3. Open the front door of the system module and locate the 22 kW

system module terminal blocks (refer to Figure 2.2).

4. Insert the incoming 24V dc logic power wires into the terminals as

follows and tighten the terminal block screws.

Insert the wires labeled: Into the terminal blocks labeled:

W1 W1 W2 W2

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

terminal block. Re-insert and tighten any loose wires.

6. Go to the section Connecting Motor Power, Thermal Switch, and

Brake.

Publication 1394-IN002B-EN-P — February 2004

3-20 Connecting Your 1394 SERCOS Interface System

Connecting Motor Power, Thermal Switch, and Brake

These procedures assume you have mounted your 1394 SERCOS interface system, wired your three-phase input power, logic power, and are ready to wire the motor power, thermal switch, and brake connections.

Note: We recommend that you start at either the first or last axis

module, wire it completely, then wire the adjacent module completely, and so on until all axis modules are wired.

IMPORTANT

Refer to Appendix B for the 1394 interconnect diagrams. For motor power cable catalog numbers, refer to Motor Power Cables in Appendix C.

When tightening screws to secure the wires, refer to the tables beginning on page 3-13 for torque values.

To ensure system performance, run wires and cables in the wireways as established in Chapter 1.

Connecting the Ground Wire and Cable Clamp

IMPORTANT

To wire your PE1 ground wire and cable clamp:

1. Connect one end of the axis module ground wire to the system

module single point bond bar.

2. Connect the other end of the ground wire to PE1 terminal block.

3. Route the motor power cable to your axis module. For the

location of motor power connections, refer to Figure 2.8.

4. Prepare 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 (refer to Figure 3.11).

To improve the bond between the motor cable shield and the axis module PE ground, a cable shield clamp is included with the Series C axis modules.

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-21

5. Remove another 22 mm (0.875 in.) of insulation to expose the

braided shield underneath for clamp attachment.

(2.0 in.)

22 mm

(.875 in.)

51 mm

Cable wires

Braided shield exposed

IMPORTANT

When cutting into the insulation use care not to cut into the braided shield underneath.

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

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

7. Tighten the clamp screw.

IMPORTANT

Do not overtighten the clamp screw or damage to the braided shield may result.

8. Thread the bracket screw into the bottom of the axis module and

tighten.

Figure 3.11 Motor Power Cable Clamp Preparation

1394 Front View

Bracket

screw

Clamp

screw

Clamp shield clamp

Axis

cable clamp

PE1 connections

Motor

cable

Cable Preparation

To bonded

System module

single point bond bar

Cable Attachment

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

Remove plastic (captive) washer, if present.

IMPORTANT

If your 1394x-AM75 axis module requires 10 mm

Motor

power

cable

Wiring to Axis Module

cabinet ground bus or power distribution ground

AWG) cable, replace the clamp that shipped with your axis module with catalog number 1394C-8AWGGCLAMP.

Publication 1394-IN002B-EN-P — February 2004

3-22 Connecting Your 1394 SERCOS Interface System

Wiring the Motor Power Connector

To wire your motor power connections:

1. Prepare your conductors by removing the precut insulation or

stripping approximately 10 mm (0.375 in.) of insulation from the end of each wire.

IMPORTANT

2. Insert the motor power wires into the axis module terminal block

as follows and tighten the terminal block screws.

Insert this wire (number/color): Into this axis 1326AB/AS

(resolver) motors:

1 / Black U / Brown U1 2 / Black V / Black V1 3 / Black W / Blue W1 Green/Yellow PE / Green/Yellow PE2

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

terminal. Re-insert and tighten each loose wire.

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

MP-Series and 1326AB (M2L/S2L) motors:

module terminal block:

If your motor: Do the following:

For this motor: Using this motor

MP-Series (low inertia) and 1326AB (M2L/S2L) motors

1326AB/AS (resolver) motors

Publication 1394-IN002B-EN-P — February 2004

Includes the brake option Go to step 5. Does not include the brake

option

power cable:

2090-XXNPMP-xxSxx 2090-CDNBPMP-xxSxx

1326-CPx1-xxx

Go to Understanding Feedback and I/O Cable Connections.

Do the following:

Go to Wiring the Relay Outputs Connector.

Go to Wiring the TB1/TB2 Connectors (1326AB/AS Motors).

Connecting Your 1394 SERCOS Interface System 3-23

Wiring the TB1/TB2 Connectors (1326AB/AS Motors)

This procedure assumes you are using 1326AB/AS (resolver) motors, have the motor cable attached to the shield clamp, have wired the axis module terminal block, and are ready to connect the thermal switch and brake wires to the TB1 and TB2 connectors. Refer to Figure 2.8 to locate the TB1/TB2 connectors.

The 1326AB/AS (resolver) motor thermal switch and brake wires are in the motor power cable and must pass through noise filters (TB1 and TB2) on the bottom of each axis module.

IMPORTANT

One axis module connector kit (included with each axis module) is for thermal switch and brake inputs. You will need one kit per axis module as each kit contains two identical connectors. Refer to Appendix C for the connector kit replacement part number.

IMPORTANT

Noise filters on the motor 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.

To wire your thermal switch and brake connections:

1. Prepare your conductors by removing the precut insulation or

stripping approximately 10 mm (0.375 in.) of insulation from the end of each wire.

IMPORTANT

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

2. Using the operating tool, insert the thermal switch and brake wires

into the first connector (TB1) as follows and tighten the TB1 screws.

Insert this 1326-CPx1-xxx motor power wire:

Into this TB1 connector plug terminal:

wire (signal) 9 (K2) 5 (K1) 2 4 (B2) 6 (B1) 4

Thermal switch connections

Brake connections

Publication 1394-IN002B-EN-P — February 2004

3-24 Connecting Your 1394 SERCOS Interface System

3. Gently pull on each TB1 wire to make sure it does not come out

of its terminal. Re-insert and tighten each loose wire.

4. Insert the first connector plug (TB1) into the front-most mating

half under the axis module.

5. Connect the appropriate thermal switch control wires to the

second connector plug (TB2) in the kit (pins 3 and 4) and tighten the TB2 screws. Refer to Appendix B for thermal switch interconnect diagrams.

ATTENTION

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

6. Connect the appropriate brake control wires to the second

connector plug (TB2) in the kit (pins 1 and 2) and tighten the screws. Refer to Appendix B for brake interconnect diagrams.

7. Gently pull on each TB2 wire to make sure it does not come out

of its terminal. Re-insert and tighten each loose wire.

8. Insert the second connector plug (TB2) into the rear-most mating

half under the axis module.

9. Go to Wiring the Relay Outputs Connector on page 3-25.

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-25

Wiring the Relay Outputs Connector

This procedure assumes you have brake wires (user-supplied) leading from the TB2 connector or a brake cable (2090-UXNBMP-18Sxx) leading from your motor brake connector and are ready to connect your brake wires to the relay outputs connector on the 1394 system module.

To wire your relay outputs connector:

1. Prepare your relay wires, 0.82 mm

(18 AWG) maximum, by stripping approximately 10 mm (0.375 in.) of insulation from the end.

IMPORTANT

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

2. Route the cable to your 1394 system module. For the location of

the relay outputs connector, refer to figures 2.1 and 2.2.

3. Reference Brake Interconnect Diagrams beginning on page B-14

for typical brake interconnect diagrams.

4. If you: Do this:

1. Move to the next axis module.

Have more axis modules to wire

2. Go to Connecting the Ground Wire and Cable Clamp.

Have wired all of your axis modules

Go to Understanding Feedback and I/O Cable Connections.

Publication 1394-IN002B-EN-P — February 2004

3-26 Connecting Your 1394 SERCOS Interface System

Understanding Feedback and I/O Cable Connections

The procedure in this section assumes that your 1394 system and axis modules are already mounted and your power is wired. In this section you will:

• Prepare the feedback and I/O cables for wiring to connector

housings.

• Make the connections and plug the housings into mating

connectors on the bottom of the 1394 system module.

• Attach the feedback cable clamp to the feedback cable shield.

For this motor series: Using this type of feedback: Use this feedback cable:

MP-Series (low inertia) or 1326AB (M2L/S2L)

MP-Series Motor resolver

1326AB/AS Motor resolver 1326-CCUx-xxx

IMPORTANT

To improve the bond between the feedback cable shield and the system module chassis ground, cable

High-resolution encoder

2090-CDNFDMP-Sxx

shield clamps are included with system modules.

Motor Feedback Connector Pin-outs

The following table provides the signal descriptions and pin-outs for the motor feedback (13-pin) connector to MP-Series and 1326AB (M2L/S2L) motors.

High Resolution Feedback

Motor Connector Pin

ASine+ 1 BSine- 2 CCos+ 3 DCos- 4 E Data+ 8 F Data- 9 N EPWR_9V 6 PECOM 5 RTS+ 12 STS- 13 Shield Shield Shield Clamp

Signals for:

MPL-Bxxx-M/-S and 1326AB-Bxxx-M2L/-S2L 460V Motors

System Module Connector Pin

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-27

The following table provides the signal descriptions and pin-outs for the motor feedback (13-pin) connector to MP-Series (resolver-based) motors.

Motor Connector Pin

Resolver MPL-Bxxxx-R 460V Motors

Feedback for

System Module Connector Pin

AS2 1 BS4 2 CS1 3 DS3 4 GR1 10 HR2 11 RTS+ 12 STS- 13 Shield Overall Shield Shield Clamp

The following table provides the signal descriptions and pin-outs for the motor feedback (13-pin) connector to 1326AB (resolver-based) motors.

Motor Connector Pin

Resolver 1326AB-Bxxxx-21 460V Motors

AR1 10 TB2-3 TS+ 12 BR2 11 TB2-4 TS- 13 Drain Drain Shield Clamp DS1 3 ES3 4 Drain Drain Shield Clamp GS2 1 HS4 2 Drain Drain Shield Clamp Shield Overall Shield Shield Clamp

Feedback for

System Module Connector Pin

Connector Pin

Axis Module

Resolver Feedback for 1326AB-Bxxxx-21

460V Motors

System Module Connector Pin

For termination of individual drain wires, use the feedback cable clamp provided and reference Figure 3.10.

Thermal switch wires (5 and 9) are in the motor power cable (1326-CPx1-xxx). Route these wires through the noise filter (TB1/TB2) and reference Figure 3.10.

Publication 1394-IN002B-EN-P — February 2004

3-28 Connecting Your 1394 SERCOS Interface System

The following table provides the signal descriptions and pin-outs for the motor feedback (13-pin) connector to motors with the 845H quadrature encoder feedback using the 1326-CEU-xxx cable.

Motor Connector Pin

AAM+ 1 HAM- 2 Drain Drain Shield Clamp BBM+ 3 IBM- 4 Drain Drain Shield Clamp FCOM 5 D +5V dc 7 Drain Drain Shield Clamp CIM+ 8 JIM- 9 Drain Drain Shield Clamp Shield Overall Shield Shield Clamp

845H Quadrature Encoder Feedback 460V Motors

System Module Connector Pin

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-29

Wiring Feedback Connectors

To wire your 1394 feedback connectors:

1. Begin preparation of the feedback cable by cutting off the pins

already crimped to the wires.

2. If not already done, remove approximately 45 mm (1.75 in.) of the

outer insulation, braided shield, and foil shield to expose the individual insulated wires and drain wires (refer to Figure 3.12).

Note: 2090-CDNFDMP-Sxx motor feedback cables do not include

drain wires.

3. Strip approximately 13 mm (0.50 in.) of insulation from the end of

the individual wires (refer to Figure 3.12).

45 mm

(1.75 in.)

22 mm

(.875 in.)

Feedback

cable

(0.50 in.)

Braided

Cable Preparation

shield exposed

IMPORTANT

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

Figure 3.12 Feedback Cable Clamp Preparation

13 mm

Drain wires

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

Only two sets of wires are shown.

Remove plastic (captive) washer, if present.

Drain wires are not included with 2090-CDNFDMP-Sxx motor feedback cables.

Bracket

screw

Clamp screw

Clamp Attachment

Drain wires

Cable shield clamp

Feedback

cable clamps

Attaching Feedback to System Module

1394 Front View

IMPORTANT

Ensure enough insulation is removed or the connector housing spring will make contact with the insulation and not the bare wire.

Publication 1394-IN002B-EN-P — February 2004

3-30 Connecting Your 1394 SERCOS Interface System

4. Select one of the six feedback connector housings shipped with

your system module, depress the clamp spring with a small screw driver, insert the wire, and release the spring.

Note: Refer to the tables beginning on page 3-26 for motor/drive

pin-out information and figures 3.13 and 3.14 for an illustration. Refer to Appendix B for interconnect drawings.

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

terminal. Re-insert and test any loose wires.

6. Plug the connector housing into the appropriate feedback

connector on the bottom of the system module (refer to Figure

2.6).

Bare wires

Wire insulation

Foil shield

Braided shield

Outer insulation

IMPORTANT

The connectors and connector housings are keyed and cannot be connected backwards. However, each housing is identical so care should be taken to match the proper feedback cable with the appropriate connector.

Note: Six feedback channels are available. Refer to Figure 2.6 on

page 2-10 for connector function and pin-out information.

Figure 3.13 Wiring 2090-CDNFDMP-Sxx Feedback Cables

1394 System Module

Feedback Connectors

(bottom view)

Front

Back

13 12 11 10

9 8 7 6 5 4 3 2 1

Blade thickness:

0.5 mm (0.02 in.)

Feedback Cable

Publication 1394-IN002B-EN-P — February 2004

Replacement connector housings are included in the system module connector kit (part number 1394C-CCK-D). Each terminal has a spring type clamping mechanism which firmly grips the bare wire.

Bare wires

Drain wire

Wire insulation

Foil shield

Braided shield

Outer insulation

1326-CCU

1326-CEU-

1394 System Module

Feedback Connectors

Front

-xxx

xxx

Back

Connecting Your 1394 SERCOS Interface System 3-31

Figure 3.14 Wiring 1326-CCU-xxx Feedback Cables

(bottom view)

13 12 11 10

9 8 7 6 5 4 3 2 1

1326-CCU-xxx or 1326-CEU-xxx

Motor Feedback Cable

Thermal Switch Wires

from TB2-3 and -4

Blade thickness:

0.5 mm (0.02 in.)

Drain Wires (3)

Replacement connector housings are included in the system module connector kit (part number 1394C-CCK-D). Each terminal has a spring type clamping mechanism which firmly grips the bare wire.

Attaching the Cable Shield Clamp

IMPORTANT

To attach the cable shield clamp:

1. Thread the cable clamp bracket screw into the bottom of the

system module and tighten using 1.6 Nm (14 lb-in.) torque.

2. Remove another 22 mm (.875 in.) of outer insulation from the

feedback cable to expose the braided shield underneath for clamp attachment (refer to Figure 3.12).

IMPORTANT

To improve the HF bond (and reduce electrical noise) between the feedback cable shield and the system module chassis ground, use the cable shield clamps included with your system module.

When cutting into the outer insulation use care not to cut into the braided shield underneath.

Publication 1394-IN002B-EN-P — February 2004

3-32 Connecting Your 1394 SERCOS Interface System

3. Fold drain wires back over the braided shield and position the

cable shield clamp over the braided shield and drain wires (refer to Figure 3.12).

Note: 2090-CDNFDMP-Sxx motor feedback cables do not include

drain wires.

IMPORTANT

Ensure clamp screw is behind clamp and not braided shield.

4. Tighten the clamp screw.

IMPORTANT

Do not overtighten the clamp screw or damage to the braided shield may result.

5. If you have: Do this:

More motor feedback or auxiliary feedback to wire

Wired all of your motors

Wiring Discrete Input Connectors

1. Move to the next motor or auxiliary feedback device.

2. Go to Wiring Feedback Connectors.

Go to Wiring Discrete Input Connectors.

Publication 1394-IN002B-EN-P — February 2004

To wire the discrete input connectors:

1. Prepare your I/O wires, 0.82 mm

(18 AWG) maximum, by stripping approximately 6 mm (0.25 in.) of insulation from the end.

IMPORTANT

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

2. Using a small blade type screw driver, 0.5 mm (0.02 in.), depress

the housing connector spring clamp next to the pin you are prepared to wire and insert the wire. Refer to Figure 3.15 for an example of how to insert wires.

3. Remove the screw driver and gently pull on the wire to make sure

it does not come out of its terminal. Re-insert and test any loose wires.

1394 SERCOS interface

Control Board

Connecting Your 1394 SERCOS Interface System 3-33

4. Repeat steps 2 and 3 for all remaining I/O connector housing

wires.

5. Plug the connector housings into the appropriate I/O connector

on the front of the system module (refer to figures 2.1 or 2.2 for connector locations).

6. Secure the I/O wires by slipping a plastic tie-down through the

tie-down anchor (refer to figures 2.1 or 2.2 for tie down anchor locations) and bundle the wires together.

Figure 3.15 Wiring I/O Cables

1394C-SJTxx-D

Axis 3

Axis 2

Axis 1

Axis 0

Blade thickness:

0.5 mm (0.02 in.)

Replacement connector housings are included in the system module connector kit (part number 1394C-CCK-D). Each terminal has a spring type clamping mechanism which firmly grips the bare wire.

Publication 1394-IN002B-EN-P — February 2004

3-34 Connecting Your 1394 SERCOS Interface System

Understanding External Shunt Connections

If your application requires an:

Internal Passive Shunt Resistor

External Passive Shunt Resistor

External Passive Shunt Module

Catalog Number:

N/A

1394-SR10A

1394-SRxxxx 1394C-SJT22-D

Follow these guidelines when wiring your Bulletin 1394 External Shunt Resistor/Module.

IMPORTANT

When tightening screws to secure the wires, refer to the tables beginning on page 3-13 for torque values.

To ensure system performance, run wires and cables in the wireways as established in Chapter 1.

Refer to Appendix B for the 1394 interconnect diagrams.

And you are wiring to this 1394C system module:

1394C-SJT05-D or 1394C-SJT10-D

Then:

• Verify the internal shunt jumper is in place between COL and INT,

as shown in Figure 3.16.

• Remove the internal shunt jumper between COL and INT.

• Refer to Planning Your Panel Layout and Mounting Your External

Shunt Resistor Kit in Chapter 1.

• Refer to System Module Input Power Pin-outs in Chapter 2.

• Refer to The Shunt Module Interconnect Diagrams in Appendix B.

1394C-SJT05-D or -SJT10-D

System Module (bottom view)

Figure 3.16 System Module Jumper

This is the factory default jumper setting.

Shunt Power

Connector

COL INT DC+

Jumper

Publication 1394-IN002B-EN-P — February 2004

Connecting Your 1394 SERCOS Interface System 3-35

Connecting Your SERCOS Fiber-Optic Cables

Front View

SERCOS interface

Tx (rear)

Rx (front)

ControlLogix 1756-M

SE SERCOS

interface Module

This procedure assumes you have your ControlLogix chassis with 1756-MxxSE interface module or personal computer with 1784PM16SE PCI card and 1394 SERCOS interface system(s) mounted and are ready to connect the fiber-optic cables.

The SERCOS fiber-optic ring is connected using the SERCOS Receive and Transmit connectors. Refer to Chapter 2 for the location of the connectors on your 1394 drive(s) and Figure 3.17 to locate the connectors on your SERCOS interface module or PCI card.

Note: Plastic cable is available in lengths up to 32 m (105.0 ft). Glass

cable is available in lengths up to 200 m (656.7 ft).

Figure 3.17 ControlLogix and SoftLogix SERCOS Connector Locations

RSLogix 5000

SoftLogix 1784-PM16SE SERCOS interface PCI Card

(as viewed from the back of your PC)

SERCOS Transmit Connector, Tx

SERCOS Receive Connector, Rx

Bottom View

SERCOS Receive Connector, Rx (front)

SERCOS Transmit Connector, Tx (rear)

Refer to Figure 3.18 for an example of fiber-optic ring connections between the 1394 SERCOS interface drive(s) and the SoftLogix SERCOS interface PCI card.

Figure 3.18 Fiber-Optic Ring Connection (Example 1)

Receive

Transmit

1394 SERCOS

interface System

Receive

SoftLogix 1784-PM16SE SERCOS interface PCI Card

SERCOS System Module

Status

DANGER

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

Tr an sm it

SERCOS fiber-optic ring

1394 SERCOS

interface System

Receive

SERCOS System Module

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

Status

DANGER

Tra ns mi t

Publication 1394-IN002B-EN-P — February 2004

3-36 Connecting Your 1394 SERCOS Interface System

Refer to figures 3.19 and 3.20 for examples of fiber-optic ring connections between the 1394 SERCOS interface drive(s) and the ContolLogix SERCOS interface module.

Figure 3.19 Fiber-Optic Ring Connection (Example 2)

1756-MxxSE SERCOS interface Module

Receive

ControlLogix Chassis

Tr an sm it

SERCOS Fiber-Optic Ring

Cable lengths of 32 m (105 ft) for plastic cable and 200 m (656.7 ft) for glass cable are possible for each transmission section (point A to B). In Figure 3.20, the second 1394 system is located in a separate cabinet and connected with bulkhead adapters.

IMPORTANT

1394 SERCOS interface System

Receive

SERCOS System Module

Status

DANGER

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

Tra ns mi t

Receive

SERCOS System Module

Status

DANGER

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

Tra ns mi t

SERCOS Fiber-Optic Ring

To avoid signal loss, do not mix glass and plastic cables when connecting to a bulkhead adapter. Use glass-to-glass or plastic-to-plastic cable on both sides of the adapter.

1394 SERCOS interface System

1394 SERCOS

interface System

Publication 1394-IN002B-EN-P — February 2004

Figure 3.20 Fiber-Optic Ring Connection (Example 3)

1756-MxxSE SERCOS Interface Module

SERCOS interface

ControlLogix Chassis

Tx (rear)

Rx (front)

SERCOS Fiber-Optic Ring

SERCOS System Module

Status

DANGER

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

SERCOS Fiber-Optic Ring

SERCOS Fiber-Optic

Bulkhead Adapter

SERCOS Fiber-Optic Ring

1394 SERCOS

interface System

SERCOS Fiber-Optic Ring

SERCOS System Module

Status

DANGER

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

Connecting Your 1394 SERCOS Interface System 3-37

IMPORTANT

Clean the fiber-optic cable connectors prior to installation. Dust in the connectors can reduce signal strength. For more information, refer to Fiber Optic Cable Installation and Handling Instructions (publication 2090-IN010x-EN-P).

To connect the SERCOS fiber-optic cables:

1. Insert one end of a fiber-optic cable into the Receive SERCOS

connector on the 1394 system module and thread the connector on finger tight.

2. Insert the other end of the cable (from step 1) into the Transmit

SERCOS connector on the ControlLogix module/SoftLogix PCI Card and thread the connector on finger tight.

3. Insert one end of another fiber-optic cable into the Transmit

SERCOS connector on the last 1394 system module in the ring and thread the connector on finger tight.

4. Insert the other end of the cable (from step 3) into the Receive

SERCOS connector on the ControlLogix module/SoftLogix PCI Card and thread the connector on finger tight.

5. Complete the ring by connecting the Transmit and Receive

connectors from one drive to the next until all are connected (refer to the examples above).

Refer to Appendix C for SERCOS fiber-optic cable and bulkhead adapter catalog numbers.

Publication 1394-IN002B-EN-P — February 2004

3-38 Connecting Your 1394 SERCOS Interface System

Publication 1394-IN002B-EN-P — February 2004

Troubleshooting Status Indicators

Chapter

Chapter Objectives

This chapter covers:

• Understanding How to Detect a Problem

• Troubleshooting System and Axis Module LEDs

• Troubleshooting the SERCOS Network Status LED

• Troubleshooting General System Problems

• Troubleshooting System and Axis Module Faults

• Troubleshooting General System Problems

For power up procedures and system integration with the ControlLogix and SoftLogix SERCOS modules/PCI cards (see table below) refer to the 1394 SERCOS interface Integration Manual (publication 1394-IN024x-EN-P). Manuals are available electronically (as a .pdf) or in hardcopy from www.theautomationbookstore.com.

Interface ControlLogix Module SoftLogix PCI Card

SERCOS interface 1756-MxxSE 1784-PM16SE

Understanding How to

When a drive fault occurs, the LED on the front panel changes and a fault message is transmitted to the position controller.

Detect a Problem

The majority of 1394 faults cause the Drive System OK contact to open. If a drive fault occurs, you can reset the fault detection circuitry by removing and reapplying logic power. However, if it is a hardware fault, you need to correct the fault before restarting.

IMPORTANT

This material, along with the diagnostic/troubleshooting information included with the position controller, will help you identify most common system malfunctions and determine which module that problem pertains to.

1 Publication 1394-IN002B-EN-P — February 2004

You can also reset a fault condition using RSLogix 5000 software.

4-2 Troubleshooting Status Indicators

Troubleshooting System and Axis Module LEDs

If the System Module LED is: Potential Cause is: Possible Resolution is:

Steady red

Flashing red

Alternating red and green

Steady green The bus is up and axes are enabled. None needed.

Flashing green

Not illuminated

The system module Status LED is visible from the front of the module. Refer to figures 2.1 and 2.2 for the location of the system module status LED.

Terminator not installed. • Install terminator.

• Verify wiring.

• Secure wiring connections.

Malfunctioning system module.

A fault has occurred in the system (check for faults through the RSLogix 5000, DriveExplorer, or the HIM).

DC bus is not up. Apply three-phase power.

Open fuse or malfunctioning contactor on user-supplied 3 phase input.

Malfunctioning system module. Replace the module.

The bus is up, but no axis is enabled.

Enable signal from position controller is not present.

Controller has detected a machine system malfunction and will not enable the 1394.

There is no power to the system module.

• Replace the module.

• Check logic supply ratings.

• Contact your local Allen-Bradley Support Representative.

• Reset faults.

• Verify wiring.

• Secure wiring connections.

• Check SERCOS fiber-optic connections.

• Check wiring to start/stop circuitry.

• Check the user program.

• Check fuse.

• Check axes and enable them, if necessary.

• Verify that enable wiring is correct and not open.

• Check axes and enable them, if necessary.

• Verify that enable wiring is correct and not open.

• Check I/O connections on control board.

• Check controller.

• Check the machine.

• Check 24V ac/dc logic power supply.

• Check main ac input power supply.

Publication 1394-IN002B-EN-P — February 2004

Troubleshooting Status Indicators 4-3

The axis module status LED is visible from the front of the module. Refer to Figure 2.8 for the location of the axis module status LED.

If the Axis Module LED is: Potential Cause is: Possible Resolution is:

• Verify wiring.

• Verify that the slider and

Steady red Malfunctioning axis module.

Flashing red Axis fault has occurred.

Alternating red and green DC bus is not up.

Steady green The bus is up and axes are enabled. None needed.

Axis is not enabled.

Enable signal from controller is not

Flashing green

Not illuminated

present.

Incorrect wiring or loose connections.

Axis setups may not be correct for the application.

There is no power to the axis module.

There is no power to the system.

terminator connections are secure.

• Secure wiring connections.

• Replace the module.

• Verify wiring.

• Secure wiring connections.

• Check fault status on the controller.

• Check main ac input power.

• Check axis status on the controller.

• Verify that the terminator is present on the last axis.

• Check the system module LED.

• Check slider connections to verify that they are properly seated.

• Check axes and enable them, if necessary.

• Verify that enable wiring is correct and not open.

• Check axes and enable them, if necessary.

• Verify that enable wiring is correct and not open.

Check I/O connections on the control board.

• Verify that axis definitions are correct.

• Check tuning parameters.

• Verify that the slider connections are secure.

• Verify that the terminator is secure on the last axis.

• Check system module power supply.

• Verify that the terminator is present on the last axis.

Publication 1394-IN002B-EN-P — February 2004

4-4 Troubleshooting Status Indicators

Troubleshooting the

The SERCOS Network Status LED is located on the system module control board and visible with the system module door open. Refer to

SERCOS Network Status LED

If the SERCOS Network Status LED is:

Steady Green Communication ready No faults or failures. System is ready.

Steady Orange Control board failure

Flashing Green

Flashing Red

Status is: Potential Cause is: Possible Resolution is:

Establishing communication

No communication

figures 2.1 and 2.2 for the location of the SERCOS Network Status LED.

Control board failure.

Hardware failure. Replace system module. System is still in the process of establishing

SERCOS communication.

Node address setting on the 1394 system module does not match SERCOS controller configuration.

Loose fiber-optic connection. Verify proper fiber-optic cable connections. Dirty fiber-optic cable connectors. Remove foreign material from connector. Broken fiber-optic cable. Replace fiber-optic cable. Weak fiber-optic signal due to long fiber-optic cable. Set SERCOS transmit level to HIGH. Distorted fiber-optic signal due to short fiber-optic

cables. Receive fiber-optic cable connected to SERCOS

transmit connector and visa versa.

Refer to Fiber Optic Cable Installation and Handling Instructions (publication 2090-IN010A-EN-P) for more information.

• Cycle power.

• Replace system module.

Wait for steady green LED status.

Verify proper SERCOS base address switch setting (refer to figures 2.1 and 2.2 for switch location).

Decrease SERCOS transmit level of previous device in SERCOS ring.

Check proper SERCOS fiber-optic cable connections.

Publication 1394-IN002B-EN-P — February 2004

Troubleshooting Status Indicators 4-5

Troubleshooting System and Axis Module Faults

Fault Message RSLogix (HIM):

DriveOvercurrent Fault

(Bus Overcurrent)

DriveOvervoltage Fault

(Bus Overvoltage)

Description: Potential Cause is: Possible Resolution is:

System module exceeded current rating.

The DC bus voltage is above limits. If it exceeds (830V dc), a fault is sensed and the power supply is disabled.

Bus Voltage Operation Shunt turns on at 805V dc. Shunt turns off at 750V dc. Over voltage trip point is 825V dc. Under voltage trip point is 275V dc. Under voltage fault clears at 300V dc.

Fault messages are transmitted to the SERCOS controller through the SERCOS ring and/or SCANport. The tables on the following pages provide a description of system and axis module faults, the potential cause, and possible resolutions.

Note: Fault messages are shown as seen in RSLogix software (bold)

and when using the HIM or DriveExplorer (not bold).

System Module Faults

Use the table below for troubleshooting system module faults.

• Check for proper motor sizing.

Motor or transmission malfunction.

System module not properly sized.

If this fault occurs when you power up the system module with the M-contactor, the power distribution impedance might be stiff or line voltage might be too high.

The position controller acceleration / deceleration rate is incorrectly set.

The system inertia is too high causing excessive energy to be returned to the power supply bus.

A vertical axis with insufficient counterbalancing is overdriving the servo motor and causing excessive energy to be returned to the power supply bus.

Input line voltage exceeds the maximum input voltage rating.

Power Driver Board is malfunctioning and is incorrectly sensing the bus voltage.

The shunt regulator or transistor has malfunctioned.

External shunt regulator fuse has blown. Check and possibly replace the shunt resistor. Shunt type not selected properly. Select proper shunt type.

• Check/replace transmission device.

• Check/replace motor.

• Check for proper system module sizing.

• Install larger kW rated system module.

• Perform line conditioning.

• Verify that line voltage is within specifications.

Change the command profile to reduce speed or increase time.

• Change the command profile to reduce speed or increase time.

• Use a larger external shunt resistor.

• Use the external shunt resistor.

• Increase the mechanical counter-balance on the machine.

Verify incoming main ac input voltage and change the supply source, if needed.

Replace the system module.

DriveUndervoltage Fault

(Bus Precharge)

DriveUndervoltage Fault

(Bus Undervoltage)

DriveHardFault

(Can Init)

The system module precharge cycle has failed.

The DC power bus activates undervoltage limit when the bus drops to 275V dc or less. It will clear at 300V dc.

SCANport hardware initialization fault detected.

The precharge circuit has malfunctioned.

The voltage on the main ac input power is low.

Control board hardware failure.

• Check main ac line voltage.

• Check fusing.

• Replace the system module.

• Verify incoming AC voltage and change the supply source, if needed.

• Check fusing.

• Cycle all input power.

• If fault persists, replace system module.

Publication 1394-IN002B-EN-P — February 2004

4-6 Troubleshooting Status Indicators

Fault Message RSLogix (HIM):

DriveHardFault

(Contactor Fault)

MotFeedbackFault

(Fdbk Watch Dog)

GroundShortFault

(Ground Short)

DriveHardFault

(IDMA Load)

DriveHardFault

(Memory Init)

DriveHardFault

(NV Mem Init)

DriveHardFault

(Objects Init)

PowerPhaseLoss Fault

(Phase Loss Flt)

Description: Potential Cause is: Possible Resolution is:

Three-phase power is either detected when it shouldn’t be or not detected when it should be.

A feedback hardware or software fault detected.

Excessive ground current in the system module was detected.

Motor feedback hardware initialization fault detected.

Memory hardware initialization fault detected.

Non-volatile memory is corrupt.

The three-phase input line is monitored and a fault will be issued whenever a phase loss is detected.

The contactor is welded or failed to open.

The input wiring to your contactor is incorrect. Correct wiring.

The feedback processor has faulted.

Incorrect wiring.

Motor malfunction.

Axis Module IGBT malfunction. Replace the axis module.

Short to ground.

Control board hardware failure.

Incorrect motor feedback wiring. • Load default parameters, save to non-

Improper feedback cable clamp attachment.

Control board hardware failure.

Control board software error.

Control board hardware failure.

One or more input line fuses have opened. Check fuses and replace, as necessary.

Input line contactor malfunction.

Incorrect wiring. Check main ac input power at system module.

• Correct wiring.

• Replace the contactor.

• Cycle all input power.

• If fault persists, replace system module.

• Verify motor and ground wiring.

• Replace cables. Check the resistance of each motor winding

phase to case ground with an ohm meter. Readings should be in mega ohms.

• Replace the system or axis module.

• Check grounding and incoming power wiring.

• Cycle all input power.

• If fault persists, replace system module.

volatile memory, and recycle power.

• Reset the drive.

• Replace the system module.

• Cycle all input power.

• If fault persists, replace system module.

• Load default parameters, save to nonvolatile memory, and recycle power.

• Reset the drive.

• Replace the system module.

• Load default parameters, save to nonvolatile memory, and recycle power.

• Reset the drive.

• Replace the system module.

• Correct wiring.

• Replace contactor.

DriveHardFault

(SCANport Comm)

SERCOSFault

(SERCOS Ring Flt)

DriveHardFault

(SERCOS Init)

DriveHardFault

(Serial Ring Init)

Publication 1394-IN002B-EN-P — February 2004

SCANport/DPI Communication Failed.

SERCOS ring not active after being active and operational.

SERCOS hardware initialization fault detected.

Intermodule serial communication failed.

The SCANport/DPI device or cable is faulty. Check SCANport/DPI connections.

SERCOS ring is physically broken.

ControlLogix program is downloaded during operation (this causes SERCOS ring to cycle).

Control board hardware failure.

Terminator is not installed.

System module failure. Replace the system module.

• Check fiber optic cable connections.

• Replace fiber optic cable.

Wait for SERCOS ring to cycle and fault to reset.

• Cycle all input power.

• If fault persists, replace system module.

• Verify that the slider and terminator connections are secure.

Troubleshooting Status Indicators 4-7

Fault Message RSLogix (HIM):

SERCOSFault

(SERCOS Same Addr)

DriveOvervoltage Fault

(Shunt Time Out)

DriveOvertemp Fault

(Sys Overtemp)

DriveHardFault

(Sys Mod Unknown)

DriveHardFault

(Task Init)

Description: Potential Cause is: Possible Resolution is:

Duplicate node address detected on SERCOS ring.

Shunt resistor continuous rating exceeded.

The 1394 thermal sensor tripped when internal ambient temperature exceeded rating.

Active when serial ring detects unknown system module.

Software initialization fault detected.

The regenerative energy produced by the motor exceeded the limit of the shunt resistor.

The fan on the system module or an axis module failed.

The cabinet ambient temperature is above rating. Check the cabinet temperature. The machine duty cycle requires an RMS current

exceeding the continuous rating of the controller. Changes in mechanics have occurred causing an

increased torque output for the application move profiles.

The airflow access to the 1394 is limited or blocked.

Unknown system module. Replace the system module.

Control board hardware failure.

Verify that each SERCOS drive is assigned a unique node address.

• Use a properly sized shunt or modify duty cycle of the application.

• System uses internal shunt and requires external shunt for additional capacity.

Replace the system or axis module.

Change the command profile to reduce speed or increase time.

• Check mechanics for improper operation.

• Verify operating torque.

Check airflow and re-route cables away from the 1394.

• Cycle all input power.

• If fault persists, replace system module.

DriveHardFault

(Unknown Fault)

Fault is detected but source is unknown.

Wrong version of software for the hardware or loose internal or external connection.

• Check system terminator.

• Reset drive.

Publication 1394-IN002B-EN-P — February 2004

4-8 Troubleshooting Status Indicators

Axis Module Faults

Use the table below for troubleshooting axis module faults.

Fault Message RSLogix (HIM):

No Fault Message (condition indicated by on-screen message)

(Ax: ATune Flt)

No Fault Message (condition indicated by on-screen message)

(Axis x Hookup Fault)

DriveHardFault

(Axis x Unknown)

AuxFeedbackFault

(Ax: Aux Fdbk AQB)

AuxFeedbackFault

(Ax: Aux Fdbk Comm)

AuxFeedbackFault

(Ax: Aux Fdbk Loss)

Description: Potential Cause is: Possible Resolution is:

Auto tune procedure failed to complete successfully.

Hookup procedure failed to complete successfully.

Active when serial ring detects unknown axis module.

Auxiliary Encoder State Error

Drive unable to communicate with auxiliary Smart feedback device.

The feedback wiring is open, shorted, or missing.

Motor or feedback device malfunction.

Unknown axis module.

Auxiliary encoder has encountered an illegal state transition.

The auxiliary encoder feedback signal is lost.

Open or short circuit has occurred on feedback wiring.

The feedback wiring or termination to system module is incorrect.

Motor feedback failure. Replace the motor feedback.

• Check motor power/feedback wiring.

• Refer to on-screen message for resolution.

• Check motor power/feedback wiring.

• Refer to on-screen message for resolution.

• Check the slider connections.

• Replace the axis module.

• Use shielded cables with twisted pair

wires.

• Route the feedback away from potential

noise sources.

• Check the system grounds.

• Replace the motor/encoder.

• Check auxiliary feedback wiring.

• Reset faults.

Check the feedback cable connectors/wiring to the system module and motor.

AuxFeedback NoiseFault

(Ax: Aux Fdbk Noise)

DriveUndervoltage Fault

(Ax: Bus Loss)

DriveOvercurrent Fault

(Ax: Desat)

DriveEnableInput Fault

(Drive Enable Flt)

Publication 1394-IN002B-EN-P — February 2004

Excessive noise detected on feedback signals.

The DC bus supply to the axis module was lost.

Too much current in the axis module.

Missing Drive Enable Input Signal

Poor grounding.

The slider connections may not be secure. Check slider connections.

An axis module’s bus link fuse has blown. Replace the axis module.

Power module malfunction. Replace the axis module.

• An attempt was made to enable the axis

through software while the Drive Enable hardware input was inactive.

• The Drive Enable input transitioned from

active to inactive while the axis was enabled.

• Check ground clamp connectors.

• Check system module grounding.

• Disable the Drive Enable Input fault.

• Verify that Drive Enable hardware input is

active whenever the drive is enabled through software.

Rockwell Automation 1394 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

Product Receiving and Storage Responsibility

Related Documentation

Conventions Used in this Manual

Allen-Bradley Support

Local Product Support

Technical Product Assistance

Comments Regarding this Manual

Chapter Objectives

Complying With European Union Directives

EMC Directive

Meeting CE Requirements

Low Voltage Directive

Before Mounting Your System

Unpacking Modules

System Mounting Requirements

Ventilation Requirements

Determining Your System Mounting Hole Layout

Mounting Your 1394 Through the Back of the Cabinet

HF Bonding Your System

Bonding Modules

Bonding Multiple Subpanels

Planning Your Panel Layout

Establishing Noise Zones

Cable Categories for the 1394

Mounting Guidelines to Reduce Electrical Noise

Mounting Your 1394 SERCOS interface System

Mounting Your External Shunt Resistor Kit

Chapter Objectives

Locating System Module Connectors and Indicators

System Module Connector Pin-outs

System Module Connectors

Discrete Input Connector Pin-out

Relay Output Connector Pin-out

Analog Output Connector

Motor Feedback Connector Pin-outs

Auxiliary Feedback Connector Pin-outs

System Module Input Power Pin-outs

SCANport Adapter

Locating Axis Module Connectors and Indicators

Axis Module Connector Pin-outs

Axis Module Connectors

Motor Power and Brake Connector Pin-outs

Understanding I/O Specifications

Discrete Input Specifications

Analog Output Specifications

Drive System OK Relay Specifications

Motor Brake Relay Specifications

SERCOS Connection Specifications

Logic Power Input Specifications

Understanding Feedback Specifications

Motor and Auxiliary Feedback Specifications

Chapter Objectives

Understanding Basic Wiring Requirements

Building Your Own Cables

Routing Power and Signal Wiring

Input Power Conditioning

Determining Your Type of Input Power

Grounded Power Configuration

Ungrounded Power Configuration

Setting the Ground Jumper in Ungrounded Power Configurations

Setting the Ground Jumper in 5 and 10 kW System Modules

Setting the Ground Jumper in 22 kW System Modules

Grounding Your 1394 SERCOS Interface System

Grounding Your System to the Subpanel

Grounding Multiple Subpanels

Motor Power Cable Shield Termination

Power Wiring Requirements

1394 Power Wiring Requirements

Connecting Input Power

Connecting Power Wiring for 5 and 10 kW System Modules