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.

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