Instalation Manual IQ2000 PDF

1398
ULTRA Plus Series

Positioning Drive
Module
(Catalog Nos. 1398-PDM-10, -20,
-30, -50, -75, -100, -150, and -150B)
Installation Manual
Important User Information %HFDXVHRIWKHYDULHW\RIXVHVIRUWKHSURGXFWVGHVFULEHGLQWKLV
SXEOLFDWLRQWKRVHUHVSRQVLEOHIRUWKHDSSOLFDWLRQDQGXVHRIWKLVFRQWURO
HTXLSPHQWPXVWVDWLVI\WKHPVHOYHVWKDWDOOQHFHVVDU\VWHSVKDYHEHHQ
WDNHQWRDVVXUHWKDWHDFKDSSOLFDWLRQDQGXVHPHHWVDOOSHUIRUPDQFHDQG
VDIHW\UHTXLUHPHQWVLQFOXGLQJDQ\DSSOLFDEOHODZVUHJXODWLRQVFRGHVDQG
VWDQGDUGV
7KHLOOXVWUDWLRQVFKDUWVVDPSOHSURJUDPVDQGOD\RXWH[DPSOHVVKRZQLQ
WKLVJXLGHDUHLQWHQGHGVROHO\IRUSXUSRVHVRIH[DPSOH6LQFHWKHUHDUH
PDQ\YDULDEOHVDQGUHTXLUHPHQWVDVVRFLDWHGZLWKDQ\SDUWLFXODU
LQVWDOODWLRQ$OOHQ%UDGOH\GRHVQRWDVVXPHUHVSRQVLELOLW\RUOLDELOLW\WR
LQFOXGHLQWHOOHFWXDOSURSHUW\OLDELOLW\IRUDFWXDOXVHEDVHGXSRQWKH
H[DPSOHVVKRZQLQWKLVSXEOLFDWLRQ
$OOHQ%UDGOH\SXEOLFDWLRQ6*,6DIHW\*XLGHOLQHVIRUWKH$SSOLFDWLRQ
,QVWDOODWLRQDQG0DLQWHQDQFHRI6ROLG6WDWH&RQWURODYDLODEOHIURP\RXUORFDO
$OOHQ%UDGOH\RIILFHGHVFULEHVVRPHLPSRUWDQWGLIIHUHQFHVEHWZHHQ
VROLGVWDWHHTXLSPHQWDQGHOHFWURPHFKDQLFDOGHYLFHVWKDWVKRXOGEH
WDNHQLQWRFRQVLGHUDWLRQZKHQDSSO\LQJSURGXFWVVXFKDVWKRVHGHVFULEHG
LQWKLVSXEOLFDWLRQ
5HSURGXFWLRQRIWKHFRQWHQWVRIWKLVFRS\ULJKWHGSXEOLFDWLRQLQZKROH
RUSDUWZLWKRXWZULWWHQSHUPLVVLRQRI5RFNZHOO$XWRPDWLRQLV
SURKLELWHG
7KURXJKRXWWKLVPDQXDOZHXVHQRWHVWRPDNH\RXDZDUHRIVDIHW\
FRQVLGHUDWLRQV
,GHQWLILHVLQIRUPDWLRQDERXWSUDFWLFHVRU
ATTENTION
FLUFXPVWDQFHVWKDWFDQOHDGWRSHUVRQDOLQMXU\RUGHDWK
SURSHUW\GDPDJHRUHFRQRPLFORVV
!
$WWHQWLRQVWDWHPHQWVKHOS\RXWR
• LGHQWLI\DKD]DUG
• DYRLGDKD]DUGDQG
• UHFRJQL]HWKHFRQVHTXHQFHV
IMPORTANT ,GHQWLILHVLQIRUPDWLRQWKDWLVFULWLFDOIRUVXFFHVVIXO
DSSOLFDWLRQDQGXQGHUVWDQGLQJRIWKHSURGXFW
$OOHQ%UDGOH\LVDWUDGHPDUNRI5RFNZHOO$XWRPDWLRQ
*0/8OWUD6RIWZDUHLVDWUDGHPDUNRI5RFNZHOO$XWRPDWLRQ
8/DQGF8/DUHUHJLVWHUHGWUDGHPDUNVRI8QGHUZULWHUV/DERUDWRULHV
:LQGRZVLVDWUDGHPDUNRI0LFURVRIW&RUSRUDWLRQ
Table of Contents
Preface
,QWURGXFWLRQ 3
:KR6KRXOG8VHWKLV0DQXDO 3
3XUSRVHRIWKLV0DQXDO 3
&RQWHQWVRIWKLV0DQXDO 3
5HODWHG'RFXPHQWDWLRQ 3
&RQYHQWLRQV8VHGLQWKLV0DQXDO 3
3URGXFW5HFHLYLQJDQG6WRUDJH5HVSRQVLELOLW\ 3
$OOHQ%UDGOH\6XSSRUW 3
/RFDO3URGXFW6XSSRUW 3
7HFKQLFDO3URGXFW$VVLVWDQFH 3
Chapter 1
Overview of the ULTRA Plus PDM )XQFWLRQDO'HVFULSWLRQ
System 6\VWHP2YHUYLHZ
*0/8OWUDIRU:LQGRZV
3RVLWLRQLQJ'ULYH0RGXOHV
3RZHU6XSSO\0RGXOH360
0RWRUV
3HUVRQDOLW\0RGXOH30
0DQXDOV
$FFHVVRULHV
2SHUDWRU7HUPLQDO
7UDQVIRUPHUV
$X[LOLDU\3RZHU6XSSO\0RGXOH360
&DEOHV
6KXQW.LWV
3HUVRQDO&RPSXWHU3&
Chapter 2
Install the ULTRA Plus PDM 0RXQWLQJ
Components (QYLURQPHQW
9HQWLODWLRQ
7UDQVIRUPHU6L]LQJ
0RXQWLQJ5HTXLUHPHQWV
3'0DQG3RZHU6XSSO\0RGXOH
360$X[LOLDU\7UDQVIRUPHUV
0RWRUV
([WHUQDO6KXQW
2SHUDWRU7HUPLQDO
,)&RQYHUVLRQ&DUG9'&6RXUFLQJ
3'0)XVLQJ5HTXLUHPHQWV
6KRUW&LUFXLW3URWHFWLRQ
3HUVRQDOLW\0RGXOH,QVWDOODWLRQ
i Publication 1398-5.1 — January 2000

ii
,QVWDOOLQJWKH3HUVRQDOLW\0RGXOH30

6\VWHP)LUPZDUH,QVWDOODWLRQ
,QVWDOOLQJWKH)LUPZDUH(3520V
-XPSHUDQG',36ZLWFKHV
5HJXODWRU\5HTXLUHPHQWV
(OHFWURPDJQHWLF&RPSDWLELOLW\'LUHFWLYH
%RQGLQJ<RXU6\VWHP
0RWRUVDQG&DEOHV
/RZ9ROWDJH'LUHFWLYH
(OHFWURPDJQHWLF&RPSDWLELOLW\
)LOWHULQJ
$&/LQH)LOWHU6HOHFWLRQ
*URXQGLQJ
6KLHOGLQJDQG6HJUHJDWLRQ
Chapter 3
Wire the ULTRA Plus PDM 6\VWHP3RZHU&RQQHFWLRQV
Components 3'0DQG%
3'0DQG
([WHUQDO6KXQW&RQQHFWLRQV
5HSODFLQJWKH3606KXQW)XVH
2SHUDWRU7HUPLQDOV
3RZHU&RQQHFWLRQV+0,
3RZHU&RQQHFWLRQV+0,
0RWRUV
3RZHU&RQQHFWLRQV
6KLHOG7HUPLQDWLRQ
'LJLWDO,QSXWVDQG2XWSXWV
,)96RXUFLQJ
'LJLWDO,QSXWV
'LJLWDO2XWSXWV
&RQQHFWLQJ,QSXWVDQG2XWSXWV7RJHWKHU
$QDORJ,QSXW
$QDORJ2XWSXW
0RQLWRU2XWSXW
5HDG\5HOD\2XWSXW
(QDEOHG5HOD\2XWSXW
(QFRGHU
(QFRGHU
6ODYLQJDQ8/75$3OXV3'0WR$QRWKHU
6WHSDQG'LUHFWLRQ,QSXWV
6HULDO3RUW&RQQHFWLRQV
+RVW&RPSXWHU
2SHUDWRU7HUPLQDO
1HWZRUNLQJ
&DEOHV
Publication 1398-5.1 — January 2000

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

iv

Preface
Introduction 5HDGWKLVSUHIDFHWRIDPLOLDUL]H\RXUVHOIZLWKWKHUHVWRIWKHPDQXDO7KLV
SUHIDFHFRYHUVWKHIROORZLQJWRSLFV
• :KRVKRXOGXVHWKLVPDQXDO
• 7KHSXUSRVHRIWKLVPDQXDO
• &RQWHQWVRIWKLVPDQXDO
• 5HODWHGGRFXPHQWDWLRQ
• &RQYHQWLRQVXVHGLQWKLVPDQXDO
• 3URGXFWUHFHLYLQJDQGVWRUDJHUHVSRQVLELOLW\
• $OOHQ%UDGOH\VXSSRUW
Who Should Use this 8VHWKLVPDQXDOLI\RXDUHUHVSRQVLEOHIRUGHVLJQLQJLQVWDOOLQJSURJUDPPLQJ

RUWURXEOHVKRRWLQJWKH8/75$3OXV3'0
Manual
,I\RXGRQRWKDYHDEDVLFXQGHUVWDQGLQJRIWKH8/75$3OXV3'0FRQWDFW
\RXUORFDO$OOHQ%UDGOH\UHSUHVHQWDWLYHIRULQIRUPDWLRQRQDYDLODEOHWUDLQLQJ
FRXUVHVEHIRUHXVLQJWKLVSURGXFW
Purpose of this Manual 7KLVPDQXDOGHVFULEHVWKHIXQFWLRQDQGLQVWDOODWLRQRIWKH8/75$3OXV

3RVLWLRQLQJ'ULYH0RGXOH3'0SURGXFWVDQGVWDQGDUG5RFNZHOO
$XWRPDWLRQ$OOHQ%UDGOH\PRWRUVUHFRPPHQGHGIRUXVHZLWKWKH8/75$
3OXV3'0,WLVLQWHQGHGIRUHQJLQHHUVRUWHFKQLFLDQVGLUHFWO\LQYROYHGLQWKH
LQVWDOODWLRQRSHUDWLRQDQGILHOGPDLQWHQDQFHRIWKH8/75$3OXV3'0
1 Publication 1398-5.1 - January 2000

Preface 2
Contents of this Manual 5HIHUWRWKHIROORZLQJPDQXDOIRUWKHGHVFULSWLYHFRQWHQWVRIWKLVLQVWDOODWLRQ

PDQXDO
Chapter Title Contents

Preface Describes the purpose, background, and
scope of this manual. Also specifies the
audience for whom this manual is intended.
1 Overview Gives a functional description of the ULTRA
Plus PDM product series.
2 Install ULTRA Plus PDM Provides mounting information for the
Components ULTRA Plus PDM system.
3 Wire the ULTRA Plus PDM Provides connection information for the
Components ULTRA Plus PDM system.
4 Apply Power for the First Outline steps when applying power to
Time equipment for the first time.
5 Check for Problems in the Diagnostic aids that help isolate problems
System to a system module.
Appendix A Specifications Provides physical, electrical, environmental,
and functional specifications for the
Appendix B Options and Accessories Provides identification numbers and
descriptions of the ULTRA Plus PDM and
related products
Publication 1398-5.1 - January 2000

Preface 3
Related Documentation 7KHIROORZLQJGRFXPHQWVFRQWDLQDGGLWLRQDOLQIRUPDWLRQFRQFHUQLQJUHODWHG

$OOHQ%UDGOH\SURGXFWV7RREWDLQDFRS\FRQWDFW\RXUORFDO$OOHQ%UDGOH\
RIILFHRUGLVWULEXWRU
For this information Read This Document Document Number

An overview of the ULTRA Plus Positioning Drive ULTRA Plus Brochure 1398-2.0
A description and specifications for the ULTRA Series family. ULTRA Series Product Data 1398-2.0
Information to help you install and set up your GML Ultra™ software. GML Ultra Getting Started 1398-5.10
Manual
Step oriented information that will help you use GML Ultra to GML Ultra User Manual 1398-5.11
program your ULTRA Plus system.
Reference material that explains the theory behind how you program GML Ultra Reference Manual 1398-5.12
your ULTRA Plus for your application needs.
An article on wire sizes and types for grounding electrical equipment National Electrical Code Published by the National Fire
Protection Association of
Boston, MA.
A complete listing of current Allen-Bradley documentation, including Allen-Bradley Publication Index SD499
ordering instructions. Also indicates whether the documents are
available on CD-ROM or in multi-languages.
A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial AG-7.1
Automation Glossary
Conventions Used in this 7KHIROORZLQJFRQYHQWLRQVDUHXVHGWKURXJKRXWWKLVPDQXDO

Manual • %XOOHWHGOLVWVVXFKDVWKLVRQHSURYLGHLQIRUPDWLRQQRWSURFHGXUDOVWHSV
• 1XPEHUHGOLVWVSURYLGHVHTXHQWLDOVWHSVRUKLHUDUFKLFDOLQIRUPDWLRQ
• :RUGVWKDW\RXW\SHRUVHOHFWDSSHDULQEROG
• :KHQZHUHIHU\RXWRDQRWKHUORFDWLRQWKHVHFWLRQRUFKDSWHUQDPHDSSHDUV
LQLWDOLFV

Preface 4
Product Receiving and <RXWKHFXVWRPHUDUHUHVSRQVLEOHIRUWKRURXJKO\LQVSHFWLQJWKHHTXLSPHQW

EHIRUHDFFHSWLQJWKHVKLSPHQWIURPWKHIUHLJKWFRPSDQ\&KHFNWKHLWHPV
Storage Responsibility \RXUHFHLYHDJDLQVW\RXUSXUFKDVHRUGHU,IDQ\LWHPVDUHREYLRXVO\GDPDJHGLW
LV\RXUUHVSRQVLELOLW\WRUHIXVHGHOLYHU\XQWLOWKHIUHLJKWDJHQWKDVQRWHGWKH
GDPDJHRQWKHIUHLJKWELOO6KRXOG\RXGLVFRYHUDQ\FRQFHDOHGGDPDJHGXULQJ
XQSDFNLQJ\RXDUHUHVSRQVLEOHIRUQRWLI\LQJWKHIUHLJKWDJHQW/HDYHWKH
VKLSSLQJFRQWDLQHULQWDFWDQGUHTXHVWWKDWWKHIUHLJKWDJHQWPDNHDYLVXDO
LQVSHFWLRQRIWKHHTXLSPHQW
/HDYHWKHSURGXFWLQLWVVKLSSLQJFRQWDLQHUSULRUWRLQVWDOODWLRQ,I\RXDUHQRW
JRLQJWRXVHWKHHTXLSPHQWIRUDSHULRGRIWLPHVWRUHLW
• LQDFOHDQGU\ORFDWLRQ
• ZLWKLQDQDPELHQWWHPSHUDWXUHUDQJHRIWR&WR)
• ZLWKLQDUHODWLYHKXPLGLW\UDQJHRIWRQRQFRQGHQVLQJ
• LQDQDUHDZKHUHLWFDQQRWEHH[SRVHGWRDFRUURVLYHDWPRVSKHUH
• LQDQRQFRQVWUXFWLRQDUHD
Allen-Bradley Support $OOHQ%UDGOH\RIIHUVVXSSRUWVHUYLFHVZRUOGZLGHZLWKRYHU6DOHV6XSSRUW

2IILFHVDXWKRUL]HG'LVWULEXWRUVDQGDXWKRUL]HG6\VWHPV,QWHJUDWRUV
ORFDWHGWKURXJKRXWWKH8QLWHG6WDWHVDORQHSOXV$OOHQ%UDGOH\UHSUHVHQWDWLYHV
LQHYHU\PDMRUFRXQWU\LQWKHZRUOG
Local Product Support
&RQWDFW\RXUORFDO$OOHQ%UDGOH\UHSUHVHQWDWLYHIRU
• VDOHVDQGRUGHUVXSSRUW
• SURGXFWWHFKQLFDOWUDLQLQJ
• ZDUUDQW\VXSSRUW
• VXSSRUWVHUYLFHDJUHHPHQWV
Technical Product Assistance
,I\RXQHHGWRFRQWDFW$OOHQ%UDGOH\IRUWHFKQLFDODVVLVWDQFHSOHDVHUHYLHZWKH
LQIRUPDWLRQLQWKH´&KHFNIRU3UREOHPVLQWKH6\VWHPµFKDSWHUILUVW7KHQFDOO
\RXUORFDO$OOHQ%UDGOH\UHSUHVHQWDWLYH)RUWKHTXLFNHVWSRVVLEOHUHVSRQVH
SOHDVHKDYHWKHFDWDORJQXPEHUVRI\RXUSURGXFWVDYDLODEOHZKHQ\RXFDOO

Chapter 1
Overview of the ULTRA Plus PDM System
Functional Description 7KH8/75$3OXV3'0PRWLRQFRQWUROV\VWHPLVDSRVLWLRQLQJGULYHV\VWHP

ZKLFKLQWHJUDWHVDKLJKSHUIRUPDQFHVLQXVRLGDOEUXVKOHVVPRWRUYHORFLW\
FRQWUROOHUDQGDSURJUDPPDEOHSRVLWLRQFRQWUROOHULQWRDVLQJOHSDFNDJH
7UDGLWLRQDOPRWLRQFRQWUROOHUDUFKLWHFWXUHXVHVVHSDUDWHGULYHDQGSRVLWLRQ
FRQWUROPRGXOHVZLWKDQDQDORJLQWHUIDFHEHWZHHQLQGLYLGXDOFRPSRQHQWV7KH
8/75$3OXV3'0PRWLRQFRQWUROOHUVXVHDGYDQFHGPLFURSURFHVVRU
WHFKQRORJ\WRFRQWUROERWKSRVLWLRQDQGYHORFLW\ZLWKDVLQJOHSURFHVVRU
HOLPLQDWLQJWKHQHHGIRUDQ\DQDORJLQWHUIDFH7KHVLQJOHSURFHVVRUDUFKLWHFWXUH
HOLPLQDWHVWKHSUREOHPVDVVRFLDWHGZLWKDQDORJFLUFXLWU\VXFKDVRIIVHWDQG
WKHUPDOGULIW%RWKWKHYHORFLW\DQGSRVLWLRQFRQWUROORRSVDUHFORVHGGLJLWDOO\
VRJDLQSDUDPHWHUVDUHVWRUHGDVQXPEHUVZKLFKJLYHUHSHDWDEOHUHVXOWVRYHU
WLPHDQGIURPFRQWUROOHUWRFRQWUROOHU
Figure 1.1 ULTRA Plus PDM Product Family
7KH8/75$3OXV3'0GULYHPD\EHXVHGDVDGLVWULEXWHGPRWLRQFRQWURO
HOHPHQWLQWHJUDWHGZLWKDKRVWFRPSXWHULQDIOH[LEOHDXWRPDWLRQV\VWHPRUDV
DVWDQGDORQHSURJUDPPDEOHPRWLRQFRQWUROOHU2SWLFDOO\LVRODWHG,2DQG
SRZHUVXSSOLHVDUHLQWHJUDWHGLQWRWKHSURGXFWV
1 Publication 1398-5.1 - January 2000

1-2 Overview of the ULTRA Plus PDM System
7KHHOHFWURQLFJHDULQJIHDWXUHDOORZVWKHFORVHGORRSD[LVWRIROORZDVHFRQG
PDVWHUHQFRGHUDWDSURJUDPPDEOHUDWLR$PXOWLD[LVDGGUHVVLQJVFKHPH
PXOWLGURSRSHUDWLRQDOORZVPXOWLSOH8/75$3OXV3'0GULYHVWREH
FRQWUROOHGIURPDKRVWFRPSXWHURYHUDVLQJOHVHULDOFRPPXQLFDWLRQVOLQN
$Q8/75$3OXV3'0V\VWHPFRQVLVWVEDVLFDOO\RIWKHIROORZLQJ
• 3RVLWLRQLQJ'ULYH0RGXOHZKLFKFRQWUROVWKHSRVLWLRQYHORFLW\DQGWRUTXH
RIWKHPRWRU
• 3HUVRQDOLW\0RGXOHWKDWSOXJVLQWRWKH8/75$3OXV3'0WRPDWFKWKH
FRQWUROOHUZLWKWKHPRWRUXVHG
• %UXVKOHVVPRWRUZLWKIHHGEDFNIURPDQLQWHJUDORSWLFDOHQFRGHU
• 3RZHU6XSSO\0RGXOHLQWHJUDOWRWKH8/75$3OXV3'0V3'0
DQG%DQGVHSDUDWHIRUWKH8/75$3OXV3'0V
3'0DQGDQG
• 2SHUDWRU7HUPLQDO
&RPELQDWLRQVRIPDWFKHG8/75$3OXV3'0VDQGPRWRUVDUHDYDLODEOH
SURYLGLQJFRQWLQXRXVWRUTXHVRI1PWR1PLQFKSRXQGWR
LQFKSRXQGDQGVSHHGVXSWR530
System Overview $Q8/75$3OXV3RVLWLRQLQJ'ULYH0RGXOH3'0PRWLRQFRQWUROV\VWHP

FRQVLVWVRIDQXPEHURIFRPSRQHQWVFRQQHFWHGWRDFFRPSOLVKDVSHFLILF
IXQFWLRQ7KLVVHFWLRQSURYLGHVDEULHIRYHUYLHZRIWKHYDULRXVFRPSRQHQWVRI
WKH8/75$3OXV3RVLWLRQLQJ'ULYH0RGXOH3'0PRWLRQFRQWUROV\VWHP

Overview of the ULTRA Plus PDM System 1-3
Figure 1.2
ULTRA Plus PDM Control System
ULTRA PLUS ULTRA PLUS PERSONALITY
POWER SUPPLY POSITIONING DRIVE MODULE
MODULE MODULE
PSM PDM
PSM USED
ONLY WITH
1398-PDM-025 MANUALS
ULTRA PLUS OPERATOR TERMINAL
1398-PDM-050
(Optional)
1398-PDM-100
OR
1398-PDM-150
PERSONAL COMPUTER
(Windows™ compatible
user supplied)
AUXILIARY ENCODER GML ULTRA™

MOTOR SERIES (User supplied option) SOFTWARE
F-SERIES
H-SERIES
N-SERIES
GML Ultra™ for Windows™
*0/LVDQH[FOXVLYH*UDSKLFDO0RWLRQ&RQWURO/DQJXDJHIURP$OOHQ%UDGOH\
*0/LQWHJUDWHVVRIWZDUHSURJUDPPLQJDQGGHEXJJLQJWRVROYH\RXUPRWLRQ
FRQWUROSUREOHPV,WRIIHUVD0LFURVRIW:LQGRZVLQWHUIDFHWRWKH8/75$
3OXV3'0VHULHVRIFRQWUROOHUV
*0/8OWUD6RIWZDUHXVHVDIORZFKDUWDSSURDFKWRPRWLRQFRQWURO
SURJUDPPLQJ<RXSURGXFHDGLDJUDPPRWLRQSURJUDPE\SODFLQJIXQFWLRQ
EORFNVUHSUHVHQWLQJWKHVSHFLILFDFWLRQVRQWKHFRPSXWHUWKHQFRQQHFWWKHP
LQWKHSURSHURUGHURIRSHUDWLRQV7KHQ\RXHQWHUWKHPRWLRQDQGSURFHVV
VSHFLILFDWLRQVXVLQJDILOOLQWKHIRUPDSSURDFK(DFKEORFNKDVLWVRZQIRUP

$IWHUDGLDJUDPLVGRZQORDGHGWRWKH8/75$3OXV3'0LWLVWUDQVODWHGLQWRD
SURJUDPRUVFULSWLQWKHQDWLYHODQJXDJHRIWKHPRWLRQFRQWUROOHU
Positioning Drive Modules
7KH8/75$3OXV3'0LVDVHOIFRQWDLQHGVLQJOHD[LVSURJUDPPDEOHPRWLRQ
FRQWUROOHU7KH8/75$3OXV3'0SURYLGHVFRQWURODQGSRZHUIRUWKH
EUXVKOHVVVHUYRPRWRU0RWLRQSURJUDPVDUHVWRUHGLQRQERDUGQRQYRODWLOH
PHPRU\7ZR5656VHULDOSRUWVSURYLGHFRPPXQLFDWLRQVZLWKWKH
SHUVRQDOFRPSXWHUDQGWKHRSWLRQDO2SHUDWRU7HUPLQDO2SWLFDOO\LVRODWHG
GLJLWDO,2DOORZVVLPSOHPDFKLQHLQWHUIDFLQJDQGFRQWURO
8/75$3OXV3'0VDUHPDQXIDFWXUHGLQGLIIHUHQWSDFNDJHVZKLFKFRYHUD
ZLGHUDQJHRISRZHUFDSDELOLW\7KH3'0DQG%
LQFRUSRUDWHDQLQWHJUDOSRZHUVXSSO\LQHDFKDQGVXSSO\FRQWLQXRXVWRUTXHV
RIWRLQFK²SRXQGVLQFRPELQDWLRQZLWKVWDQGDUGPRWRUV7KH
3'0DQGXVHDVHSDUDWHSRZHUVXSSO\PRGXOHZKLFK
FDQEHVKDUHGDPRQJPXOWLSOHGULYHVDQGSURYLGHFRQWLQXRXVWRUTXHVRIWR
LQFKSRXQGVZLWKWKHVWDQGDUGPRWRUV
Integral Power Supply Modules
7KH3'0DQG%DUHUDWHGIRUDQG
DPSSHDNFXUUHQWVUHVSHFWLYHO\7KHVHPRGXOHVDUHSDFNDJHGZLWKDQLQWHJUDO
SRZHUVXSSO\WRDFKLHYHDVPDOOVL]H
,QSXWSRZHUWRD-3'0RULVVLQJOHSKDVHRU9$&
,QSXWSRZHUWRD3'0RU3'0%LVWKUHHSKDVHRU
9$&7KHLQSXWSRZHUPD\EHRSWLRQDOO\LVRODWHGWKURXJKDWUDQVIRUPHU
7KHVH8/75$3OXV3'0VKDYHDEXLOWLQVROLGVWDWH´VRIWFKDUJHµRIWKH
LQWHUQDO'&EXVFDSDFLWRU7KH\DOVRLQFOXGHDEXLOWLQGLVVLSDWLYHVKXQW
UHJXODWRUWKDWSURYLGHVV\QFKURQRXVPRWRUG\QDPLFEUDNLQJ7KH8/75$
3OXV3'0VDOORZXVHRIDQRSWLRQDOH[WHUQDOVKXQWUHVLVWRUIRUDSSOLFDWLRQV
UHTXLULQJKLJKHUVKXQWSRZHUFDSDELOLW\WKDQSURYLGHGE\WKHLQWHUQDOVKXQW
UHVLVWRU
Separate Power Supply Modules
7KH3'0DQGDUHUDWHGIRUDQGDPS
SHDNFXUUHQWVUHVSHFWLYHO\7KHVH8/75$3OXV3'0PRGXOHVXVHDVHSDUDWH
SRZHUVXSSO\PRGXOH360RU360ZKLFKPD\EHVKDUHG
DPRQJPXOWLSOH8/75$3OXV3'0VWRDFKLHYHWKHPRVWHFRQRPLFDOV\VWHP
SDFNDJH2WKHUWKDQWKHSDFNDJLQJDQGSRZHUUDQJHVDOOWKH8/75$3OXV
3'0VDUHDOOLGHQWLFDOLQVHWXSDQGSURJUDPPLQJ

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

Accessories Operator Terminal
7KHRSWLRQDO2SHUDWRU7HUPLQDODOORZVWKHPDFKLQHRSHUDWRUFRQYHQLHQW
DFFHVVWRVWDWXVLQIRUPDWLRQSURJUDPYDULDEOHVFRQWUROIXQFWLRQVDQG
PHVVDJHGLVSOD\FDSDELOLWLHV7KH2SHUDWRU7HUPLQDOKDVDEULJKWOLQHE\
FKDUDFWHUYDFXXPIOXRUHVFHQWGLVSOD\DQGDVHDOHGPHPEUDQHNH\ERDUGZLWK
WDFWLOHIHHGEDFN
7KHWZRDYDLODEOH2SHUDWRU7HUPLQDOVGLVSOD\PXOWLSOHVWDWXVVFUHHQVIRU
PRQLWRULQJDQGGLDJQRVWLFV)RXUSURJUDPPDEOHIXQFWLRQNH\VDUHDYDLODEOHWR
SHUIRUPXSWRWZHQW\IRXUSUHGHILQHGIXQFWLRQVVRPHRIZKLFKDUH
VHOHFWLQJDQGUXQQLQJDSURJUDPMRJJLQJWKHV\VWHPDQGVWRSSLQJDSURJUDP
7KH*0/8OWUD6RIWZDUHPD\GLVSOD\PHVVDJHVDQGSURPSWVRQWKHVFUHHQ
DQGUHFHLYHLQSXWIURPWKHNH\SDG)RXUDGGLWLRQDOXVHUSURJUDPPDEOHNH\V
LGHQWLILHGDV´;µNH\VSURYLGHH[WUDIOH[LELOLW\ZLWKLQDXVHU·VSURJUDP
Figure 1.3
ULTRA Plus 1398-HMI-002 Operator Terminal (front)
numeric keypad
function keys
programmable keys
Figure 1.4
ULTRA Plus 1398-HMI-003 Operator Terminal (front)
function keys
numeric keypad F1 F2 F3 F4
programmable keys X1 STATUS

1 2 3 YES
X2 MODE
4 5 6 NO
X3 CLEAR
7 8 9 -
X4 0 ENTER

Transformers
0XOWLWDSVLQJOHSKDVHDQGWKUHHSKDVHLVRODWLRQWUDQVIRUPHUVDUHDYDLODEOHLQD
YDULHW\RISRZHUUDWLQJVIRUOLQHYROWDJHPDWFKLQJ5HIHUWR 7UDQVIRUPHUVRQ
SDJH %
Auxiliary Power Supply Module (PSM)
$QDX[LOLDU\SRZHUVXSSO\PRGXOH360$8;LVDYDLODEOHWRVXSSO\'&

SRZHUWRWKHORJLFVXSSOLHVRIXSWRIRXU8/75$3OXV3'0VLIWKH360VDUH
2))7KH360$8;XVHVVLQJOHSKDVH9$&SRZHUDVWKHLQSXW7KLV
RSWLRQLVRQO\QHFHVVDU\IRUWKH3'0DQGZLWKWKH
VHSDUDWHSRZHUVXSSO\PRGXOH7KHUHPDLQLQJ8/75$3OXV3'0VKDYHDQ
LQWHJUDOSRZHUVXSSO\
7KH360$8;RSWLRQLVXVHIXOLI8/75$3OXV3'0ORJLFSRZHULVQHHGHGWR
VWD\21HYHQZKHQWKHPRWRUVXSSO\WKH360LVRII$EVROXWHSRVLWLRQLQJLV
RQHH[DPSOHRIZKHQWKH360$8;ZRXOGEHXVHIXOVLQFHSRVLWLRQ
LQIRUPDWLRQLVPDLQWDLQHGDVORQJDVORJLFSRZHULVRQ$QRWKHUH[DPSOH
ZRXOGEHPDLQWDLQLQJ8/75$3OXV3'0ORJLFSRZHUVRWKHVHULDOLQWHUIDFH
FRXOGEHXVHGIRUWURXEOHVKRRWLQJDQGGLDJQRVWLFV5HIHUWR 360$8;
2XWOLQHDQG&RQQHFWLRQ'LDJUDPRQSDJH IRUDGGLWLRQDOLQIRUPDWLRQRQ
LQVWDOOLQJWKH360$8;DQGRSWLRQDO360$8;LVRODWLRQWUDQVIRUPHU6HHD
OLVWLQJRI5HIHUWR 3RZHU6XSSO\0RGXOHVRQSDJH %
Cables
0RWRUSRZHUFDEOHVZLWKFRQQHFWRUVDUHDYDLODEOHLQIRXUVWDQGDUGOHQJWKV
DQGPHWHUVDQGIW0RWRUHQFRGHUFDEOHVZLWK
FRQQHFWRUVDQGILIWHHQSLQ´'µFRQQHFWRUVDUHDYDLODEOHLQWKHIRXUVWDQGDUG
OHQJWKV1LQHSLQVHULDOFDEOHVDUHDYDLODEOHLQDQGPHWHUIWDQGIW
OHQJWKV5HIHUWR &DEOHVRQSDJH %
Motor Connectors
0DWLQJFRQQHFWRUVDUHDYDLODEOHLI\RXFKRRVHWREXLOG\RXURZQPRWRUFDEOHV
5HIHUWR 0RWRU&RQQHFWRUVRQSDJH %

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

Chapter 2
Install the ULTRA Plus PDM Components
7KLVFKDSWHUH[SODLQVWKHSK\VLFDOLQVWDOODWLRQRIWKHLQGLYLGXDOFRPSRQHQWV
DVVRFLDWHGZLWKDQ8/75$3OXV3'0V\VWHP
3ULRUWRLQVWDOODWLRQRIWKH8/75$3OXV3'0V\VWHPYHULI\WKDWDOOWKH
QHFHVVDU\FRPSRQHQWVDUHDYDLODEOH(DFKD[LVRIPRWLRQUHTXLUHVDQ8/75$
3OXV3'0DQGDPRWRU,I3'0DQGLVXVHGWKHUHPXVW
EHDWOHDVWRQHSRZHUVXSSO\PRGXOHIRUWKHV\VWHP
2EVHUYHDOODSSOLFDEOHORFDOQDWLRQDODQGLQWHUQDWLRQDO
ATTENTION
VDIHW\FRGHVZKHQXVLQJWKLVHTXLSPHQW
! :LULQJSUDFWLFHVJURXQGLQJGLVFRQQHFWVDQGRYHUFXUUHQW
SURWHFWLRQDUHRISDUWLFXODULPSRUWDQFH
)DLOXUHWRREVHUYHVDIHW\FRGHVFRXOGUHVXOWLQSHUVRQDO
LQMXU\RUGDPDJHWRHTXLSPHQW
Mounting %HIRUHPRXQWLQJWKH3'0\RXVKRXOGLQVWDOODQ\RSWLRQFDUGV3HUVRQDOLW\
0RGXOHVDQGV\VWHPILUPZDUH2WKHURSHUDWLRQVVXFKDVUHPRYLQJMXPSHUVRQ
WKHORJLFERDUGVKRXOGDOVREHSHUIRUPHGEHIRUHPRXQWLQJWKHV\VWHP
'XULQJLQVWDOODWLRQSURWHFWHTXLSPHQWIURPPHWDOFKLSV
ATTENTION
ZHOGVSODWWHUVDQGRWKHUGHEULV
! &RPSOHWHDOOGULOOLQJFXWWLQJZHOGLQJHWFEHIRUH
PRXQWLQJWKHHTXLSPHQW
)DLOXUHWRREVHUYHWKLVSUHFDXWLRQFRXOGUHVXOWLQGDPDJHWR
RUGHVWUXFWLRQRIWKHHTXLSPHQW
1 Publication 1398-5.1 — January 2000

2-2 Install the ULTRA Plus PDM Components
Environment
7KH8/75$3OXV3'0DQGSRZHUVXSSO\PRGXOHVDUHGHVLJQHGIRUVLPSOH
LQVWDOODWLRQRQDIODWVXUIDFHVXFKDVWKHEDFNZDOORUSODWHRIDQHQFORVXUH
7KH\PXVWEHHQFORVHGLQDJURXQGHGPHWDOHQFORVXUHRIIHULQJSURWHFWLRQDV
GHILQHGLQVWDQGDUG(1,(&WRDWOHDVW,3VXFKWKDWWKH\DUHQRW
DFFHVVLEOHWRDQRSHUDWRURUXQVNLOOHGSHUVRQ1(0$HQFORVXUHH[FHHGV
WKHVHUHTXLUHPHQWVSURYLGLQJSURWHFWLRQWR,37KHHQYLURQPHQWLQWKH
HQFORVXUHPXVWEHFOHDQDQGIUHHRIRLOPLVWFRRODQWPLVWFRQGXFWLYHSDUWLFOHV
ZDWHUDQGFRUURVLYHFKHPLFDOV7KHHQFORVXUHPXVWDOVREHSURSHUO\VL]HGDQG
YHQWLODWHGLIUHTXLUHGWRHQVXUHWKDWWKHUHTXLUHGRSHUDWLQJWHPSHUDWXUHRIWKH
8/75$3OXV3'0LVQRWH[FHHGHG5HIHUWR ´6SHFLILFDWLRQVµRQSDJH $

Install the ULTRA Plus PDM Components 2-3
Ventilation
7KHPD[LPXPSRZHUORVVHVDUHVKRZQEHORZWRKHOSLQVL]LQJDQHQFORVXUH
DQGDQ\UHTXLUHGYHQWLODWLRQ7\SLFDOKHDWORVVHVFDQUXQDSSUR[LPDWHO\
RQHKDOIPD[LPXPSRZHUORVVHV
Maximum power losses for help in sizing enclosures

Model Maximum Loss (Watts)
1398-PDM-10 50 + dissipative shunt
1398-PDM-25 200
1398-PDM-50 180
1398-PDM-100 275
1398-PDM-150 300
1398-PDM-150B 500 + dissipative shunt
1398-PSM-50 110 + dissipative shunt
1398-PSM-125 240 + dissipative shunt
Operator Terminal 25
3.0 kVA Transformer 350
TF-03 (3 kW transformer) 350
$VDQDGGLWLRQDODLGLQVL]LQJDQHQFORVXUHZLWKQRDFWLYHPHWKRGRIKHDW
GLVVLSDWLRQWKHIROORZLQJDSSUR[LPDWHHTXDWLRQLVXVHG
T = 4.08  ---- + 1.1
Q
 A
:KHUH7LVWHPSHUDWXUHGLIIHUHQFHEHWZHHQLQVLGHDLUDQGRXWVLGHDPELHQW
)4LVKHDWJHQHUDWHGLQHQFORVXUH:DWWVDQG$LVHQFORVXUHVXUIDFHDUHD
IWñ
7KHH[WHULRUVXUIDFHRIDOOVL[VLGHVRIDQHQFORVXUHLVFDOFXODWHGDV
( 2dw + 2dh + 2wh )
A = -----------------------------------------------
144
:KHUHGGHSWKZZLGWKDQGKKHLJKWDUHLQLQFKHV

Transformer Sizing
8/75$3OXV3'0V\VWHPVGRQRWUHTXLUHLVRODWLRQWUDQVIRUPHUV$
WUDQVIRUPHUPD\EHUHTXLUHGKRZHYHUWRPDWFKWKHYROWDJHUHTXLUHPHQWVRI
WKHFRQWUROOHUWRWKHDYDLODEOHVHUYLFH7RVL]HDWUDQVIRUPHUIRUD8/75$3OXV
3'0WKHSRZHURXWSXW.9$RIHDFKD[LVPXVWEHNQRZQ7KLVFDQEH
GHULYHGE\FDOFXODWLQJWKHKRUVHSRZHUIRUHDFKD[LVDQGFRQYHUWLQJWKDW
KRUVHSRZHULQWRXQLWVIZDWWV,I\RXDUHVXSSOLQJSRZHUWRPRUHWKDQRQH
PRWRUDQG3'0VLPSO\DGGWKH.:UDWLQJVWRJHWKHUIURPHDFKFDOFXODWLRQWR
JHWDV\VWHP.:WRWDO
'HILQLWLRQV
.: SRZHURU´UHDOSRZHUµ
.9$ DSSDUHQWSRZHU
7UDQVIRUPHU.9$UDWLQJ 6XPRIDYHUDJHRXWSXWSRZHURIHDFKD[LV[
IMPORTANT &DOFXODWLRQVDUHPXOWLSOLHGE\DIDFWRUWRFRPSHQVDWHIRU
WKHSRZHUDQGORVVHOHPHQWVZLWKLQDSRZHUV\VWHP$
IDFWRURILVXVHGZLWKDVLQJOHSKDVHV\VWHPDQGDIDFWRU
RILVXVHGZLWKDWKUHHSKDVHV\VWHP7KLVIDFWRUVKRXOG
PLQLPL]HWKHHIIHFWVRIWKHVHFRQGDU\OLQHYROWDJHVDJJLQJ
LQWKHWUDQVIRUPHUGXULQJSHDNFXUUHQWSHULRGV
Intro
Speed ( RPM ) × Torque ( lb – in ) 746Watts KVA

KVA = -------------------------------------------------------------------------------- × ------------------------ × --------------------------- × 2.0
63, 025 HP 1000Watts

IMPORTANT ,I\RXDUHXVLQJWKH5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\
V\VWHPVL]LQJSURJUDPWKHDYHUDJHVSHHGDQGDYHUDJH
WRUTXHGDWDKDVDOUHDG\EHHQFDOFXODWHGDQGFDQEHXVHGLQ
WKHDERYHHTXDWLRQ,I\RXDUHQRWVXUHRIWKHH[DFWVSHHG
DQGWRUTXHLQ\RXUDSSOLFDWLRQDQRWKHUDSSURDFKLVWRORRN
DWWKHVSHHGWRUTXHFXUYHIRU\RXU3'0PRWRU
FRPELQDWLRQDQGXVHWKHYDOXHVIRUWKHZRUVWFDVH
FRQWLQXRXVVSHHGDQGWRUTXH

6L]LQJDWUDQVIRUPHUZLWKDQ3'0DQG+PRWRU
IMPORTANT 7KHVSHHGWRUTXHFXUYHLQIRUPDWLRQLVEDVHGXSRQD3'0
PRGXOHLQSXWYROWDJHRI9$&)RUD9$&LQSXW
YROWDJHWKHPD[LPXPVSHHGLVUHGXFHGE\KDOI
3000RPM × 75lb – in 746Watts KVA

KVA = ------------------------------------------------------ × ------------------------ × --------------------------- × 2.0
63, 025 HP 1000Watts
Transformer Size = 5.3KVA

Figure 2.1
Single PhaseTransformer Load Regulation Curve
1 PHASE TRANSFORMER SECONDARY VOLTAGE
RELIANCE MOTION CONTROL
AND CORRESPONDING DC BUS VOLTAGE,
1 PHASE TRANSFORMER
VERSUS DC BUS CURRENT
PART NUMBER kVA
TRANSFORMER SECONDARY VOLTAGE

3 kVA TRANSFORMER
0020-5097 3
(VAC RMS LINE TO LINE, 3 PHASE)

330 233
320 226
310 219
NOTES:
300 212
BUS VOLTAGE (VDC)
1 DC BUS VOLTAGE AND CURRENT IS MEASURED AT MOTOR POWER

290 205
CIRCUITS INTERNAL TO THE DRIVE MODULE
280 198 (NOT ACCESSIBLE TO THE USER).
270 191
2. CURVE SHOWS REDUCTION IN TRANSFORMER SECONDARY VOLTAGE
1
260 184
AND DRIVE MODULE INTERNAL DC BUS VOLTAGE, DUE TO TRANSFORMER
INTERNAL LOSSES, AS BUS CURRENT LOAD INCREASES.
250 177
3. ALL DATA TAKEN WITH TRANSFORMER PRIMARY VOLTAGE HELD
240 170
TO 230 VAC 1 PHASE LINE TO LINE 60 Hz AND WITH SECONDARY
230 163 WIRED FOR 230 VAC LINE TO LINE NO LOAD.
220 156
210 149
C 20625 JL UPDATE TITLE BLOCK __ __
200
50
142 B 19960 BC PDM UPDATE 2-19-92 BC
0 10 20 30 40
BUS CURRENT (ADC) A 19866 BC RELEASED 11-22-91 JH
1
REV ECO BY REVISION DESCRIPTION DATE CHKR
UNLESS OTHERWISE SPECIFIED DRAWN BY DATE DESIGN ENGR DATE
DO NOT SCALE DRAWING
BC 11-22-91 JH 11-22-91
DIMENSIONS ARE IN INCHES
BREAK ALL EDGES .02 MAX
FILLETS AND ROUNDS .02 R MAX DIAG, XFMR LOAD REG
TOLERANCE ON: PART NO.
ANGLES ±1ANGLES ˚
FRACTIONS:±1/64"
9101-1057
DECIMALS.XX±.020 SCALE DWG SIZE SHEET
.XXX±.010 1:1 A 1 of 1

Figure 2.2
Three PhaseTransformer Load Regulation Curves
3 PHASE TRANSFORMER SECONDARY VOLTAGE
RELIANCE MOTION CONTROL
TRANSFORMER SECONDARY VOLTAGE

AND CORRESPONDING DC BUS VOLTAGE,
3 PHASE TRANSFORMERS
(VAC RMS LINE TO LINE, 3 PHASE)

VERSUS DC BUS CURRENT
FOR 3, 6, 12, AND 18 kVA TRANSFORMERS PART NUMBER kVA
233 0020-5091-001 3
330
0020-5091-002 6
320 226 0020-5091-003 12
0020-5091-004 18
1
310 219
BUS VOLTAGE (VDC)
NOTES:
300 212
12/18 kVA 1 DC BUS VOLTAGE AND CURRENT IS MEASURED AT POS & NEG
290 205 OUTPUT TERMINALS OF THE POWER SUPPLY MODULE.
280 198 2. CURVES SHOW REDUCTION IN TRANSFORMER SECONDARY VOLTAGE

AND THE DRIVE MODULE DC BUS VOLTAGE, DUE TO TRANSFORMER
270 191 INTERNAL LOSSES, AS BUS CURRENT LOAD INCREASES.
6 kVA
260 184 3. ALL DATA TAKEN WITH TRANSFORMER PRIMARY VOLTAGE HELD
3 kVA
TO 480 VAC 3 PHASE LINE TO LINE 60 Hz AND WITH SECONDARY
250 100 177 WIRED FOR 230 VAC LINE TO LINE NO LOAD.
0 10 20 30 40 50 60 70 80 90
BUS CURRENT (ADC) 1
D 20625 JL UPDATE TITLE BLOCK __ __
B-C B-19866,C-19960
A 16383 BC RELEASED 8-5-88 JH

DO NOT SCALE DRAWING
BC 8-5-88 JH 8-5-88
FILLETS AND ROUNDS .02 R MAX DIAG, XFMR LOAD REG
TOLERANCE ON:
ANGLES ±1ANGLES ˚ PART NO.
FRACTIONS:±1/64"
9101-0132
.XXX±.010 1:1 A 1 of 1

Figure 2.3
Single PhaseTransformer Outline Diagram
NOTES:
1. DIMENSIONS ARE IN INCHES (mm)
2 RING OR SPADE LUG CONNECTORS (NOT PROVIDED)

1/4-20 GROUND STUD SECONDARY CONNECTIONS ARE REQUIRED FOR WIRING CONNECTIONS TO
(6.35 DIA) 8-32 THD BOLTS 2 TRANSFORMER TERMINAL STRIPS.
(TRANSFORMER CHASSIS) (4.17 DIA)
CONNECTION INSTRUCTIONS
PRIMARY CONNECTIONS
8-32 THD BOLTS 2
(4.17 DIA)
8.00 MIN. CLEARANCE RECOMMENDED

9.10 MAX. 8.20 MAX.
(210) (200) FOR ACCESS TO WIRING
(230)
9.20 MAX.
(235)
3kVA TRANSFORMER
ELECTRO-CRAFT P/N 0020-5097
MOUNTING HOLES: 0.28 ±0.02 DIA (4)

B1 A00759 TM CHG'D TEXT __ __
(7.1 ±0.5)
B 19866 SJ UPDATED TITLE BLOCK 12-20-91 BC
3.32 ±0.06
(84 ±1.5) A 17320 BC RELEASED 2-23-89 JH
DRAWN BY DATE DESIGN ENGR DATE
UNLESS OTHERWISE SPECIFIED
DO NOT SCALE DRAWING BC 1-10-89 BB 2-22-89
DIAGRAM,OUTLINE,TRANSFORMER
FILLETS AND ROUNDS .02 R MAX
ANGLES ±1ANGLES ˚
8.00 ±0.06 FRACTIONS:±1/64" 9101-1056
(203 ±1.5) DECIMALS.XX±.010 SCALE DWG SIZE SHEET
.XXX±.005 1:1 C 1 of 1

Figure 2.4
Three Phase Transformer Outline Diagram
PART NO.
9101-0131
1 CONNECTION INSTRUCTIONS
PRIMARY
CONNECTIONS
G REF
1
SECONDARY
CONNECTIONS
E ±0.06
B MAX
0.56 ±0.03 DIA THRU (4)
0.25-20 GROUND STUD

(TRANSFORMER CHASSIS)
1
8.0 MIN CLEARANCE

RECOMMENDED FOR
ACCESS TO WIRING
RELIANCE MOTION CONTROL KVA OVERALL DIMENSIONS MOUNTING HOLES LOCATION SCREW SIZES
C MAX
TRANSFORMER PART NO. RATING
A B C D E F G PRIMARY SECONDARY
0020-5091-001 3 12.50 6.50 9.50 5.50 4.20 3.50 1.15 5-40 2 6-32
0020-5091-002 6 15.25 6.50 12.50 10.50 3.78 2.38 1.36 6-32 8-32
0020-5091-003 12 15.25 8.50 13.25 10.50 5.90 2.38 1.30 6-32 10-32
0020-5091-004 18 22.50 9.00 18.25 16.00 5.38 3.25 1.81 8-32 10-32
.012 REF
D ±0.06
F REF
A MAX
C1 A00761
TM REDRAWN __ __
B-C 19866,20625
NOTES:
A 16383 BC
RELEASED 8-88 JH
DATE DATE
1 RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED FOR WIRING UNLESS OTHERWISE SPECIFIED DRAWN BY DESIGN ENGR
CONNECTIONS TO TRANSFORMER TERMINAL STRIPS.TERMINAL STRIP SCREW DO NOT SCALE DRAWING BCB 2-5-87
JH 8-5-88
SIZES ARE LISTED IN THE DIMENSION CHART.
BREAK ALL EDGES .02 MAX DIAG,OUTLINE,XFMR,BRU-500/IQ5000
2 USE LUGS DESIGNED FOR #6 SCREW MOUNTING. FILLETS AND ROUNDS .02 R MAX
TOLERANCE ON:
PART NO.
ANGLES ±1ANGLES ˚
FRACTIONS:±1/64"
9101-0131
.XXX±.005 1:1 D 1 of 1

Mounting Requirements
3RVLWLRQWKH8/75$3OXV3'0LQDYHUWLFDOSRVLWLRQRQDIODWVROLGVXUIDFH
WKDWPHHWVWKHPRXQWLQJUHTXLUHPHQWVIRUZHLJKWKXPLGLW\DQGWHPSHUDWXUH
OLVWHGLQ$SSHQGL[$7KHIROORZLQJGLDJUDPVOLVWGLPHQVLRQDOPRXQWLQJ
UHTXLUHPHQWV
Figure 2.5
1398-PDM-10, 20 and 30 Mounting
4.10 8.93
104.1 226.8
AIR
1.05 1.00 1.00 CLEARANCE HOLES FOR #10
26.6 25.4 25.4 (M5) MOUNTING SCREWS EXHAUST
0.27
7.0
Allen-Bradley
Ultra Plus Series
External Shunt
Status
Internal
P7
2 Serial 1
Auxiliary
U10
3
TB2
P6
Serial 2
Computer
P5
Encoder 1
Motor
WARNING:High Voltage
May Exist Up To Five Minutes
After Removing Power
P4
Encoder 2
Auxiliary
DC Bus 14.20
13.75
349.2 360.6
R
5
P3
Motor
S Status/
Analog
I/O
T 1
10
DC Bus+ P2
Digital
Inputs
100-240 Vac 50/60 Hz
DC Bus- And
Outputs
L1 5
L2/N
L1 Aux
L2/N Aux 10
P1
TB1 Digital Inputs
1
SW1
AIR INTAKE

Figure 2.6
1398-PDM-75 Mounting
5.97 8.93
151.7 226.8
0.27 1.99 1.00 1.00

7.0 50.5 25.4 25.4
AIR EXHAUST
Allen-Bradley
Ultra Plus Series
Status
1
Internal
External Shunt
P7
2 Serial 1
Auxiliary
U10
3
FINAL INSPECTION
TB2
P6
Serial 2
Computer
P5
Encoder 1
Motor
WARNING: High Voltage

After Removing Power P4
Encoder 2
Auxiliary
DC Bus
13.75 R 14.20
349.2 360.7
S
5
Motor
P3
T Status/Analog
I/O
1
DC Bus+
10
DC Bus-
P2
Digital Inputs
L1 And Outputs
100-240 Vac 50/60 Hz
L2/N 5
L3
L1 Aux
10
L2/N Aux
P1
TB1 Digital Inputs
1
SW1
AIR INTAKE AIR INTAKE

Figure 2.7
1398-PDM-25, 50, 100, and 150 Mounting
4.50
114.3 9.93
252.1
1.38 0.25
34.9 6.4 9.70
1.38 246.4
0.45
34.9
11.4 AIR
EXHAUST
Allen-Bradley
Ultra Plus Series
P7
Serial
Port 1
P6
Serial
Port 2
P5
Encoder
Input 1
P4
Encoder
Input 2
P3
Analog
I/O And
Status
16.87 17.50
16.15
428.6 444.5
410.2
P2
General Purpose
Inputs And Outputs
P1
General Purpose
Inputs
WARNING: Do Not Apply Power With Cover Removed.

Do Not Remove Cover With Power Applied.
Dangerous Voltages May Exist Up To 5 Minutes After
Removing Power.
AIR INTAKE

Figure 2.8
1398-PDM-150B Mounting
5.97 8.93
151.7 226.8
0.27 1.25 2.75 2.75

7.0 69.9
31.8 69.9
AIR EXHAUST
Allen-Bradley
Ultra Plus Series P8 P9 P10
Status
1 1 1
External Shunt
1
Internal
P7
U10
Serial 1
2 Auxiliary
U10
FINAL INSPECTION
P6
TB2
Serial 2
WARNING: High Voltage May
DC BUS Exist Up To Fifteen Minutes Computer
POT1 POT2 POT3
After Removing Power.
R P5
Encoder 1
Motor
S
Motor
T P4
Encoder 2
Auxiliary
U57
13.75 14.20
349.2 360.7 U57
DC Bus+
U67
U66
P3
DC Bus- Status/Analog U67
U66
I/O
AC Mains (30 Only)
L1
100-240 Vac 50/60 Hz
L2
P2
Digital Inputs
L3 And Outputs U87
U87
Auxiliary
L1 Aux
L2/N Aux
P1
Digital Inputs
TB1
1.25 5.50
[31.8] [139.7]
AIR INTAKE AIR INTAKE AIR INTAKE

1398-PDM-25, 50, 100, and 150 Power Supply Module
7KHSRZHUVXSSO\PRGXOHVKRXOGEHFHQWUDOO\ORFDWHGWRPLQLPL]HWKHGLVWDQFH
EHWZHHQLWDQGWKH3'0PRGXOHV7KHKLJKHUFXUUHQWUDWLQJ3'0PRGXOHV
VKRXOGEHORFDWHGFORVHVWWRWKHSRZHUVXSSO\PRGXOH
PSM Auxiliary Transformers
)LJXUHVKRZVWKHPRXQWLQJGLDJUDPDQGFRQQHFWLRQVIRUWKH360
$X[LOLDU\7UDQVIRUPHU
Figure 2.9
PSM Auxiliary Transformer mounting
5.50 MAX.
SPECIFICATIONS:
4.38
OUTPUT POWER @ 50/60Hz
110 VAC OUTPUT VOLTAGE
50˚C MAX. TEMPERATURE RISE 500 VA MIN.
NOMINAL OPERATING VOLTAGES 480 OR 240 INPUT, 120 OUTPUT

460 OR 230 INPUT, 115 OUTPUT
H1 H3 H2 H4
440 OR 220 INPUT, 110 OUTPUT
CONNECTION INSTRUCTIONS
6.25 4.25
MAX.
9101-0233
X2 X1 0.69
SCHEMATIC SYMBOL
1.
8-32 TERMINAL SCREWS (6) 0.31 H1 H3 H2 H4
INPUT (PRIMARY) CONNECTIONS: H1,H4
480 VAC INPUT: JUMPER H3 to H2
240 VAC INPUT: JUMPER H1 to H3 AND H2 to H4
OUTPUT (SECONDARY) CONNECTIONS: X1,X2

8.0 MIN. CLEARANCE RECOMMENDED FOR ACCESS TO WIRING 120 VAC
X2 X1
5.00 MAX
NOTES:
1. RING OR SPADE LUG CONNECTORS (NOT PROVIDED) ARE REQUIRED

FOR WIRING CONNECTIONS TO THE TRANSFORMER.

Figure 2.10
PSM-AUX Outline and Connection Diagram
3.50
(89)
1.75
(44.5)
0.50 0.50
(13) (13)
0.25
(6.5)
0.50
(13)
9.00 8.38
(229) (213)
3.00
(77)
2.00
(50)
DIAGRAM, OUTLINE & CONNECTION DRAWING
AUXILIARY POWER SUPPLY MODULE

DOCUMENT NO. 9101-0134 REV D1

Motors
7KHLQVWDOODWLRQDQGRSHUDWLRQRIPRWRUVVKRXOGDGKHUHWRWKHIROORZLQJ
JXLGHOLQHV
• 'RQRWUXQPRWRUVWKDWDUHQRWSURSHUO\PRXQWHG$WWDFKDOOPRWRUFDEOHV
DIWHUPRWRULVPRXQWHG
• 0RXQWPRWRUZLWKFRQQHFWRUVSRLQWLQJGRZQZDUGDQGXVHDGULSORRSWR
NHHSOLTXLGVIORZLQJDZD\IURPFRQQHFWRUV
• &RQVLGHUPRWRUFDVHWHPSHUDWXUHLIQHFHVVDU\WRVDIHJXDUGRSHUDWRUDQG
PDLQWHQDQFHVWDII0D[LPXPFDVHWHPSHUDWXUHLVDSSUR[LPDWHO\&
)IRUDPRWRUXVHGDWFRQWLQXRXVUDWLQJLQD&DPELHQW
WHPSHUDWXUH
(QVXUHDOOPRYLQJFRPSRQHQWVDUHVDIHEHIRUHHQHUJL]LQJD
ATTENTION
V\VWHP
! (TXLSPHQWWREHZRUNHGRQVKRXOGEHDSSURSULDWHO\
LGHQWLILHGDQGDFFHVVWRSRZHUUHVWULFWHGDFFRUGLQJWR
UHTXLUHGORFNRXWWDJRXWSURFHGXUHV0RWRUVDQGOLQNDJHV
PXVWEHVHFXUHO\DWWDFKHGEHIRUHDV\VWHPLVPDGH
RSHUDWLRQDO
)DLOXUHWRREVHUYHWKHVHVDIHW\SURFHGXUHVFRXOGUHVXOWLQ
SHUVRQDOLQMXU\DQGGDPDJHWRHTXLSPHQW

External Shunt
7KHIROORZLQJSURFHGXUHRXWOLQHVWKHLQVWDOODWLRQRI([WHUQDO6KXQW:
DQG([WHUQDO6KXQW:XQLWV
5HPRYHMXPSHUEHWZHHQWHUPLQDOVDQGDWWKHLQWHUQDOVKXQW
FRQQHFWLRQ7KHMXPSHULVVXSSOLHGZLWKWKHDPSOLILHU
:LUHDQH[WHUQDOVKXQWUHVLVWRUEHWZHHQWHUPLQDOVDQGDWWKHH[WHUQDO
VKXQWFRQQHFWLRQV8VHZLUHRIWKHUHFRPPHQGHGZLUHVL]H
Figure 2.11
External Shunt (200W) mounting and connection diagram
3.05
(77.5)
2.00 0.50
#10 (M5) (50.8) (12.7)
MTG HOLES (3) 1.00 8.60
(25.4) 0.25 (218.4)
(6.3)
EXTERNAL SHUNT
RESISTOR
4 EXTERNAL SHUNT RESISTOR

4.5 A 5.20 4.75
(132) (120.6) 4.00
600V (101.6)
2
3
3.40 MIN AIR
(86.3)
EXHAUST
1 2 3 1
2
Terminal
3
TERMINAL
CONNECTION DIAGRAM
NOTES:
1 FOR INTERNAL SHUNT RESISTOR:

JUMPER INSTALLED BETWEEN PINS 1 & 2 OF TERMINAL.
FOR EXTERNAL SHUNT RESISTOR:
REMOVE JUMPER INSTALLED BETWEEN PINS 1 & 2 OF TERMINAL.
INSTALL WIRING AS SHOWN.
2 36" OF #14 AWG WIRE IS SUPPLIED WITH EXTERNAL SHUNT RESISTOR.
CUT TO LENGTH AS REQUIRED.
TB1
3 #6-32 STUD (NUT AND WASHER SUPPLIED) FOR CUSTOMER GROUNDING.
4 LITTLEFUSE PART NUMBER : CCMR-4.5
INCHES
(mm)
AIR INTAKE

Figure 2.12
External Shunt (900W) mounting and connection diagram
At terminal block,
Cabinet There must be 155mm (6.1 in.) Of
clearance on all sides of
remove jumper shunt module

installed at factor y
for internal shunt
There must be
STATUS
155mm (6.1 in.)
EXTERNAL SHUNT
INTERNAL
of clearance on
2 A1
A2 all sides of
3 COM
345
shunt module
0 12
6
87
TB2
A9
FE
D CB
J5
SERIAL 1
WARNING: High Voltage

After Removing Power
DC Bus
J4
SERIAL 2
S
Motor
J3
AUXILIARY
DC Bus +
DC Bus -
Use twisted conductors
L1
(2 twists per foot)
J2
100-240 VAC 50/60 Hz
L2/N
minimum or a shielded
MOTOR ENCODER
L3
twisted pair
L1 AUX
8 AWG (8.4 mm)
L2/N AUX J1
105 °C, 600V wire

TB1
CONTROLLER
Max. Length 3.05 m
(10 ft) for each wire
Connect wires
to terminal block
inside front cover

Operator Terminal
)LJXUHDQG)LJXUHRQSDJHLOOXVWUDWHWKHGLPHQVLRQVRIWKHWZR
DYDLODEOH2SHUDWRU7HUPLQDOV$OOGLPHQVLRQVDUHLQLQFKHVPP$OORZILIW\
PLOOLPHWHUVWZRLQFKHVFOHDUDQFHDERYHDQGEHORZWKH2SHUDWRU7HUPLQDOIRU
DLUIORZDQGPLOOLPHWHUVIRXULQFKHVFOHDUDQFHEHKLQGWRDOORZIRUFDEOH
FRQQHFWRUV
5HIHUWR ´6SHFLILFDWLRQVµRQSDJH $IRUDGGLWLRQDOWHFKQLFDOLQIRUPDWLRQ
Figure 2.13
Operator Terminal (1398-HMI-002) Dimensions
3.50 0.65 10.50
(88.9) (16.5) (266.7)
5.05 6.00
(128.3) (152.4)
GASKET

Figure 2.14
Operator Terminal (1398-HMI-003) Dimensions
GASKET SUPPLIED
8.11 WITH UNIT 3.86 3.86
0.20
[206.0] [98.0] [98.0]
[5.0]
3.28
[83.25]
6.89 6.13 MAX.

[175.0] [155.7]
3.28
[83.25]
2.22 0.17
[56.5] [4.25]
7.40
1 2 3 4 5 6 7 8 9 10
[188.0]
Not used 24 VDC RS-232 connector

3.28
[83.25]
3.13
[79.5]
6.26 7.27 MAX.
[159.0] [184.7]
3.70
Ø 0.14 (8)
[94.0]
3.86 Ø [3.5]
[98.0]
RECOMMENDED PANEL CUTOUT DIMENSIONS

I/F Conversion Card, 24VDC Sourcing
)LJXUHLOOXVWUDWHVWKHGLPHQVLRQVRIWKH,)9&RQYHUVLRQ&DUGDQGWKH
',1PRXQWLQJSDQHO$OOGLPHQVLRQVDUHLQPLOOLPHWHUVLQFKHVDUH
DSSUR[LPDWHFRQYHUVLRQV7KHFRQYHUVLRQFDUGPXVWEHPRXQWHGLQWKHVDPH
HQFORVXUHDVWKH8/75$3OXV3'0WRFRPSO\ZLWKWKH(8/9'GLUHFWLYH
Figure 2.15
I/F 24 Volt Sourcing Conversion Card Mounting Dimensions
P1
1 26
77.0
(1.9)
P2 1 26
USER
47.0
(1.9)
169.0
(6.7)
77.0
(1.9)
7.5
(0.3)
42.5 85.0
(1.7) (3.4)
35.0 25
(1.4) (1.0)
17.5
(0.7)
170.0
(6.7)

PDM Fusing Requirements )XVLQJIRUWKH8/75$3OXV3'0VGLIIHUVEHFDXVHRIWKHVHSDUDWHSRZHU

VXSSO\IRUVRPHPRGHOV
Short Circuit Protection
,QWKH8QLWHG6WDWHVWKH1DWLRQDO(OHFWULFDO&RGHVSHFLILHVWKDWIXVHVHOHFWLRQ
PXVWEHEDVHGRQWKHPRWRU·V)XOO/RDG$PSHUDJH)/$ZKLFKLVQRWWREH
FRQIXVHGZLWKWKH3'0LQSXWFXUUHQW7KHODUJHVWIXVHDOORZHGXQGHUDQ\
FLUFXPVWDQFHVLVIRXUWLPHVWKHPRWRU·V)/$7KHUHIRUHWKHODUJHVWIXVHV
SHUPLVVLEOHIRUXVHDUHIRXUWLPHVWKHPRWRU·V)/$PDUNHGRQWKHPRWRU
FRQYHUWHGWRD506YDOXH7KH8/75$3OXV3'0VKDYHEHHQHYDOXDWHGDQG
OLVWHGE\8QGHUZULWHU/DERUDWRULHV,QFDFFRUGLQJWR8/&ZLWKIXVHV
VL]HGDVIRXUWLPHVWKHFRQWLQXRXVRXWSXWFXUUHQW)/$RIWKH3'0
,QDOPRVWDOOFDVHVIXVHVVHOHFWHGWRPDWFKWKH3'0LQSXWFXUUHQWUDWLQJZLOO
PHHWWKH1DWLRQDO(OHFWULFDO&RGHUHTXLUHPHQWVDQGSURYLGHWKHIXOO3'0
FDSDELOLWLHV'XDOHOHPHQWWLPHGHOD\IXVHVVKRXOGEHXVHGWRDYRLGQXLVDQFH
WULSVGXULQJSRZHULQLWLDOL]DWLRQGXHWRLQUXVKFXUUHQW
6ROLGVWDWHPRWRURYHUORDGSURWHFWLRQRSHUDWHV
• ZLWKLQPLQXWHVDWRYHUORDGDQG
• ZLWKLQVHFRQGVDWRYHUORDG
1398-PDM-10, 20, 30, 75, and 150B
$VKRUWFLUFXLWFXUUHQWUDWLQJZLWKRXWIXVHUHVWULFWLRQVPXVWEHVXLWDEOHIRUXVH
RQDFLUFXLWFDSDEOHRIGHOLYHULQJQRWPRUHWKDQ506V\PPHWULFDO
$PSHUHV 9ROWVPD[LPXP
$VKRUWFLUFXLWFXUUHQWUDWLQJZLWKIXVHUHVWULFWLRQVPXVWEHVXLWDEOHIRUXVHRQ
DFLUFXLWFDSDEOHRIGHOLYHULQJQRWPRUHWKDQ506V\PPHWULFDO
$PSHUHV9ROWVPD[LPXPZKHQSURWHFWHGE\KLJKLQWHUUXSWLQJFDSDFLW\
FXUUHQWOLPLWLQJIXVHV&ODVV&&*-/57
1398-PDM-25, 50, 100, and 150
$VKRUWFLUFXLWFXUUHQWUDWLQJVXLWDEOHIRUXVHRQDFLUFXLWFDSDEOHRIGHOLYHULQJ
QRWPRUHWKDQ506V\PPHWULFDO$PSHUHV9ROWVPD[LPXPZKHQ
SURWHFWHGE\
• 360FODVV5IXVHVUDWHG$DQG
• 360FODVV5IXVHVUDWHG$
5HIHUWR ´3RZHU6XSSO\0RGXOHVµRQSDJH %IRUSURGXFWQXPEHUV

Personality Module 7KH3HUVRQDOLW\0RGXOHLVDOUHDG\LQVWDOOHGRQWKH8/75$3OXV3'07KH

IROORZLQJSURFHGXUHLVWREHXVHGLIWKH3HUVRQDOLW\0RGXOHQHHGVWREH
Installation FKDQJHGIRUPDFKLQHVHUYLFLQJ5HIHUWR)LJXUHIRUWKHORFDWLRQRIWKH
3HUVRQDOLW\0RGXOHRQWKH8/75$3OXV3'0ORJLFERDUG
Figure 2.16
Location of Personality Module
F1 F1
DS1
DS1
U10
U10
Personality
Module
1
1
SW1
SW1
1398 PDM-10, 20, 30, 75, and 150B 1398 PDM-25, 50, 100, and 150
LOGIC BOARD LOGIC BOARD
(component side) (component side)
Installing the Personality Module (PM)
6WUD\HOHFWULFDOGLVFKDUJHFDQGDPDJHWKHSHUVRQDOLW\
ATTENTION
PRGXOH
! 7XUQSRZHU2IIGLVVLSDWHDQ\VWRUHGHOHFWULFDOHQHUJ\DQG
ZHDUDFRQGXFWLYHZULVWVWUDSZKLOHKDQGOLQJWKH3HUVRQDOLW\
0RGXOH
)DLOXUHWRREVHUYHWKLVVDIHW\SURFHGXUHFRXOGUHVXOWLQ
GDPDJHWRWKHHTXLSPHQW
&KHFNWKDWSRZHUWRWKH8/75$3OXV3'0LV2))
3'0DQG%
0HDVXUHYROWDJHEHWZHHQ8/75$3OXV3'0WHUPLQDOVPDUNHG/DQG
/1//1DQG/IRU8/75$3OXV3'0WRHQVXUHLQFRPLQJ
SRZHULV2))$OVRPHDVXUHYROWDJHEHWZHHQWHUPLQDOVPDUNHG/$8;
DQG/1$8;LIXVHGWRHQVXUHSRZHULV2))7KHJUHHQ'&%86
/('DQGWKHELFRORU67$786/('VKRXOGEH2))

3'0DQG
0HDVXUHYROWDJHVDW3RVLWLYHDQG1HJDWLYHEXVWHUPLQDOVWRHQVXUH
LQFRPLQJSRZHULV2)),ID360$8;LVXVHGPHDVXUHWKHYROWDJHDW
/DQG/RIWKH360$8;WRHQVXUHWKDWLQFRPLQJSRZHULV2))
5HPRYHWKH8/75$3OXV3'0FRYHU3'0DQG
RQO\
,QVWDOO3HUVRQDOLW\0RGXOHRQ8/75$3OXV3'0ORJLFERDUGLQVRFNHWDW
ORFDWLRQ87KHHQGRIWKH3HUVRQDOLW\0RGXOH30ZLWKWKHFRORUHG
ODEHOPXVWEHWRZDUGWKHIURQWRIWKH8/75$3OXV3'0,IWKHUHLVD
FRORUHGODEHORQWKHORJLFERDUGWKH30ODEHOZLOOEHQH[WWRLWDQGWKH
FRORUVVKRXOGPDWFK
,QVWDOOWKH8/75$3OXV3'0FRYHULIUHPRYHG
IMPORTANT 7KH3HUVRQDOLW\0RGXOHLVSURJUDPPHGZLWKVWDQGDUG
IDFWRU\GHIDXOWVHWWLQJV,IUHSODFLQJDSUHYLRXVO\LQVWDOOHG
3HUVRQDOLW\0RGXOHXVHUSURJUDPVDQGXVHUVHOHFWHG
SDUDPHWHUVPXVWEHUHHQWHUHGLQWRWKHQHZ3HUVRQDOLW\
0RGXOHPHPRU\XVLQJ*0/8OWUD6RIWZDUH

System Firmware $OO8/75$3OXV3'0VFRPHZLWKWKHV\VWHPILUPZDUHLQVWDOOHG7KHUHIRUH

XQOHVV\RXDUHXSJUDGLQJ\RXU8/75$3OXV3'0WRDQHZHUYHUVLRQRI
Installation ILUPZDUH\RXZLOOQRWQHHGWRLQVWDOOV\VWHPILUPZDUH5HIHUWR)LJXUHIRU
V\VWHPILUPZDUHORFDWLRQ
Figure 2.17
Location of system firmware
U57
U57
U66 U67 SYSTEM U66 U67
FIRMWARE
U87
U87
1398 PDM-25, 50, 100, and 150

1398 PDM-10, 20, 30, 75, and 150B LOGIC BOARD
LOGIC BOARD (component side)
(component side)

Installing the Firmware EPROMs
6WUD\HOHFWULFDOGLVFKDUJHFDQGDPDJHWKH)LUPZDUH
ATTENTION
(3520V
! 7XUQSRZHU2IIGLVVLSDWHDQ\VWRUHGHOHFWULFDOHQHUJ\DQG
ZHDUDFRQGXFWLYHZULVWVWUDSZKLOHKDQGOLQJWKH3HUVRQDOLW\
0RGXOH
GDPDJHWRWKHHTXLSPHQW
&KHFNWKDWSRZHUWRWKH8/75$3OXV3'0LV2))
3'0DQG%
0HDVXUHYROWDJHEHWZHHQ8/75$3OXV3'0WHUPLQDOVPDUNHG/DQG
/1DQG/RQ3'0DQG%WRHQVXUHLQFRPLQJSRZHU
LV2))$OVRPHDVXUHYROWDJHEHWZHHQWHUPLQDOVPDUNHG/$8;DQG
/1$8;LIXVHGWRHQVXUHSRZHULV2))7KHJUHHQ'&%86/('
DQGWKHELFRORU67$786/('VKRXOGEH2))
3'0DQG
0HDVXUHYROWDJHVDW3RVLWLYHDQG1HJDWLYHEXVWHUPLQDOVWRHQVXUH
LQFRPLQJSRZHULV2)),ID360$8;LVXVHGPHDVXUHWKHYROWDJHDW
/DQG/RIWKH360$8;WRHQVXUHWKDWLQFRPLQJSRZHULV2))
5HPRYHWKH8/75$3OXV3'0FRYHU3'0DQG
RQO\
,QVWDOOWKHIRXU(3520VRQWKH8/75$3OXV3'0ORJLFERDUGLQVRFNHWV
888DQG87KHHQGRIWKH(3520ZLWKWKHQRWFKPXVW
EHWRZDUGWKHIURQWRIWKH8/75$3OXV3'0
,QVWDOOWKH8/75$3OXV3'0FRYHULIUHPRYHG
Jumper and DIP Switches -XPSHUV:DQG:PD\EHUHPRYHGLIDQH[WHUQDO9'&SRZHUVXSSO\LV

XVHG5HPRYLQJWKHVHMXPSHUVZLOOGLVFRQQHFWWKHLQWHUQDOVXSSO\7KH
MXPSHUVGRQRWQHHGWREHUHPRYHGLIRQO\WKH9FRPPRQ3SLQLV
FRQQHFWHGWRPDFKLQHFRPPRQEXWPXVWEHUHPRYHGLIDQH[WHUQDO9'&
VXSSO\LVFRQQHFWHGWR3SLQ
'LSVZLWFK6:VHWVWKHDGGUHVVZKHQPXOWLSOH8/75$3OXV3'0VDUH
FRQQHFWHGLQPXOWLGURSVHULDOFRPPXQLFDWLRQVPRGHDQGVHWVWKHPRGHRI
RSHUDWLRQIRUWKH2SHUDWRU7HUPLQDO6HULDO$X[LODU\35HIHU
WR ´1HWZRUNLQJµRQSDJH IRUPRUHLQIRUPDWLRQ

5HIHUWR ´/RFDWLRQRIMXPSHUDQG',3VZLWFKµRQSDJH IRUWKHORFDWLRQV

RIMXPSHUV::DQGGLSVZLWFK6:RQWKH8/75$3OXV3'0ORJLF
ERDUG
Figure 2.18
Location of jumper and DIP switch
F1 F1
DS1
DS1
U10
U10
DIP SWITCH Sw1
1
1
W3 SW1
SW1
W3 W4
JUMPERS
W4
1398 PDM-25, 50, 100, and 150

1398 PDM-10, 20, 30, 75, and 150B
LOGIC PC BOARD
LOGIC PC BOARD
(component side)
(component side)
Regulatory Requirements 7KHVHJXLGHOLQHVGLVFXVVZD\VWRPLQLPL]HQRLVHSUREOHPV+RZHYHU

HTXLSPHQW(0&SHUIRUPDQFHPXVWPHHWUHJXODWRU\UHTXLUHPHQWVLQYDULRXV
SDUWVRIWKHZRUOGVSHFLILFDOO\WKH(XURSHDQ8QLRQ8OWLPDWHO\LWLVWKH
UHVSRQVLELOLW\RIWKHPDFKLQHEXLOGHUWRHQVXUHWKDWWKHPDFKLQHPHHWVWKH
DSSURSULDWHUHTXLUHPHQWVDVVWDWHG
7KHIROORZLQJLQVWDOODWLRQUHTXLUHPHQWVDUHIRUFRPSOLDQFHWRWKH/RZ9ROWDJH
'LUHFWLYH/9'DQGWKH(OHFWURPDJQHWLF&RPSDWLELOLW\(0&'LUHFWLYHIRU
8/75$3OXV3'0V7KHLQIRUPDWLRQEHORZLVEDVHGRQVXFFHVVIXOWHVWLQJ
XVLQJWKHVSHFLILHGLQVWDOODWLRQPHWKRGV

Electromagnetic Compatibility Directive
,WLVLPSRVVLEOHWRJXDUDQWHHDVSHFLILF8/75$3OXV3'0LQVWDOODWLRQZLOO
PHHWWKH(0&UHTXLUHPHQWVZLWKRXWWHVWLQJ7KH3'0
DQG%LQVWDOOHGDVGHVFULEHGEHORZVKRXOGEHFRPSOLDQWZLWK(XURSHDQ
(0&UHTXLUHPHQWV7KH3'0DQGDUHQRW&(
FRPSOLDQW
Figure 2.19
Recommended installation for EMC
Encoder
Leads
Bulkhead Connectors
or Clamps
R
R
S
S T
T Bracket
No Shield ENCLOSURE
Connection
Required MOTOR POWER CABLE
Ground Bus Bar
ALTERNATIVE MOTOR POWER

CABLE SHIELD TERMINATION
FILTER
Bulkhead Connector
or Clamp
MOTOR LEADS

,PSRUWDQWSRLQWVDUH
• &DEOHVKLHOGVPXVWEHERQGHGWRWKHHQFORVXUHDWDOOHQWU\SRLQWVLQRQHRI
WZRZD\V$PDWLQJEXONKHDGFRQQHFWRUFDQEHPRXQWHGRQWKHHQFORVXUH
RUWKHFDEOHMDFNHWPD\EHUHPRYHGVRWKDWWKHVKLHOGFDQEHFODPSHGWRWKH
HQFORVXUH7KHPRWRUSRZHUFDEOHVKLHOGPD\EHWHUPLQDWHGWRWKH3'0
FKDVVLVRQWKRVHGULYHVWKDWKDYHWKHPRWRUSRZHUFDEOHEUDFNHWVXSSOLHG
ZLWKWKHP,QWKLVFDVHWKHPRWRUSRZHUFDEOHVKLHOGGRHVQRWKDYHWREH
WHUPLQDWHGWRWKHHQFORVXUH
• 7KHOHDGOHQJWKEHWZHHQWKH3'0DQGILOWHUGRHVQRWQHHGWREHVKLHOGHG
EXWLWVKRXOGEHDVVKRUWDVSRVVLEOH$OORWKHUFDEOHVPXVWEHVKLHOGHGZLWK
WKHVKLHOGVWHUPLQDWHGDWERWKHQGV,IJURXQGORRSVDUHDQLVVXHWKHVKLHOG
FDQEHFDSDFLWLYHO\WHUPLQDWHGDWRQHHQG
• 7KH3'0VKRXOGEHPRXQWHGLQDJURXQGHGPHWDOHQFORVXUHDQ´(0,µ
HQFORVXUHLVQRWUHTXLUHG
• 5RXWHWKHHQFRGHUIHHGEDFNVHULDOFRPPXQLFDWLRQVDQGGLJLWDO,2FDEOHV
VHSDUDWHO\IURP$&DQGPRWRUSRZHUFDEOLQJ
2QHRIWKHPRVWLPSRUWDQWIDFWRUVLVWKHPRWRUFDEOHVKLHOGWHUPLQDWLRQDWWKH
PRWRUHQG7KHVKLHOGPXVWEHWHUPLQDWHGWRWKHFDVHRIWKHPRWRUWKURXJK
WKHFRQQHFWRUEDFNVKHOORUWKURXJKDPHWDOJODQGLQWKHFDVHRIDPRWRUZLWK
IO\LQJOHDGV,IWKHUHDUHDQ\LQWHUPHGLDWHFRQQHFWRUVLQDQ\RIWKHVFUHHQHG
FDEOHVWKHVFUHHQPXVWFRQQHFWWKURXJKWKHEDFNVKHOOVDQGQRWE\URXWLQJD
GUDLQZLUHWKURXJKDSLQLQVLGHWKHFRQQHFWRU8VHRIDGUDLQZLUHYLUWXDOO\
JXDUDQWHHVIDLOXUHWRPHHWWKH(0&UHTXLUHPHQWV
7KH3'0DQG%KDYHVXFFHVVIXOO\SDVVHGDOO(0&
WHVWVEXWVKRZVVRPHVHQVLWLYLW\WRUDGLDWHGILHOGV9PLQWKHHQFRGHU
IHHGEDFNFLUFXLWZKHQWKHVHULDOOHDGLVFRQQHFWHG&DUHPXVWEHWDNHQLQ
VFUHHQLQJDQGJURXQGLQJZLWKERWKWKHVHULDOOHDGDQGWKHPRWRUIHHGEDFNOHDG
RUQXLVDQFHWULSSLQJPD\RFFXU7KH3'0HQGFRQQHFWRUIRUWKHVHOHDGVLVD
'W\SHDQGVFUHHQHGEDFNVKHOOVVKRXOGEHXVHGZLWKWKHVFUHHQSURSHUO\
WHUPLQDWHG7KHUHLVQRUHTXLUHPHQWIRUDWUDQVIRUPHULQWKLVGHVLJQDQGD
FRPPRQPRGHFKRNHIRUWKHPRWRUOHDGVLVLQFOXGHGLQWKH3'0

7KH3'0LQSXWFXUUHQWUDWLQJVDQGVXLWDEOHVXSSO\ILOWHUVRQHILOWHUSHU3'0
DUHOLVWHGEHORZ
PDM current ratings and suitable supply filters

PDM Current Rating Schaffner Roxburgh
1398-PDM-10 1φ 10 A FN350-12-29 MDF16 or MIF10
1398-PDM-150B 3φ 50 A --- MDF 350
5R[EXUJKILOWHUVPD\EHRUGHUHGGLUHFWO\IURP5RFNZHOO$XWRPDWLRQLQWKH
8QLWHG6WDWHVRU(XURSH3DUWQXPEHUVDQGUDWLQJVDUHLQGLFDWHGEHORZ
Roxburgh filters available directly from Rockwell Automation

Roxburgh Current Rating Rockwell - USA Rockwell - Crewe
MDF18 1φ 18A NONE 48-0428
MDF36 1φ 36A 9101-1387 48-0429
MDF336 3φ 36A 9101-1389 48-0430
MDF501 1φ 50A 9101-1388 NONE

MDF350 3φ 50A 9101-1575 NONE
MDF3701 3φ 70A 9101-1390 NONE

MIF10 1φ 10A 9101-1517 NONE
MIF23 1φ 23A 9101-1518 NONE
1.MDF50 & MDF370 can be used for multiple PDMs
$VXSSO\ILOWHUIRUWKHDX[LOLDU\VXSSO\LVXQQHFHVVDU\DVDILOWHULVLQFOXGHGLQ
WKH3'0DQG%
6KLHOGHGSRZHUFDEOHVPXVWEHJURXQGHGDWDPLQLPXPRI
ATTENTION
RQHSRLQWIRUVDIHW\
! SHUVRQDOLQMXU\RUGDPDJHWRHTXLSPHQW

Bonding Your System
%RQGLQJLVWKHSUDFWLFHRIFRQQHFWLQJPHWDOFKDVVLVDVVHPEOLHVIUDPHVVKLHOGV
DQGHQFORVXUHVWRUHGXFHWKHHIIHFWVRIHOHFWURPDJQHWLFLQWHUIHUHQFH(0,
8QOHVVVSHFLILHGPRVWSDLQWVDUHQRWFRQGXFWLYHDQGWKH\DFWDVLQVXODWRUV7R
DFKLHYHDJRRGERQGEHWZHHQPRGXOHVDQGWKHVXESDQHOVXUIDFHVQHHGWREH
SDLQWIUHHRUSODWHG%RQGLQJPHWDOVXUIDFHVFUHDWHVDORZLPSHGDQFHH[LWSDWK
IRUKLJKIUHTXHQF\HQHUJ\
)LJXUHLOOXVWUDWHVUHFRPPHQGHGERQGLQJSUDFWLFHVIRUSDLQWHGSDQHOV
HQFORVXUHVDQGPRXQWLQJEUDFNHWV,PSURSHUERQGLQJEORFNVWKDWGLUHFWH[LW
SDWKDQGDOORZVKLJKIUHTXHQF\HQHUJ\WRWUDYHOHOVHZKHUHLQWKHFDELQHW
([FHVVLYHKLJKIUHTXHQF\HQHUJ\FDQHIIHFWWKHRSHUDWLRQRIRWKHU
PLFURSURFHVVRUFRQWUROOHGHTXLSPHQW
Figure 2.20
Recommended bonding practices

Multiple Sub Panels
%RQGLQJPXOWLSOHVXESDQHOVFUHDWHVDFRPPRQORZLPSHGDQFHH[LWSDWKIRU
WKHKLJKIUHTXHQF\HQHUJ\LQVLGHWKHFDELQHW6XESDQHOVWKDWDUHQRWERQGHG
WRJHWKHUPD\QRWVKDUHDFRPPRQORZLPSHGDQFHSDWK7KLVGLIIHUHQFHLQ
LPSHGDQFHPD\DIIHFWQHWZRUNVDQGRWKHUGHYLFHVWKDWVSDQPXOWLSOHSDQHOV
5HIHUWRWKHLOOXVWUDWLRQEHORZIRUUHFRPPHQGHGERQGLQJSUDFWLFHV
Figure 2.21
Multiple sub-panels and cabinet

Motors and Cables
7KHV\VWHPWHVWVZHUHPDGHXVLQJ5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\
PRWRUVDQGERWKVKLHOGHGDQGXQVKLHOGHGSRZHUFDEOHV7KHVKLHOGHGFDEOHV
KDYHDµSRUWLRQRIWKHFDEOHMDFNHWVWULSSHGRIIH[SRVLQJWKHVKLHOG
DSSUR[LPDWHO\µIURPWKH3'0HQGRIWKHFDEOH7KLVVWULSSHGDUHDLVWREH
FODPSHGRQWRWKHFKDVVLVIRUVKLHOGWHUPLQDWLRQZKHQXVHGZLWKWKH8/75$
3OXV3'0V5HIHUWR ´0RWRUSRZHU(0&VKLHOGFRQQHFWLRQµRQSDJH
Low Voltage Directive
7KH3'0VPXVWEHPRXQWHGLQDQHQFORVXUHWKDWSURYLGHVDPLQLPXPRI
,3;SURWHFWLRQVXFKWKDWRQO\DXWKRUL]HGLQGLYLGXDOVKDYHDFFHVVWRWKHP
+LJKYROWDJHLVSUHVHQWRQWKH'&%XVDQGWHUPLQDOEORFN
ATTENTION
FRQQHFWLRQVIRUVHYHUDOPLQXWHVDIWHUHOHFWULFDOSRZHULV
UHPRYHG
! 0RWRUFRQQHFWRUVDUHIRUDVVHPEO\DQGGLVDVVHPEO\RQO\
7KHVHFRQQHFWLRQVVKRXOGQHYHUEHPDGHRUEURNHQZKLOH
WKH3'0LVHQHUJL]HG0HDVXUHUHPDLQLQJYROWDJHRQ
WHUPLQDOEORFNSULRUWRUHPRYLQJWKHSURWHFWLYHFRYHURU
WRXFKLQJDQ\FRQQHFWLRQV
SHUVRQDOLQMXU\RUGDPDJHWRHTXLSPHQW

I/F 24V Sourcing Conversion Card
7KH8/75$3OXV3'0KDVVLQNLQJDFWLYHORZ,2ZKLFKLVFRPPRQLQWKH

866RXUFLQJDFWLYHKLJK,2VDUHSUHIHUUHGLQ(XURSH5RFNZHOO
$XWRPDWLRQRIIHUVD',1UDLOPRXQWHGFDUGZKLFKFRQYHUWVWKH,2IURP
VLQNLQJWRVRXUFLQJ7KLVFDUGPXVWEHPRXQWHGLQWKHVDPHHQFORVXUHDVWKH
3'0
IMPORTANT $XVHUVXSSOLHGH[WHUQDO9'&SRZHUVXSSO\LVUHTXLUHG
IRUWKLVRSWLRQ
ULTRA Plus PDM I/F Conversion Card

Description Alternate Number
I/F Conversion Card, 24V Sourcing(1) 9103-0152
Cable, I/F Conversion Card 3ft (1m) 44-0141-003

Cable I/F Conversion Card 10ft (3m) 44-0141-010
(1) Required for compliance with the European Union Low Voltage Directive (LVD). It must be mounted in the same
enclosure as ULTRA Plus PDM.

Emergency Stop Contactor
6RPHPDFKLQHVUHTXLUHWKDWDFRQWDFWRUEHLQVHUWHGEHWZHHQWKHPRWRUDQG
3'0IRUHPHUJHQF\VWRSSXUSRVHV$KD]DUGDQDO\VLVRIWKHPDFKLQHZLOO
GHWHUPLQHLIWKLVLVQHHGHG,IXVHGWKHFRQWDFWRUPXVWQRWVLPSO\EUHDNWKH
PRWRUFXUUHQWLWPXVWVZLWFKDSKDVHUHVLVWLYHORDGLQSDUDOOHOZLWKWKHPRWRU
ZLQGLQJV7KHWKUHHUHVLVWRUVZLOOSURYLGHG\QDPLFEUDNLQJDQGDFDWHJRU\]HUR
VWRS7KHUHVLVWRUVDOVRFDQSUHYHQWFRQWLQXRXVDUFLQJDWWKHPDLQFRQWDFWV
ZKHQEUHDNLQJ'&FXUUHQWVVXFKDVZKHQWKHPRWRULVDWVWDOO6LPSO\
EUHDNLQJWKHPRWRUFXUUHQWFDQUHVXOWLQYHU\KLJKYROWDJHVGXHWRPRWRU
LQGXFWDQFHZKLFKFDQFDXVHSURORQJHGDUFLQJLQWKHFRQWDFWRU7KHFRQWDFWRU
FRXOGFDWFKILUHLQH[WUHPHFDVHV
$FRQWDFWRUZDVVLPXODWHGLQPRVW(0&WHVWVE\EUHDNLQJWKHPRWRUOHDGDQG
WDNLQJLWWKURXJKODUJHUDLOPRXQWHGWHUPLQDOV7KLVVLPXODWHVDFORVHG
FRQWDFWRUZKLFKLVDFFHSWDEOHDVWKHFRQWDFWRUZRXOGEHFORVHGIRUQRUPDO
RSHUDWLRQRIWKH3'07KHPHWKRGRIFRQQHFWLRQRIWKHVFUHHQDQGJURXQG
FDEOHVZDVDVVKRZQEHORZ7KHVKLHOGVVKRXOGEHXQEUDLGHGUDWKHUWKDQ
VROGHULQJDGUDLQZLUHWRWKHVKLHOG&RQQHFWLRQOHQJWKVVKRXOGEHPLQLPL]HG
Figure 2.22
Emergency Stop Contactor Wiring
Resistor
Resistor
Resistor
R R
Drive S S Motor
T T
GND GND
Isolated terminal
Unbraided shield
Grounded terminal or stud
Enclosure wall
7KHVDIHW\JURXQG*1'DQGVKLHOGFRQQHFWLRQVDUHSHUPDQHQWO\FRQQHFWHG

7KLVLVHVVHQWLDOIRUHOHFWULFDOVDIHW\
IMPORTANT 7KHVDIHW\JURXQGLVQRWFRQQHFWHGWRORFDOJURXQGDWWKH
SRLQWZKHUHWKHFRQWDFWRULVLQVHUWHGLQWKHOLQHVEXWWKH
VKLHOGLV7KLVLVGRQHIRU(0&UHDVRQV

Electromagnetic 3HUKDSVQRRWKHUVXEMHFWUHODWHGWRWKHLQVWDOODWLRQRILQGXVWULDOHOHFWURQLF
HTXLSPHQWLVVRPLVXQGHUVWRRGDVHOHFWULFDOQRLVH7KHVXEMHFWLVFRPSOH[DQG
Compatibility WKHWKHRU\HDVLO\ILOOVDERRN7KLVVHFWLRQSURYLGHVJXLGHOLQHVWKDWFDQ
PLQLPL]HQRLVHSUREOHPV
7KHPDMRULW\RILQVWDOODWLRQVGRQRWH[KLELWQRLVHSUREOHPV+RZHYHUWKH
ILOWHULQJDQGVKLHOGLQJJXLGHOLQHVDUHSURYLGHGDVFRXQWHUPHDVXUHV7KH
JURXQGLQJJXLGHOLQHVSURYLGHGEHORZDUHVLPSO\JRRGJURXQGLQJSUDFWLFHV
7KH\VKRXOGEHIROORZHGLQDOOLQVWDOODWLRQV
(OHFWULFDOQRLVHKDVWZRFKDUDFWHULVWLFVWKHJHQHUDWLRQRUHPLVVLRQRI
HOHFWURPDJQHWLFLQWHUIHUHQFH(0,DQGUHVSRQVHRULPPXQLW\WR(0,7KH
GHJUHHWRZKLFKDGHYLFHGRHVQRWHPLW(0,DQGLVLPPXQHWR(0,LVFDOOHG
WKHGHYLFH·V(OHFWUR0DJQHWLF&RPSDWLELOLW\(0&
(TXLSPHQWIRUXVHLQWKH(XURSHDQ8QLRQOHJDOO\UHTXLUHVDVSHFLILFOHYHORI
(0&6LQFHWKLVDSSOLHVZKHQWKHHTXLSPHQWLVEURXJKWLQWRXVHLWLVRI
FRQVLGHUDEOHLPSRUWDQFHWKDWD3'0V\VWHPDVDFRPSRQHQWRIDPDFKLQHEH
FRUUHFWO\LQVWDOOHG,QVWDOODWLRQJXLGHOLQHVIRUVSHFLILFSURGXFWVFDQEHIRXQGLQ
WKHSURGXFWPDQXDOVRUDVVHSDUDWHGRFXPHQWVDYDLODEOHIURP5RFNZHOO
$XWRPDWLRQ
)LJXUHVKRZVWKHFRPPRQO\XVHG(0,PRGHO7KHPRGHOFRQVLVWVRIDQ
(0,VRXUFHDFRXSOLQJPHFKDQLVPDQGDQ(0,YLFWLP'HYLFHVVXFKDVVHUYR
GULYHVDQGFRPSXWHUVZKLFKFRQWDLQVZLWFKLQJSRZHUVXSSOLHVDQG
PLFURSURFHVVRUVDUH(0,VRXUFHV7KHPHFKDQLVPVIRUWKHFRXSOLQJRIHQHUJ\
EHWZHHQWKHVRXUFHDQGYLFWLPDUHFRQGXFWLRQDQGUDGLDWLRQ9LFWLP
HTXLSPHQWFDQEHDQ\HOHFWURPDJQHWLFGHYLFHWKDWLVDGYHUVHO\DIIHFWHGE\WKH
(0,FRXSOHGWRLW

Figure 2.23
EMI Source-Victim Model
CONDUCTED EMI
EMI EMI
SOURCE VICTIM
RADIATED
EMI
EMI
VICTIM
,PPXQLW\WR(0,LVSULPDULO\GHWHUPLQHGE\HTXLSPHQWGHVLJQEXWKRZ\RX
ZLUHDQGJURXQGWKHGHYLFHLVDOVRFULWLFDOWRDFKLHYLQJ(0,LPPXQLW\
7KHUHIRUHLWLVLPSRUWDQWWRVHOHFWHTXLSPHQWWKDWKDVEHHQGHVLJQHGDQG
WHVWHGIRULQGXVWULDOHQYLURQPHQWV7KH(0,VWDQGDUGVIRULQGXVWULDO
HTXLSPHQWLQFOXGH(1;VHULHV,(&;DQG,(&;
VHULHV$16,&DQG&DQG0,/67'$OVRLQLQGXVWULDO
HQYLURQPHQWV\RXVKRXOGXVHHQFRGHUVZLWKOLQHGULYHURXWSXWVUDWKHUWKDQ
VLQJOHHQGHGRXWSXWVDQGGLJLWDOLQSXWVRXWSXWVZLWKHOHFWULFDOLVRODWLRQVXFK
DVWKRVHSURYLGHGZLWKRSWRFRXSOHUV
7KH(0,PRGHOSURYLGHVRQO\WKUHHRSWLRQVIRUHOLPLQDWLQJWKH(0&
SUREOHP
• UHGXFHWKH(0,DWWKHVRXUFH
• LQFUHDVHWKHYLFWLP·VLPPXQLW\WR(0,KDUGHQWKHYLFWLP
• UHGXFHWKH(0,DWWKHYLFWLPHOLPLQDWHWKHFRXSOLQJPHFKDQLVP
,QWKHFDVHRIVHUYRGULYHVUHGXFLQJWKH(0,VRXUFHUHTXLUHVVORZLQJSRZHU
VHPLFRQGXFWRUVZLWFKLQJVSHHGV+RZHYHUWKLVDGYHUVHO\DIIHFWV3'0
SHUIRUPDQFHZLWKUHVSHFWWRKHDWGLVVLSDWLRQDQGVSHHGWRUTXHUHJXODWLRQ
+DUGHQLQJWKHYLFWLPHTXLSPHQWPD\QRWEHSRVVLEOHRUSUDFWLFDO7KHILQDO
DQGRIWHQWKHPRVWUHDOLVWLFVROXWLRQLVWRUHGXFHWKHFRXSOLQJPHFKDQLVP
EHWZHHQWKHVRXUFHDQGYLFWLP7KLVFDQEHDFKLHYHGE\ILOWHULQJVKLHOGLQJDQG
JURXQGLQJ

Filtering
$VPHQWLRQHGDERYHKLJKIUHTXHQF\HQHUJ\FDQEHFRXSOHGEHWZHHQFLUFXLWV
YLDUDGLDWLRQRUFRQGXFWLRQ7KH$&SRZHUZLULQJLVRQHRIWKHPRVW
LPSRUWDQWSDWKVIRUERWKW\SHVRIFRXSOLQJPHFKDQLVPV7KH$&OLQHFDQ
FRQGXFWQRLVHLQWRWKH3'0IURPRWKHUGHYLFHVRULWFDQFRQGXFWQRLVH
GLUHFWO\IURPWKH3'0LQWRRWKHUGHYLFHV,WFDQDOVRDFWDVDQDQWHQQDDQG
WUDQVPLWRUUHFHLYHUDGLDWHGQRLVHEHWZHHQWKH3'0DQGRWKHUGHYLFHV
2QHPHWKRGWRLPSURYHWKH(0&FKDUDFWHULVWLFVRID3'0LVWRXVHDQ
LVRODWLRQ$&SRZHUWUDQVIRUPHUWRIHHGWKHDPSOLILHULWVLQSXWSRZHU7KLV
PLQLPL]HVLQUXVKFXUUHQWVRQSRZHUXSDQGSURYLGHVHOHFWULFDOLVRODWLRQ,Q
DGGLWLRQLWSURYLGHVFRPPRQPRGHILOWHULQJDOWKRXJKWKHHIIHFWLVOLPLWHGLQ
IUHTXHQF\E\WKHLQWHUZLQGLQJFDSDFLWDQFH8VHRID)DUDGD\VKLHOGEHWZHHQ
WKHZLQGLQJVFDQLQFUHDVHWKHFRPPRQPRGHUHMHFWLRQEDQGZLGWKVKLHOG
WHUPLQDWHGWRJURXQGRUSURYLGHGLIIHUHQWLDOPRGHVKLHOGLQJVKLHOG
WHUPLQDWHGWRWKHZLQGLQJ
IMPORTANT ´&RPPRQPRGHµQRLVHLVSUHVHQWRQDOOFRQGXFWRUV
UHIHUHQFHGWRJURXQG´'LIIHUHQWLDOPRGHµQRLVHLVSUHVHQW
RQRQHFRQGXFWRUUHIHUHQFHGWRDQRWKHUFRQGXFWRU
$QDOWHUQDWLYHLVWRXVH$&OLQHILOWHUVWRUHGXFHWKHFRQGXFWHG(0,HPLWWLQJ
IURPWKH3'07KLVDOORZVQHDUE\HTXLSPHQWWRRSHUDWHXQGLVWXUEHG,QPRVW
FDVHVDQ$&OLQHILOWHUZLOOQRWEHUHTXLUHGXQOHVVRWKHUVHQVLWLYHFLUFXLWVDUH
SRZHUHGRIIWKHVDPH$&EUDQFKFLUFXLW7KHEDVLFRSHUDWLQJSULQFLSOHLVWR
PLQLPL]HWKHKLJKIUHTXHQF\SRZHUWUDQVIHUWKURXJKWKHILOWHU$QHIIHFWLYH
ILOWHUDFKLHYHVWKLVE\XVLQJFDSDFLWRUVDQGLQGXFWRUVWRPLVPDWFKWKHVRXUFH
LPSHGDQFH$&OLQHDQGWKHORDGLPSHGDQFH3'0DWKLJKIUHTXHQFLHV
)RU5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\3'0VEURXJKWLQWRXVHLQ(XURSH
WKHXVHRIWKHFRUUHFWILOWHULVHVVHQWLDOWRPHHWHPLVVLRQVUHTXLUHPHQWV
'HWDLOHGLQIRUPDWLRQRQILOWHUVLVLQFOXGHGLQWKH3'0VSHFLILFGRFXPHQW
7UDQVIRUPHUVVKRXOGDOVREHXVHGDVVSHFLILHGLQWKH3'0PDQXDO

7KHIROORZLQJWDEOHVKRZVVXLWDEOHILOWHUW\SHVIRU5RFNZHOO$XWRPDWLRQ
$OOHQ%UDGOH\SURGXFWV7KHILOWHUVLGHQWLILHGDUHPDQXIDFWXUHGE\6FKDIIQHURU
5R[EXUJKDQGDUHZLGHO\DYDLODEOHIURPFRPPHUFLDOVRXUFHV)LOWHUV
PDQXIDFWXUHGE\5DVPLKDYHDOVREHHQWHVWHGVXFFHVVIXOO\IRU(8FRPSOLDQFH
7KHUHDUHPDQ\$&OLQHILOWHUPDQXIDFWXUHUVZKRVHSURGXFWVFRXOGEH
VXFFHVVIXOO\LQWHJUDWHG2QHPDQXIDFWXUHUFDQQRWEHUHFRPPHQGHGRYHU
DQRWKHUPDQXIDFWXUHU7KHPDFKLQHEXLOGHULVUHVSRQVLEOHIRUWKHVXLWDELOLW\RI
WKHILOWHUVHOHFWLRQLQDVSHFLILFDSSOLFDWLRQ)XUWKHULQIRUPDWLRQLVDYDLODEOH
IURPWKHPDQXIDFWXUHUV
Rockwell Automation/Allen-Bradley Roxburgh Schaffner

PDM/ Power Supply Part Number Part Number
Suitable AC Line Filter Types
Single phase PDMs MIF xx or MDF FN 350-xx
xx
Three phase PDMs MIF3xx or MDF FN 351-xx
3xx
Rockwell Automation stocks some Roxburgh filters, but does not offer low current
single phase filters. Most applications are multiple axis such that multiple PDMs may
be connected to a filter (e.g. MDF xx) with higher current rating.
Manufacturer phone numbers:
Roxburgh 01724-281770 (011-44-1724-281770 from USA), and
Schaffner (1-800-367-5566).

AC Line Filter Selection
6HOHFWLRQRIWKHSURSHUILOWHULVRQO\WKHILUVWVWHSLQUHGXFLQJFRQGXFWHG
HPLVVLRQV&RUUHFWILOWHULQVWDOODWLRQLVFUXFLDOWRDFKLHYLQJERWK(0,
DWWHQXDWLRQDQGWRHQVXUHVDIHW\$OORIWKHIROORZLQJJXLGHOLQHVVKRXOGEHPHW
IRUHIIHFWLYHILOWHUXVH
7KHILOWHUPXVWEHPRXQWHGFORVHWRWKH3'0LQSXWWHUPLQDOV7KLVLV
SDUWLFXODUO\LPSRUWDQWIRUKLJKHUIUHTXHQF\HPLVVLRQV0+],IWKH
GLVWDQFHH[FHHGVPPIWWKHQDVWUDSVKRXOGEHXVHGWRFRQQHFW
WKHJURXQGEHWZHHQWKH3'0DQGILOWHUUDWKHUWKDQDZLUH
7KHZLUHVFRQQHFWLQJWKH$&VRXUFHWRWKHILOWHUVKRXOGEHVKLHOGHGIURP
RUDWOHDVWVHSDUDWHGIURPRWKHUKLJKSRZHUFDEOHVLHFRQQHFWLRQ
EHWZHHQWKH3'0DQGWKHILOWHUPRWRUSRZHUFDEOHHWF,IWKH
FRQQHFWLRQVDUHQRWVHJUHJDWHGIURPHDFKRWKHUWKHQWKH(0,RQWKH
3'0VLGHRIWKHILOWHUFDQFRXSOHRYHUWRWKHVRXUFHVLGHRIWKHILOWHU
WKHUHE\UHGXFLQJRUHOLPLQDWLQJWKHILOWHUHIIHFWLYHQHVV7KHFRXSOLQJ
PHFKDQLVPFDQEHUDGLDWLRQRUVWUD\FDSDFLWDQFHEHWZHHQWKHZLUHV7KH
EHVWPHWKRGRIDFKLHYLQJWKLVLVWRPRXQWWKHILOWHUZKHUHWKH$&SRZHU
HQWHUVWKHHQFORVXUH)LJXUHRQSDJHFRQWUDVWVDJRRG
LQVWDOODWLRQZLWKDSRRURQH
:KHQPXOWLSOHSRZHUFDEOHVHQWHUDQHQFORVXUHDQXQILOWHUHGOLQHFDQ
FRQWDPLQDWHDILOWHUHGOLQHH[WHUQDOWRWKHHQFORVXUH7KHUHIRUHDOOOLQHV
PXVWEHILOWHUHGWREHHIIHFWLYH7KHVLWXDWLRQLVVLPLODUWRDOHDN\ERDW
$OOWKHKROHVPXVWEHSOXJJHGWRSUHYHQWVLQNLQJ
,IWKHILOWHULVPRXQWHGH[FHVVLYHO\IDUIURPWKH3'0LWPD\EHQHFHVVDU\
WRPRXQWLWWRDJURXQGHGFRQGXFWLYHVXUIDFHWKHHQFORVXUHWR
HVWDEOLVKDKLJKIUHTXHQF\+)FRQQHFWLRQWRWKDWVXUIDFH7RDFKLHYH
WKH+)JURXQGWKHVXUIDFHLQWHUIDFHEHWZHHQWKHILOWHUDQGWKHVWUXFWXUH
VKRXOGEHIUHHIURPSDLQWRUDQ\RWKHULQVXODWRU7KLVPD\UHTXLUHSDLQW
UHPRYDOIURPWKHLQVLGHRIDFDELQHWRUSDQHO

Figure 2.24
AC Line Filter installation
POOR GOOD
CONDUCTED EMI
PDM PDM
AC CONDUCTED EMI
LINE
RADIATED RADIATED
EMI EMI
FILTER
RADIATED
EMI
AC
FILTER CONDUCTED EMI
LINE

+LJKYROWDJHH[LVWVLQ$&OLQHILOWHUV
ATTENTION
7KHILOWHUPXVWEHJURXQGHGSURSHUO\EHIRUHDSSO\LQJ
! SRZHU)LOWHUFDSDFLWRUVUHWDLQKLJKYROWDJHVDIWHUSRZHU
UHPRYDO%HIRUHKDQGOLQJWKHHTXLSPHQWYROWDJHVVKRXOG
EHPHDVXUHGWRGHWHUPLQHVDIHOHYHOV
)DLOXUHWRREVHUYHWKLVSUHFDXWLRQFRXOGUHVXOWLQSHUVRQDO
LQMXU\
7KHRQO\UHDVRQDEOHILOWHULQJDWWKH3'0RXWSXWWHUPLQDOVLVWKHXVHRI
LQGXFWDQFH&DSDFLWRUVZRXOGVORZWKHRXWSXWVZLWFKLQJDQGGHWHULRUDWHWKH
3'0SHUIRUPDQFH$FRPPRQPRGHFKRNHFDQEHXVHGWRUHGXFHWKH3'0
HPLVVLRQV7KLVZLOOUHGXFHHPLVVLRQFRXSOLQJWKURXJKWKH3'0EDFNWRWKH
$&OLQH+RZHYHUWKHPRWRUFDEOHVWLOOFDUULHVDODUJH+)YROWDJHDQGFXUUHQW
,QIDFWWKHPRWRUFDEOHOHQJWKGLUHFWO\DIIHFWVWKHDPSOLWXGHDQGIUHTXHQF\RI
WKHHPLVVLRQVRQWKH$&OLQH7KHUHIRUHLWLVYHU\LPSRUWDQWWRVHJUHJDWHWKH
PRWRUFDEOHIURPWKH$&SRZHUFDEOH)RUDSSOLFDWLRQVZKHUHORQJPRWRU
FDEOHVDUHUHTXLUHGWKHQHHGIRU$&OLQHILOWHULQJLQFUHDVHV

Grounding
+LJKIUHTXHQF\+)JURXQGLQJLVGLIIHUHQWIURPVDIHW\JURXQGLQJ$ORQJ
ZLUHLVVXIILFLHQWIRUDVDIHW\JURXQGEXWLVFRPSOHWHO\LQHIIHFWLYHDVDQ+)
JURXQGGXHWRWKHZLUHLQGXFWDQFH$VDUXOHRIWKXPEDZLUHKDVDQ
LQGXFWDQFHRIQ+FPQ+LQUHJDUGOHVVRIGLDPHWHU$WORZIUHTXHQFLHV
LWDFWVDVDFRQVWDQWLPSHGDQFHDWLQWHUPHGLDWHIUHTXHQFLHVDVDQLQGXFWRUDQG
DWKLJKIUHTXHQFLHVDVDQDQWHQQD7KHXVHRIJURXQGVWUDSVLVDEHWWHU
DOWHUQDWLYHWRZLUHV+RZHYHUWKHOHQJWKWRZLGWKUDWLRPXVWEHRUEHWWHU
\HWWRUHPDLQDJRRGKLJKIUHTXHQF\FRQQHFWLRQ
7KHJURXQGV\VWHP·VSULPDU\SXUSRVHLVWRIXQFWLRQDVDUHWXUQFXUUHQWSDWK,W
LVFRPPRQO\WKRXJKWRIDVDQHTXLSRWHQWLDOFLUFXLWUHIHUHQFHSRLQWEXW
GLIIHUHQWORFDWLRQVLQDJURXQGV\VWHPPD\EHDWGLIIHUHQWSRWHQWLDOV7KLVLV
GXHWRWKHUHWXUQFXUUHQWIORZLQJWKURXJKWKHJURXQGV\VWHPVILQLWH
LPSHGDQFH,QDVHQVHJURXQGV\VWHPVDUHWKHVHZHUV\VWHPVRIHOHFWURQLFV
DQGDVVXFKDUHVRPHWLPHVQHJOHFWHG
7KHSULPDU\REMHFWLYHRIDKLJKIUHTXHQF\JURXQGV\VWHPLVWRSURYLGHDZHOO
GHILQHGSDWKIRU+)FXUUHQWVDQGWRPLQLPL]HWKHORRSDUHDRIWKH+)FXUUHQW
SDWKV,WLVDOVRLPSRUWDQWWRVHSDUDWH+)JURXQGVIURPVHQVLWLYHFLUFXLW
JURXQGV$VLQJOHSRLQWSDUDOOHOFRQQHFWHGJURXQGV\VWHPLVUHFRPPHQGHG
)LJXUHVKRZVVLQJOHSRLQWJURXQGVIRUERWKVHULHVGDLV\FKDLQDQG
SDUDOOHOVHSDUDWHFRQQHFWLRQV0XOWLSOH3'0VVKRXOGEHFRQQHFWHGWRWKH$&
VRXUFHLQDSDUDOOHOIDVKLRQ
Figure 2.25
Single point ground types
SERIES CONNECTION PARALLEL CONNECTION
CIRCUIT CIRCUIT CIRCUIT CIRCUIT CIRCUIT CIRCUIT

1 2 3 1 2 3
GROUND BUS BAR
$JURXQGEXVEDURUSODQHVKRXOGEHXVHGDVWKH´VLQJOHSRLQWµZKHUHFLUFXLWV
DUHJURXQGHG7KLVZLOOPLQLPL]HFRPPRQJURXQGLPSHGDQFHQRLVH
FRXSOLQJ7KHJURXQGEXVEDU*%%VKRXOGEHFRQQHFWHGWRWKH$&JURXQG
DQGLIQHFHVVDU\WRWKHHQFORVXUH$OOFLUFXLWVRUVXEV\VWHPVVKRXOGEH
FRQQHFWHGWRWKH*%%E\VHSDUDWHFRQQHFWLRQV7KHVHFRQQHFWLRQVVKRXOGEH
DVVKRUWDVSRVVLEOHDQGVWUDSVVKRXOGEHXVHGZKHQSRVVLEOH7KHPRWRU
JURXQGFRQGXFWRUPXVWUHWXUQWRWKHJURXQGWHUPLQDORQWKH3'0QRWWKH
*%%

Shielding and Segregation
7KH(0,UDGLDWLQJIURPWKH3'0HQFORVXUHGURSVRIIYHU\TXLFNO\RYHU
GLVWDQFH0RXQWLQJWKH3'0LQDFRQGXFWLYHHQFORVXUHVXFKDVDQLQGXVWULDO
FDELQHWIXUWKHUUHGXFHVWKHUDGLDWHGHPLVVLRQV7KHFDELQHWVKRXOGEHVHWXS
WRDFWDVD)DUDGD\FDJH7KHFDELQHWVKRXOGKDYHDKLJKIUHTXHQF\JURXQGDQG
WKHVL]HRIRSHQLQJVVKRXOGEHPLQLPL]HG$OO8/75$3OXV3'0VPXVWEH
PRXQWHGLQDQLQGXVWULDOFDELQHWWRPHHWVDIHW\UHTXLUHPHQWV
7KHSULPDU\SURSDJDWLRQURXWHIRU(0,HPLVVLRQVIURPD3'0LVWKURXJK
FDEOLQJ7KHFDEOHVFRQGXFWWKH(0,WRRWKHUGHYLFHVDQGFDQDOVRUHUDGLDWH
WKH(0,)RUWKLVUHDVRQFDEOHVHJUHJDWLRQDQGVKLHOGLQJDUHLPSRUWDQWIDFWRUV
LQUHGXFLQJHPLVVLRQV&DEOHVKLHOGLQJFDQDOVRLQFUHDVHWKHOHYHORILPPXQLW\
IRUD3'0
:KHUHVKLHOGHGFDEOHVDUHXQWHUPLQDWHGDVWKHFDEOHFRQQHFWLRQSDVVHV
WKURXJKWKHZDOORIWKHFDELQHWWKHVKLHOGPXVWEHERQGHGWRWKHFDELQHWZDOO
WRSUHYHQWQRLVHSLFNHGXSE\WKHVKLHOGLQJLQVLGHWKHFDELQHWIURPEHLQJ
UDGLDWHGRXWVLGHWKHFDELQHWE\WKHFDEOH:KHUHVKLHOGHGFDEOHVDUHWHUPLQDWHG
XVLQJFRQQHFWRUVWKHVKLHOGPXVWQRWEHJURXQGHGLQVLGHWKHFRQQHFWRU
WKURXJKDGUDLQZLUHRUQRLVHRQWKHVKLHOGZLOOFRXSOHRQWRWKHVLJQDO
FRQGXFWRUVLQVLGHWKHFRQQHFWRU&RQQHFWRUVVKRXOGKDYHFRQGXFWLYH
EDFNVKHOOVDQGWKHVKLHOGVKRXOGEHWHUPLQDWHGWRJURXQGRQO\WKURXJKWKH

EDFNVKHOO7KHIROORZLQJVXJJHVWLRQVDUHUHFRPPHQGHGIRUDOOLQVWDOODWLRQV
HVSHFLDOO\VLQFHWKH\DUHLQH[SHQVLYH
8VHDVKLHOGHGPRWRUFDEOHWKDWLVWHUPLQDWHGDWERWKHQGV7KHVKLHOG
VKRXOGEHFRQQHFWHGWRWKH*%%RUFKDVVLVDWWKH3'0HQGDQGWKH
PRWRUIUDPHDWWKHPRWRUHQG7KHFRD[LDOFRQILJXUDWLRQSURYLGHV
PDJQHWLFVKLHOGLQJDQGWKHVKLHOGSURYLGHVDUHWXUQSDWKIRU+)
FXUUHQWVZKLFKDUHFDSDFLWLYHO\FRXSOHGIURPWKHPRWRUZLQGLQJVWRWKH
IUDPH,ISRZHUIUHTXHQF\FLUFXODWLQJFXUUHQWVDUHDQLVVXHD9$&
FDSDFLWRUVKRXOGEHXVHGDWRQHRIWKHFRQQHFWLRQVWREORFNWR
+]FXUUHQWVZKLOHSDVVLQJ+)FXUUHQWV
6LJQDOFDEOHVHQFRGHUVHULDODQDORJVKRXOGEHURXWHGDZD\IURPWKH

PRWRUFDEOHDQGSRZHUZLULQJ6HSDUDWHVWHHOFRQGXLWFDQEHXVHGWR
SURYLGHVKLHOGLQJEHWZHHQWKHVLJQDODQGSRZHUZLULQJ'RQRWURXWH
VLJQDODQGSRZHUZLULQJWKURXJKFRPPRQMXQFWLRQVRUUDFHZD\V
6LJQDOFDEOHVIURPRWKHUFLUFXLWVVKRXOGQRWSDVVZLWKLQPPIWRI

WKH3'0
7KHOHQJWKRUSDUDOOHOUXQVEHWZHHQRWKHUFLUFXLWFDEOHVDQGWKHPRWRURU
SRZHUFDEOHVKRXOGEHPLQLPL]HG$UXOHRIWKXPELVPPIWRI
VHSDUDWLRQIRUHDFKPIWRISDUDOOHOUXQ7KHPPIW
VHSDUDWLRQFDQEHUHGXFHGLIWKHSDUDOOHOUXQLVOHVVWKDQPIW
&DEOHLQWHUVHFWLRQVVKRXOGDOZD\VRFFXUDWULJKWDQJOHVWRPLQLPL]H
PDJQHWLFFRXSOLQJ
'RQRWURXWHDQ\FDEOHVFRQQHFWHGWRWKH3'0GLUHFWO\RYHUWKH3'0
YHQWRSHQLQJV2WKHUZLVHWKHFDEOHVZLOOSLFNXSWKHHPLVVLRQVOHDNHG
WKURXJKWKHYHQWVORWV
,I\RXFRQVWUXFW\RXURZQPRWRUFDEOHDFRQGXFWRUFDEOHVKRXOGEH
XVHGZLWKWKHFRQGXFWRUVWZLVWHG7KHJURXQGFRQGXFWRUPXVWEH
DWWDFKHGWRWKHPRWRUDQG3'0HDUWKWHUPLQDOV7KHVKLHOGPXVWEH
VHSDUDWHO\WHUPLQDWHGDFFRUGLQJWRWKHJXLGHOLQHVIRUWKHVSHFLILF3'0
7KHHQFRGHUPRXQWHGRQWKHEUXVKOHVVVHUYRPRWRUVKRXOGEHFRQQHFWHG
WRWKH3'0ZLWKDFDEOHXVLQJPXOWLSOHWZLVWHGZLUHSDLUVDQGDQRYHUDOO
FDEOHVKLHOG6WDQGDUG5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\HQFRGHU
FDEOHVDUHRIIHUHGWKDWDUHWHUPLQDWHGLQYDULRXVOHQJWKV,IEXLOGLQJ\RXU
RZQFDEOHEHVXUHWRFRQQHFWWKHFDEOHVKLHOGWRWKHPRWRUFDVHDQGWR
WKH3'0FKDVVLVWKURXJKWKHFRQQHFWRUVIRUDFRPSOHWH
FRQQHFWLRQSHUWKHFDEOHDVVHPEO\GLDJUDPRWKHUZLVHQRLVHRQWKH
HQFRGHUVLJQDOVFDQFDXVHIDXOWVLQWKH3'0

,I(0,SUREOHPVSHUVLVWDGGLWLRQDOFRXQWHUPHDVXUHVFDQEHDWWHPSWHG
6HYHUDOVXJJHVWLRQVIRUV\VWHPVPRGLILFDWLRQVIROORZ
$IHUULWH´GRXJKQXWµRUWRUURLGDURXQGDVLJQDOFDEOHPD\KHOS7KHIHUULWH
ZLOODWWHQXDWHFRPPRQPRGHQRLVHEXWZLOOGRQRWKLQJIRUGLIIHUHQWLDO
PRGHQRLVH6SHFLILFDOO\WKLVVKRXOGKHOS56FRPPXQLFDWLRQ
SUREOHPV
Figure 2.26
Torroid encoder shielding method for brushless servo motors
PDM
BRUSHLESS
MOTOR
ENCODER CABLE
ENCODER
SHIELD
MOTOR CASE
Recommended raw cable for

building your own cable
Belden Part number Carol Part number
8337 C0625
6XSSUHVVHDFKVZLWFKHGLQGXFWLYHGHYLFHWKDWLVQHDUWKHVHUYRDPSOLILHU
7KLVLQFOXGHVVROHQRLGVUHOD\FRLOVVWDUWHUFRLOVDQG$&PRWRUVVXFKDV
LQPRWRUGULYHQPHFKDQLFDOWLPHUV
'&FRLOVVKRXOGEHVXSSUHVVHGZLWKD¶IUHHZKHHOLQJ·GLRGHFRQQHFWHG
DFURVVWKHFRLO
$&FRLOVVKRXOGEHVXSSUHVVHGZLWK5&ILOWHUVDRKP:DWW
UHVLVWRULQVHULHVZLWKDPLFUR)DUDG9ROWFDSDFLWRULVFRPPRQO\
XVHG
0RWRUSRZHUZLQGLQJVFDQEHJURXQGHGVKLHOGHGDQGFKRNHGWR
PLQLPL]HQRLVHHPLVVLRQV

Figure 2.27
Motor power winding methods to minimize noise emissions
PDM
BRUSHLESS
MOTOR
TWISTED TOGETHER
R
R
S S
T T
MOTOR CASE
CHASSIS
TO SINGLE POINT
EARTH GROUND
PDM
BRUSHLESS
MOTOR
TWISTED TOGETHER
R
S R
S
T T
CHASSIS MOTOR CASE
SHIELD
TO SINGLE POINT
EARTH GROUND
PDM
BRUSHLESS
MOTOR
COMMON MODE CHOKE
(10-20 TURNS ON COMMON
FERRITE TORROID CORE)
R
S R
S
T T
CHASSIS
MOTOR CASE
TWISTED TOGETHER
TO SINGLE POINT
EARTH GROUND

Chapter 3
Wire the ULTRA Plus PDM Components
7KLVFKDSWHUH[SODLQVWKHZLULQJUHTXLUHPHQWVRIDQ8/75$3OXV3'0
V\VWHP
System Power Connections

7KHXVHULVUHVSRQVLEOHIRUFRQIRUPLQJWR1DWLRQDO
ATTENTION
(OHFWULFDO&RGHVDQGDOORWKHUDSSOLFDEOHORFDOFRGHV
)DLOXUHWRFRQIRUPWRFRGHVFDQUHVXOWLQGDPDJHWRWKH
! HTXLSPHQWRUVHYHUHERGLO\LQMXU\
1398-PDM-10, 20, 75, and 150B
7KH3'0DQGUHTXLUHVLQJOHSKDVH$&SRZHUWR
9$&7KH3'0DQG%UHTXLUHWKUHHSKDVH$&SRZHUWR
9$&7KHLQSXWSRZHUPD\EHRSWLRQDOO\LVRODWHGWKURXJKDWUDQVIRUPHU)LHOG
ZLULQJPXVWEHFRSSHUZLWKDPLQLPXPUDWLQJRI&7KHSKDVLQJRI/DQG
/1WRWKH3'0DQGLVDUELWUDU\7KHSKDVLQJRIWKH
3'0DQG%LV//1DQG/7KHHDUWKJURXQGFRQQHFWLRQLV
UHTXLUHGIRUVDIHDQGSURSHUV\VWHPRSHUDWLRQ7HUPLQDOEORFNFRQQHFWLRQV
VKRXOGEHWRUTXHGWROELQ1P7KH3'0DQG%
GRHVQRWFRQWDLQVXSSO\IXVHVRUGLVFRQQHFWLQJGHYLFHV7KHVHPXVWEH
VXSSOLHGE\WKHPDFKLQHEXLOGHUDQGFRQQHFWHGH[WHUQDOO\IRUVDIHW\DQG
PDLQWHQDQFHSXUSRVHV

3-2 Wire the ULTRA Plus PDM Components
Figure 3.1
Power Wiring Diagram for 1398-PDM-10, 20, and 30
MOTOR POWER WIRES R,S,T,GND MOTOR POWER CONNECTOR INPUT POWER WIRES DRIVE MODULE INPUT CURRENT REQUIREMENTS
IQ TERMINALS
MOTOR POWER MINIMUM PIN SIGNAL
RECOMMENDED
RECOMMENDED TERMINAL(S) POWER WIRE 1.0 Amps AC at 115 Volts AC
MOTOR MATING CONNECTOR A R DRIVE (GAUGE/mmÉ) L1 AUX, L2/N AUX
CONTACT SIZE POWER WIRE 0.5 Amps AC at 230 Volts AC
B S (60˚C
˚ COPPER ONLY)
(GAUGE/mmÉ)
(GAUGE/mmÉ) L1 AUX, L1,L2/N, PDM-10 10.0 AMPS AC
C T 16 AWG/1.5mmÉ
(60˚C
˚ COPPER ONLY) ALL L2/N AUX AC AUXILIARY POWER PDM-20 19.0 AMPS AC
D MOTOR CASE INPUT (OPTIONAL) PDM-30 28.0 AMPS AC
H-2005
H-3007 16 AWG/1.5mmÉ PDM-10 L1,L2/N, 14 AWG/2.5mmÉ NOTE: SLOW BLOW FUSES ARE REQUIRED TO ALLOW FOR INRUSH
CURRENT DURING POWER INITIALIZATION AT THE MAIN
H-3016 16 AWG/1.5mmÉ
AND AUXILIARY TERMINALS. TIME DELAY VERSIONS OF
H-4030 PDM-20 UL CLASS J,CLASS R OR EQUIVALENT FUSES ARE
L1,L2/N, 14 AWG/2.5mmÉ
F-4030 ACCEPTABLE, LOCAL REGULATIONS MUST BE OBSERVED.
H-4050 12 AWG/3.0mmÉ
PDM-30 L1,L2/N, 10 AWG/4mmÉ 10
F-4050 14 AWG/2.5mmÉ
H-4075
F-4075 TERMINAL STRIP
ACCEPTABLE WIRE RANGE DRIVE DRIVE
(GAUGE/mmÉ) MODULE MODULE
22-10 AWG/0.5-6mmÉ
9 9
SUGGESTED RELIANCE TORQUE ALL TERMINALS
TO 11 LB-IN. TB1 3 TB1
TRANSFORMER SIZES PART NUMBER DC BUS DC BUS
4
PDM-30 3.0kVA 0020-5097
R 3 R
S S
T T
9 9
FUSE 7 FUSE 7
BLOCK „XCON… DC+ BLOCK „XCON… DC+
DC- DC-
L1 AC LINE L1
AC LINE FILTER
FILTER L2/N L2/N
MOTOR POWER
L1 AUX L1 AUX CONNECTOR MATING
L2/N AUX L2/N AUX
MOTOR POWER
CONNECTOR
1
1 H-SERIES H-SERIES
F-SERIES F-SERIES
N-SERIES N-SERIES
TERM
MOTORS MOTORS
BLOCK
2 FUSED DISCONNECT
OR CIRCUIT BREAKER
ISOLATION OR AUTO TRANSFORMER L1
SINGLE PHASE (OPTIONAL, NOT REQUIRED WHEN
AC LINE DESIRED INPUT VOLTAGE IS
50/60Hz AVAILABLE DIRECTLY FROM THE 5 COMMON GROUNDING COMMON GROUNDING
LINE)
POINT FOR AMPLIFIER POINT FOR AMPLIFIER
TRANSFORMER
L2 SYSTEM (ONE PER AXIS) SYSTEM (ONE PER AXIS)
CHASSIS
MACHINE COMMON
TO PROTECTIVE GROUNDING BUS BAR
EARTH TERMINAL
NOTES
1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2 TERMINALS
(EXAMPLE: TO RETAIN DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2 POWER DOWN). WHEN USING A THREE PHASE SUPPLY CONNECT THE MAIN
AND AUXILIARY INPUTS TO THE SAME PHASE.
2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IN EUROPE,IF A GROUNDED NEUTRAL IS USED INSTEAD
OF L2 OR L2/AUX, ONLY L1 MAY BE SWITCHED OR FUSED.
3 JUMPER INSTALLED AT FACTORY FOR INTERNAL SHUNT. SEE DRAWING 9101-1328 FOR TERMINAL WIRING OF EXTERNAL SHUNT OPTION TERMINALS.
4 TRANSFORMER SIZES SHOWN ARE FOR MOST APPLICATIONS: APPLICATIONS REQUIRING MAXIMUM PEAK TORQUE AT MAXIMUM MOTOR SPEED MAY REQUIRE A LARGER TRANSFORMER.
SECONDARY VOLTAGE MAY DROP (BASED ON TRANSFORMER LOAD REGULATION PERFORMANCE) WHEN THE MOTOR DELIVERS PEAK TORQUE. THIS DROP IN TRANSFORMER VOLTAGE WILL
LIMIT MAXIMUM MOTOR SPEED WHILE PEAK TORQUE IS REQUIRED. SEE DRAWING 9101-1057 FOR TRANSFORMER LOAD REGULATION OF RELIANCE MOTION CONTROL TRANSFORMER
0020-5097.
DRIVE RATED 100-240 VAC RMS,SINGLE PHASE INPUT VOLTAGE (230 VAC STANDARD).
A 21936 JM RELEASED __ __
5
6. DO NOT DAISY CHAIN DRIVE MODULES. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
DO NOT SCALE DRAWING JM 6-3-96 __ __
7 DRIVE ENABLE INPUT MUST BE OPENED WHEN MAIN POWER IS REMOVED AND AUXILIARY POWER IS PRESENT, OR A DRIVE FAULT WILL OCCUR.
8. MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE. BREAK ALL EDGES .02 MAX POWER WIRING CONNECTIONS
FILLETS AND ROUNDS .02 R MAX
9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL. TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY. THE AUX INPUT HAS AN TOLERANCE ON:
PART NO.
INTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD BE AS CLOSE ANGLES ±1ANGLES ˚
TO THE DRIVE AS POSSIBLE. FRACTIONS:±1/64" 1398-PDM-10, 9101-2195
DECIMALS.XX±.020 20, and 30 SCALE DWG SIZE SHEET
10 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED. .XXX±.010 N/A C 1 of 1

Wire the ULTRA Plus PDM Components 3-3
Figure 3.2
Power Wiring for 1398-PDM-75
MOTOR POWER MINIMUM PIN SIGNAL RECOMMENDED BRU/IQ TERMINALS CURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS)
MATING CONNECTOR RECOMMENDED TERMINAL(S) POWER WIRE 4 L1 AUX,L2/N AUX 1.0 Amps AC at 115 Volts AC
MOTOR A R DRIVE (GAUGE/mmÉ)
CONTACT SIZE POWER WIRE 0.5 Amps AC at 230 Volts AC
B S (60˚C COPPER MIN)
(GAUGE/mmÉ) L1 AUX, L1,L2/N,L3 DM/PDM-75 28.0 Amps at 100-240 Volts AC Three Phase
(GAUGE/mmÉ) C T ALL
(60˚C COPPER MIN) L2/N AUX 16 AWG/1.5mmÉ AC AUXILIARY L1,L2/N DM/PDM-75 28.0 Amps at 100-240 Volts AC Single Phase
D MOTOR CASE
H-4050 POWER INPUT NOTE: POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSH
F-4050 DM/PDM-75 L1,L2/N,
L3 10 AWG/2.5mmÉ (OPTIONAL) CURRENT OF 50A FOR THE MAIN INPUT AND 95A FOR THE
12 AWG/3.0mmÉ 14 AWG/2.5mmÉ AUXILIARY INPUT. DUAL ELEMENT TIME DELAY (SLOW BLOW)
H-4075
FUSES ARE RECOMMENDED. FUSE SIZES MUST BE SELECTED
F-4075 ACCORDING TO LOCAL REGULATIONS.
H-6100 10
F-6100
8 AWG/10.0mmÉ 10 AWG/6.0mmÉ
H-6200
F-6200 TERMINAL STRIP
10 ACCEPTABLE WIRE RANGE DRIVE MODULE
DRIVE MODULE
(GAUGE/mmÉ)
22-10 AWG/0.5-6mmÉ
TORQUE ALL TERMINALS 9 9

DC BUS DC BUS
3
R R
S S
T T
9 9
FUSE 7 FUSE 7
BLOCK „XCON… DC+ BLOCK „XCON… DC+
DC- DC-
L1 L1
AC LINE AC LINE
FILTER L2/N FILTER L2/N
L3 L3
MOTOR POWER
L2/N AUX L2/N AUX
TB1 TB1 MOTOR POWER
CONNECTOR
1
TERM 1 H-SERIES H-SERIES
F-SERIES F-SERIES
BLOCK N-SERIES N-SERIES
5 MOTORS MOTORS
2 FUSED DISCONNECT
OR CIRCUIT BREAKER L1 11 11
ISOLATION OR AUTO TRANSFORMER
(OPTIONAL, NOT REQUIRED WHEN
THREE PHASE DESIRED INPUT VOLTAGE IS
AC LINE AVAILABLE DIRECTLY FROM THE
50/60Hz LINE)
L2/N
TRANSFORMER 5 COMMON GROUNDING COMMON GROUNDING
L3 POINT FOR AMPLIFIER POINT FOR AMPLIFIER
CHASSIS
SYSTEM (ONE PER AXIS) SYSTEM (ONE PER AXIS)
MACHINE COMMON
NOTES TO PROTECTIVE GROUNDING BUS BAR
EARTH TERMINAL
1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2/N, L3 TERMINALS (EXAMPLE: TO RETAIN
DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2/N, L3 POWER DOWN).
2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IF A GROUNDED NEUTRAL IS USED INSTEAD OF
L2 OR L2/AUX, ONLY L1 MAY BE SWITCHED OR FUSED.
4 CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE. REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED, BUT NOT TORQUE. DRIVE RATED 35/75 AMPS FOR
THREE PHASE INPUT, 15/50 AMPS FOR SINGLE PHASE INPUT.
5 DRIVE RATED 100-240 VAC RMS, SINGLE OR THREE PHASE INPUT VOLTAGE (230 VAC STANDARD).
6. DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
8. MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE. REV ECO BY REVISION DESCRIPTION DATE CHKR
9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY, AND ARE REQUIRED TO MEET THE
DO NOT SCALE DRAWING __ __
EUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE. CAUTION: AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND REQUIRE DISCHARGE TIME UPON POWER REMOVAL.
JM 4-19-96
THE AUX INPUT HAS AN INTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD
BE AS CLOSE TO THE DRIVE AS POSSIBLE. BREAK ALL EDGES .02 MAX POWER WIRING CONNECTIONS
FILLETS AND ROUNDS .02 R MAX 75A
10 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED. TOLERANCE ON: PART NO.
ANGLES ±1ANGLES ˚
11 TERMINATE THE MOTOR POWER CABLE SHIELD BY CLAMPING IT TO THE DRIVE WITH THE BRACKET PROVIDED. THIS BRACKET CAN BE USED FOR STRAIN RELIEF IF FRACTIONS:±1/64"
9101-1453
NON-SHIELDED CABLES ARE USED. SNUG BRACKET SCREWS, DO NOT OVERTIGHTEN. NEVER TORQUE OVER 10 LB-IN. THE SHIELDS ON SHIELDED POWER CABLES MUST DECIMALS.XX±.020 SCALE DWG SIZE SHEET
BE GROUNDED AT A MINIMUM OF ONE POINT FOR SAFETY.
.XXX±.010 N/A C 1 of 1

Figure 3.3
Power Wiring for 1398-PDM-150B
RECOMMENDED IQ TERMINALS CURRENT REQUIREMENT, MAXIMUM (AMPS AC RMS)
MOTOR POWER MINIMUM PIN SIGNAL
RECOMMENDED DRIVE POWER WIRE 4 1.0 Amps AC at 115 Volts AC
MATING CONNECTOR A R TERMINAL(S) 2 L1 AUX,L2/N AUX
MOTOR POWER WIRE
(GAUGE/mm ) 0.5 Amps AC at 230 Volts AC
CONTACT SIZE B S (75 C COPPER MIN)
2
2
(GAUGE/mm ) AC AUXILIARY L1,L2,L3 PDM-150B 46.0 Amps at 100-240 Volts AC Three Phase
(GAUGE/mm ) C T L1 AUX, 2
(75 C COPPER MIN) ALL 16 AWG/1.5mm POWER INPUT NOTE: POWER INITIALIZATION REQUIRES A SHORT PERIOD OF INRUSH
D MOTOR CASE L2/N AUX
H-6200 2 2 (OPTIONAL) CURRENT OF 70A (PEAK) FOR THE MAIN INPUT AND 105A (PEAK)
8 AWG/10.0mm 10 AWG/6.0mm L1,L2, 8 AWG/10.0mm2 FOR THE AUXILIARY INPUT. DUAL ELEMENT TIME DELAY (SLOW
F-6200 PDM-150B
L3 BLOW) FUSES ARE RECOMMENDED. FUSE SIZES MUST BE SELECTED
H-6300 2 2 ACCORDING TO LOCAL REGULATIONS.
8 AWG/10.0mm 8 AWG/10.0mm
F-6300
H-8350 4 AWG/25.0mm
2
8 AWG/10.0mm
2
TERMINAL STRIP
10
2 2 10 ACCEPTABLE WIRE RANGE
H-8500 4 AWG/25.0mm 6 AWG/16.0mm 2
(GAUGE/mm )
2
22-10 AWG/0.5-6mm
TORQUE ALL TERMINALS DRIVE MODULE DRIVE MODULE

TO 11 LB-IN.
2
12-6 AWG/8.0-14mm
TORQUE ALL TERMINALS 9 9

DC BUS DC BUS
3
R R
S S
T T
9 9
FUSE
7 FUSE
7
DC+ DC+
BLOCK XCON DC- BLOCK XCON DC-
L1 L1
AC LINE L2 AC LINE L2
FILTER FILTER
L3 L3
MOTOR POWER
L2/N AUX L2/N AUX
TB1 TB1 MOTOR POWER
CONNECTOR
1
1 H-SERIES H-SERIES
TERM F-SERIES F-SERIES
BLOCK N-SERIES N-SERIES
5 MOTORS MOTORS
2 FUSED DISCONNECT
OR CIRCUIT BREAKER L1
11 11
ISOLATION OR AUTO TRANSFORMER
(OPTIONAL, NOT REQUIRED WHEN
THREE PHASE DESIRED INPUT VOLTAGE IS
AC LINE AVAILABLE DIRECTLY FROM THE
50/60Hz LINE) L2
TRANSFORMER L3 5 COMMON GROUNDING COMMON GROUNDING

CHASSIS POINT FOR AMPLIFIER POINT FOR AMPLIFIER
SYSTEM (ONE PER AXIS) SYSTEM (ONE PER AXIS)
MACHINE COMMON
TO PROTECTIVE GROUNDING BUS BAR
EARTH TERMINAL
NOTES
1 MAY BE USED TO KEEP LOGIC SECTION OF DRIVE MODULE SUPPLIES POWERED AFTER MAIN MOTOR SUPPLY IS TURNED OFF AT L1, L2, L3 TERMINALS (EXAMPLE: TO RETAIN
DIAGNOSTIC STATUS OF DRIVE MODULE AFTER L1, L2, L3 POWER DOWN).
2 A SUPPLY DISCONNECTING DEVICE IS REQUIRED FOR MAINTAINANCE & SAFETY. LOCAL REGULATIONS SHOULD BE OBSERVED. IF A GROUNDED NEUTRAL IS USED INSTEAD OF
L2/N AUX, ONLY L1 AUX MAY BE SWITCHED OR FUSED.
4 CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE. REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED, BUT NOT TORQUE. DRIVE RATED 65/150 AMPS (PEAK)
FOR THREE PHASE INPUT.
5 DRIVE RATED 100-240 VAC RMS (230 VAC STANDARD).
6. DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS. MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY.
8. MULTIPLE DRIVE MODULES MAY BE POWERED FROM ONE TRANSFORMER OR OTHER AC SUPPLY SOURCE.
DRAWN BY DESIGN ENGR
UNLESS OTHERWISE SPECIFIED DATE DATE
9 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE TO BE USED FOR IMPROVING THE DRIVE MODULES ELECTROMAGNETIC COMPATABILITY, AND ARE REQUIRED TO MEET THE DO NOT SCALE DRAWING JM 5-12-98 __ __
EUROPEAN ELECTROMAGNETIC COMPATABILITY DIRECTIVE. CAUTION: AC LINE FILTERS HAVE LARGE LEAKAGE CURRENTS AND MAY REQUIRE DISCHARGE TIME UPON POWER REMOVAL. DIMENSIONS ARE IN INCHES
THE AUX INPUT HAS AN INTERNAL FILTER. WIRING BETWEEN THE DRIVE MODULE AND FILTER SHOULD BE KEPT AS SHORT AS POSSIBLE. THE COMMON GROUND BUS BAR SHOULD BREAK ALL EDGES .02 MAX POWER WIRING
BE AS CLOSE TO THE DRIVE AS POSSIBLE. FILLETS AND ROUNDS .02 R MAX 1398-PDM-150B
10 WIRE SIZES ARE MINIMUM RECOMMENDED VALUES. THE REQUIREMENTS OF LOCAL REGULATIONS SHOULD BE OBSERVED. ANGLES :+/- 1
FRACTIONS: +/- 1/64" 9101-2236
11 TERMINATE THE MOTOR POWER CABLE SHIELD BY CLAMPING IT TO THE DRIVE WITH THE BRACKET PROVIDED. THIS BRACKET CAN BE USED FOR STRAIN RELIEF IF
DECIMALS: .XX +/- .020 SCALE DWG SIZE SHEET
NON-SHIELDED CABLES ARE USED. SNUG BRACKET SCREWS, DO NOT OVERTIGHTEN. NEVER TORQUE OVER 10 LB-IN.
.XXX +/- .010 N/A C 1 of 1
7KHDERYHGUDZLQJVGHVFULEHDQRSWLRQDO$&OLQHILOWHUDQGVKLHOGHGPRWRU
FDEOH7KHVHFDQEHXVHGLQFRQMXQFWLRQZLWKWKHJURXQGHGPHWDOHQFORVXUHWR
PHHWWKH(OHFWURPDJQHWLF&RPSDWLELOLW\UHTXLUHPHQWVRIWKH(XURSHDQ
0DFKLQHU\'LUHFWLYH5HIHUWR ´(OHFWURPDJQHWLF&RPSDWLELOLW\µRQSDJH
IRUDGLVFXVVLRQRI(0&
$SRZHUFDEOHZLWKDQXQJURXQGHGVKLHOGFDQUHVXOWLQ
ATTENTION
KLJKYROWDJHVRQWKHVKLHOGDQGDQ\WKLQJFRQQHFWHGWRLW
! RQHSRLQWIRUVDIHW\
WKHHTXLSPHQWRUVHYHUHERGLO\LQMXU\

Auxiliary Logic Power
6LQJOHSKDVH$&SRZHU9$&PD\EHVXSSOLHGWRWKHLQWHUQDOORJLF
VXSSO\WKURXJK/$8;DQG/1$8;
$X[LOLDU\VXSSO\SRZHUWRWKHLQWHUQDOORJLFVXSSO\LVXVHIXOLIWKH8/75$3OXV
3'0ORJLFPXVWVWD\21ZKHQWKHPRWRUSRZHUPXVWEHWXUQHG2))
$EVROXWHSRVLWLRQLQJLVRQHH[DPSOHRIZKHQWKLVZRXOGEHXVHIXOVLQFH
SRVLWLRQLQIRUPDWLRQLVPDLQWDLQHGDVORQJDVORJLFSRZHULVRQ$QRWKHU
H[DPSOHZRXOGEHPDLQWDLQLQJWKH8/75$3OXV3'0ORJLFSRZHUVRWKH
8/75$3OXV3'0VHULDOLQWHUIDFHFRXOGEHXVHGIRUGLDJQRVWLFV
1398-PDM-25, 50, 100, and 150
Figure 3.4
Power Wiring Diagram (1398-PDM-25, 50, 100, and 100)
PART NO.
9101-0411
POWER SUPPLY MODULE AND

DRIVE MODULE TERMINALS
1 1 1 1 11
DRIVE MODULE DRIVE MODULE POWER SUPPLY MODULE DRIVE MODULE DRIVE MODULE ACCEPTABLE WIRE RANGE
(GAUGE/mmÉ)
PRODUCT TERMINALS
60˚C COPPER ONLY
6-0 AWG/16-55mmÉ
L1,L2,L3
PSM-125
8 AWG/10mmÉ 4
8
PSM-50 L1,L2,L3 10-4 AWG/6-25mmÉ
POS NEG GND POS NEG GND POS NEG GND POS NEG GND POS NEG GND
AND ALL R,S,T
7
R S T 7
R S T L1 L2 L3 R S T R S T DRIVE MODULES
14-12 AWG/2.5-4mmÉ 4
9 16 AWG/1.5mmÉ 5
MOTOR POWER WIRES R,S,T,GND

MOTOR POWER MINIMUM
MOTOR MATING CONNECTOR RECOMMENDED
CONTACT SIZE POWER WIRE
(GAUGE/mmÉ) (GAUGE/mmÉ)
S-3007
16 AWG/1.2mmÉ
RED WIRE S-3016
16 AWG/1.5mmÉ
100 TO 240 VAC RMS S-4030 5
BLACK WIRE 3 PHASE INPUT POWER
GREEN WIRE B 21871 JM ADDED H-SERIES MTR OPTION
AC
__ __ F-4030
PHASING OF L1,L2 AND L3 S-4050
DC BUS POS, NEG, AND GND WIRES (1 EACH) LINE 12 AWG/3.0mmÉ
ARE PROVIDED WITH EACH DRIVE MODULE 1 INPUT POWER IS ARBITRARY FILTER F-4050
R,S AND T MOTOR 14 AWG/2.5mmÉ
S-4075 4
POWER WIRES MUST
BE CORRECTLY F-4075
PHASED S-6100
10 12 AWG/4mmÉ
COMMON GROUNDING POINT FOR 10 F-6100 4
2 FUSED DISCONNECT POWER SUPPLY-DRIVE MODULE S-6200
SYSTEM 8 AWG/8.6mmÉ
3 PHASE ISOLATION OR AUTO F-6200 8 AWG/10mmÉ
TRANSFORMER. L1 S-6300
3 F-6300
L2
3 PHASE AC LINE (OPTIONAL, NOT REQUIRED MOTOR POWER MATING CONNECTOR S-8350
WHEN DESIRED INPUT VOLTAGE 4 AWG/21.6mmÉ 6 AWG/16mmÉ
50/60 Hz S-8500
IS AVAILABLE DIRECTLY L3 MOTOR POWER CONNECTOR I-5300 8 AWG/10mmÉ
FROM THE LINE). TERMINAL BLOCK
6 I-6600 6 AWG/16mmÉ
TRANSFORMER
CHASSIS
MOTOR POWER CONNECTOR

RELIANCE MOTION CONTROL H-SERIES, S-SERIES, PIN SIGNAL
MACHINE COMMON
TO PROTECTIVE 3 PHASE TRANSFORMERS F-SERIES AND W-SERIES A R
EARTH TERMINAL MOTORS B S
GROUNDING BUS BAR 208/230/240/380/460/480 VAC PRIMARY, 115/230
NOTES: VAC SECONDARY, 50/60 Hz C T
D MOTOR CASE
1 THE PSM MUST BE CENTERED BETWEEN THE DRIVE MODULES TO MINIMIZE THE DC BUS INDUCTANCE, SO THAT AN RELIANCE
EQUIVILENT NUMBER OF DRIVES ARE LOCATED ON EACH SIDE OF THE PSM. KVA MOTOR TERMINAL BOX
PART NUMBER
MOTOR POWER TERMINAL STRIP
2 FUSE SIZE: PSM-125-UL CLASS RK5 90 AMP (5000 AIC) A DISCONNECTING DEVICE IS REQUIRED FOR SAFETY AND MAINTENANCE. 0020-5091-001
PSM-50-UL CLASS RK5 40 AMP (5000 AIC) 3
0020-5091-002 6
3 NOTES ON SIZING OF POWER TRANSFORMERS AND INPUT WIRES: MOTOR POWER TERMINAL STRIP
0020-5091-003 12
TERMINAL SIGNAL
3 3 0020-5091-004 18 I-5300 AND I-6600 6
a) TRANSFORMER 3 PHASE KVA = X (LINE-TO-LINE SECONDARY VOLTS RMS) X (PER PHASE SECONDARY CURRENT RMS) = MOTORS U S
1000 1000
V R
X (LINE-TO-LINE PRIMARY VOLTS RMS) X (PER PHASE PRIMARY CURRENT RMS). W T
E MOTOR CASE
b) TRANSFORMER 3 PHASE KVA = (SUMMATION OF EACH MOTORS ACTUAL AVERAGE OUTPUT POWER) X (1.2) 1.2 FACTOR ADDS 20%
AS ROUGH ESTIMATE OF DRIVE MODULE & MOTOR LOSSES.
c) SEE DRAWING 9101-0132, TRANSFORMER LOAD REGULATION, TO DETERMINE EFFECT OF PEAK LOADS ON SYSTEM DC BUS VOLTAGE.
4 FOR WIRE GAUGES NOTED: STRIPPED ENDS OF STRANDED WIRES MUST BE FULLY TINNED SO WIRE DIA. STAYS LARGE ENOUGH FOR
PROPER CLAMPING IN POWER SUPPLY MODULE OR DRIVE MODULE TERMINAL. 8 TORQUE TO 24 LB-IN.
5 FOR 16 GAUGE MOTOR POWER WIRE: STRIPPED ENDS OF STRANDED WIRES MUST BE DOUBLED OVER AND FULLY TINNED FOR 9 TORQUE TO 11.5 LB-IN.
PROPER CLAMPING IN DRIVE MODULE TERMINAL.
I-SERIES MOTORS ARE USED WITH BRU-500 DRIVES ONLY. 10
6 AC LINE FILTER AND SHIELDED MOTOR CABLE ARE OPTIONAL.
TO BE USED FOR IMPROVING THE SYSTEM'S ELECTROMAGNETIC
A1 A00787 TM CHG'D NOTE 1 5-30-95 RB
COMPATABILITY. WIRING BETWEEN THE POWER SUPPLY AND
7 TERMINAL POST HARDWARE DETAILS:
SPRING DISK WASHERS
M6 TERMINAL POST FILTER SHOULD BE AS SHORT AS POSSIBLE. THE COMMON A 21244 TM RELEASED 2-2-95 BCB
M6 TERMINAL POST M6 NUT GROUND SHOULD BE AS CLOSE TO THE MODULE AS POSSIBLE. REV ECO BY REVISION DESCRIPTION DATE CHKR
M6 NUT FLAT WASHER
CAUTION CONNECTING LUGS 11 WIRE SIZES ARE RECOMMENDATIONS. THE REQUIREMENTS
CONNECTING LUGS DO NOT SCALE DRAWING TM 1-24-95 CO 5-30-95

OF LOCAL REGULATIONS MUST BE OBSERVED. DIMENSIONS ARE IN INCHES
DO NOT OVERTIGHTEN BREAK ALL EDGES .02 MAX
POWER WIRING CONNECTIONS
USE NUT DRIVER ONLY FILLETS AND ROUNDS .02 R MAX
36 LB-IN (4.0 Nm) ABSOLUTE TERMINAL POST BASE DRIVE OR POWER SUPPLY TOLERANCE ON:
PART NO.
BUS BAR ANGLES ±1ANGLES ˚
MAXIMUM TIGHTENING TORQUE.
GROUND TERMINAL POSTS FRACTIONS:±1/64"
1398-PDM-25, 50, 9101-0411
POSITIVE,NEGATIVE TERMINAL POSTS DECIMALS.XX±.020 100, and 150 SCALE DWG SIZE SHEET
.XXX±.010 N/A D 1 of 1

Power Supply Module (PSM)
7KH3RZHU6XSSO\0RGXOH360FDQVXSSO\'&SRZHUWRDVPDQ\DVVL[

8/75$3OXV3'0V7KUHHSKDVH$&SRZHU9$&LVWKHRQO\
UHTXLUHGLQSXWSRZHUIRUWKH3607KHLQSXWSRZHUPD\EHRSWLRQDOO\LVRODWHG
WKURXJKDWUDQVIRUPHU)LHOGZLULQJPXVWEHFRSSHUZLWKDPLQLPXPUDWLQJRI
&7KHSKDVLQJRIWKHLQSXWSRZHU//DQG/LVDUELWUDU\7KHHDUWK
JURXQGFRQQHFWLRQLVUHTXLUHGIRUVDIHDQGSURSHUV\VWHPRSHUDWLRQ7HUPLQDO
EORFNFRQQHFWLRQVVKRXOGEHWRUTXHGWROELQ1PRQWKH
360DQGOELQ1PRQWKH360
IMPORTANT 7KH3'0DQGGRHVQRWFRQWDLQ
VXSSO\IXVHVRUGLVFRQQHFWLQJGHYLFHV7KHVHPXVWEH
VXSSOLHGE\WKHPDFKLQHEXLOGHUDQGFRQQHFWHGH[WHUQDOO\
IRUVDIHW\DQGPDLQWHQDQFHSXUSRVHV
7KH3RZHU6XSSO\0RGXOHVZLOOFRQWLQXHWRRSHUDWHZLWKUHGXFHGFDSDFLW\
ZLWKWKHORVVRIRQHSKDVH7KHUHGSKDVHORVV/('RQWKHIURQWRIWKH360
ZLOOWXUQ21WRLQGLFDWHWKHORVVRIWKHSKDVH
7KHSRZHUVXSSO\PRGXOHDOORZVIRURSHUDWLRQWRFRQWLQXH
ATTENTION
HYHQLQWKHHYHQWRIORVVRIRQHSKDVHRUGXULQJSRZHU
GLVUXSWLRQRQWKHWKUHHSKDVH$&LQSXWV
! 8QGHUWKHVHFRQGLWLRQVWKH3KDVH/RVV/('ZLOOOLJKWEXW
WKHSRZHUVXSSO\LVQRWGLVDEOHG
([WHQGHGRSHUDWLRQRIWKLVSURGXFWZLWKDQ$&SKDVHLQSXW
PLVVLQJZLOOUHGXFHWKHOLIHRIWKHSURGXFW
5HIHUWR ´3RZHU:LULQJ'LDJUDP3'0DQGµRQ

SDJH IRUGHWDLOV7KLVGUDZLQJVKRZVDQRSWLRQDO$&OLQHILOWHUDQG
VKLHOGHGPRWRUFDEOH7KHVHFDQEHXVHGLQFRQMXQFWLRQZLWKWKHJURXQGHG
PHWDOHQFORVXUHWRPHHWWKH(OHFWURPDJQHWLF&RPSDWLELOLW\UHTXLUHPHQWVRI
WKH(XURSHDQ0DFKLQHU\'LUHFWLYH5HIHUWR ´(OHFWURPDJQHWLF&RPSDWLELOLW\µ
RQSDJH IRUDGLVFXVVLRQRI(0&

DC Bus Power
7KH'&EXVIURPWKH360VXSSOLHVSRZHUWRWKH8/75$3OXV3'0
3'0DQG7KH360'&EXVPXVWEHFRQQHFWHGDV
VKRZQLQ3RZHU:LULQJ'LDJUDP)LJXUHRQSDJHZLWKWKH360LQWKH
FHQWHUXVLQJWKHFRQQHFWLRQZLUHVSURYLGHG
'RQRWVXEVWLWXWHWKH'&EXVZLUHVSURYLGHGZLWKRWKHU
ATTENTION
ZLUHV
)DLOXUHWRREVHUYHWKLVSUHFDXWLRQPD\UHVXOWLQGDPDJHWR
! WKHHTXLSPHQW
Auxiliary Logic Supply
$QDX[LOLDU\SRZHUVXSSO\PRGXOH360$8;LVDYDLODEOHWRVXSSO\'&

SRZHUWRWKHLQWHUQDOORJLFVXSSOLHVRIXSWRIRXU8/75$3OXV3'0VLIWKH
360LV2))7KH360$8;XVHVVLQJOHSKDVH9$&SRZHUDVWKHLQSXW
7KH360$8;RSWLRQLVXVHIXOLI8/75$3OXV3'0LQWHUQDOORJLFSRZHU
PXVWVWD\RQHYHQZKHQWKHPRWRUVXSSO\WKH360LVRII$EVROXWH
SRVLWLRQLQJLVRQHH[DPSOHRIZKHQWKH360$8;ZRXOGEHXVHIXOVLQFH
SRVLWLRQLQIRUPDWLRQLVPDLQWDLQHGDVORQJDVORJLFSRZHULVRQ$QRWKHU
H[DPSOHZRXOGEHPDLQWDLQLQJ8/75$3OXV3'0ORJLFSRZHUVRWKHVHULDO
LQWHUIDFHFRXOGEHXVHGIRUWURXEOHVKRRWLQJDQGGLDJQRVWLFV5HIHU
WR ´360$8;2XWOLQHDQG&RQQHFWLRQ'LDJUDPµRQSDJH IRUZLULQJ
LQIRUPDWLRQRQWKH360$8;DQGRSWLRQDO360$8;LVRODWLRQWUDQVIRUPHU

Figure 3.5
Auxiliary Power Supply Connections
SAMPLE INPUT POWER WIRING CONFIGURATIONS, PSM-AUX WITH 1398-PDM-25, 50, 100, and 150
EXAMPLE:
POWER SUPPLY DRIVE
EXAMPLE: 240V LINE 9
POWER SUPPLY MODULE (PSM) MODULE
480V LINE DRIVE
8 MODULE (PSM) MODULE
240VAC,
NEG
NEG
POS
POS
3 PHASE L1 L2 L3 R S T
NEG
NEG
GND GND
POS
POS
L1 L2 L3 R S T
480VAC, GND GND
3 PHASE
L1 L2 L3 GND
L1 L2 L3 GND
480VAC, 3 PHASE PRIMARY

240VAC, 3 PHASE SECONDARY F1
0020-5091-XXX
F1
F2
F2 F3
F3
PSM-AUX
TRANSFORMER
0020-5093
10
CONTROL CIRCUIT
TRANSFORMER
21
240VAC 120VAC
21
PSM-AUX
480VAC 120VAC 9
PSM-AUX
CONTROL CIRCUIT
TRANSFORMER
8 F4
L1 L2 L3 240VAC 120VAC
CUSTOMER'S
F4 CUSTOMER'S
NOTES: 120VAC
120VAC
CONTROL
CONTROL
CIRCUITS
CIRCUITS
L1 L2 L3
8 IN THIS EXAMPLE, PSM-AUX INPUT POWER IS CONNECTED TO AT THE CONTROL CIRCUIT
TRANSFORMER SECONDARY. THEREFORE THE PSM INPUT POWER MUST BE ISOLATED
FROM AND FROM THE 480V INPUT LINE. THE THREE PHASE TRANSFORMER PROVIDES
THE ISOLATION AND ALSO STEPS DOWN THE VOLTAGE.
9 IN THIS EXAMPLE, THE PSM INPUT POWER IS SUPPLIED DIRECTLY FROM THE 3 PHASE LINE.
DIAGRAM, OUTLINE & CONNECTION
THEREFORE, THE PSM-AUX INPUT POWER MUST BE ISOLATED FROM AND FROM THE 240V INPUT LINE.
IN THIS EXAMPLE THE PSM-AUX TRANSFORMER SECONDARY MUST NOT BE CONNECTED TO . PSM-AUX, 1398-PDM-25, 50, 100, and 150
10 SIZE TRANSFORMER FOR 400 VA (PSM-AUX)+ CUSTOMER CONTROL CIRCUIT REQUIREMENTS.
9101-0134 REV D1

PSM Interface Logic
7KH6WDWXVDQG(QDEOHVLJQDOVRQWKH360DUHLQGLFDWHGLQWKHIROORZLQJWDEOH
WKDWLQWHUIDFHWKH360ZLWKWKH3'0RUDQRWKHUFRQWUROLOOXVWUDWHVW\SLFDO
LQWHUQDOFLUFXLWU\IRUWKHLQWHUIDFHFRQQHFWLRQV)LJXUHVKRZVH[WHUQDO
FRQQHFWLRQVRIWKH3'0V
PSM Connector Pin # Signal Name

P1 1 Status-
General 2 Status +
Purpose 3 PSM Enable-
Inputs/Outputs 4 PSM Enable +
Figure 3.6
PSM interface - internal circuit examples
Figure 3.7
PSM interface - external connection examples

Status Outputs
7KH6WDWXVRXWSXWVDUHWKHFRQWDFWVRIDQRUPDOO\RSHQUHOD\ZKLFKFORVHVWR
LQGLFDWHWKDWWKH360LVRSHUDWLQJSURSHUO\$QRSHQUHOD\VLJQDOVWKDWQR$&
SRZHULVDSSOLHGWRWKH360RUWKDWD360IDXOWKDVRFFXUUHG5HIHUWRWKH
DERYHGUDZLQJIRUFRQQHFWLRQH[DPSOHV
Enable Input
7KH360(QDEOHLQSXWLVDQRSWLFDOO\LVRODWHGLQSXWZKLFKFRQWUROVWKHSRZHU
RXWSXWRIWKHSRZHUVXSSO\PRGXOH7KH360(QDEOHLQSXWLVWXUQHGRQE\
VRXUFLQJFXUUHQWWKURXJKWKHRSWRLVRODWRU5HIHUWR ´360LQWHUIDFHH[WHUQDO
FRQQHFWLRQH[DPSOHVµRQSDJH IRUFRQQHFWLRQH[DPSOHV7KHLQSXWLVRQO\
IXQFWLRQDOLIMXPSHU:LVLQWKHRSWLRQDOSRVLWLRQ$5HIHUWR ´3RZHU6XSSO\
0RGXOHMXPSHUORFDWLRQµRQSDJH
:LWKWKHMXPSHULQWKHHQDEOHLQSXWDFWLYDWHGSRVLWLRQRSWLRQDO3RVLWLRQ$
WKH360LVHQDEOHGLIWKHHQDEOHLQSXWLV21:LWKWKHHQDEOHLQSXW2))WKH
360'&EXVLVWXUQHG2))DQGWKHGLVVLSDWLYHVKXQWLVWXUQHG21WRTXLFNO\
GLVFKDUJHWKH'&EXVFDSDFLWRUVDQGG\QDPLFDOO\EUDNHV\QFKURQRXVPRWRUV
7KLVLVWRDOORZWLPHIRUWKH3'0VWRSRZHUXSDQGDSSO\WKHHQDEOHVLJQDOWR
WKH360LIWKH360LVWRUHPDLQ21
,IWKH360LVGLVDEOHGGXULQJDSRZHUXSWKH'&EXV
ATTENTION
YROWDJHZLOOEHSUHVHQWIRUDWOHDVWWZRVHFRQGVEHIRUH
UHWXUQLQJWRD]HURYROWFRQGLWLRQ
!
:LWKWKHMXPSHULQWKHHQDEOHLQSXWGHDFWLYDWHGSRVLWLRQVWDQGDUG3RVLWLRQ%
WKHHQDEOHLQSXWKDVQRHIIHFWRQWKH360RSHUDWLRQDQGWKH360DFWLYDWHV
LWVHOIZKHQWKUHHSKDVHYROWDJHLQWKHSURSHUYROWDJHUDQJHLVFRQQHFWHGWRWKH
LQSXW

Figure 3.8
Power Supply Module jumper location
DS1
DIAGNOSTIC
INDICATOR
LIGHTS
POWER SUPPLY MODULE
CIRCUIT BOARD
(COMPONENT SIDE) TB1
1
A INTERFACE
W1 B 4 CONNECTOR
W1 JUMPER SETTING SELECTS:
SHORTING JUMPER ACROSS EXTERNAL ENABLE INPUT IS SELECTED.

TOP 2 PINS (POSITION A) EXTERNAL CONNECTION IS REQUIRED
TO CONNECTOR TB1 SIGNALS ENABLE+
AND ENABLE-. REFER TO INSTRUCTION
MANUAL FOR SIGNAL SPECIFICATION
AND DETAILS OF OPERATION BEFORE
USING POSITION A.
SHORTING JUMPER ACROSS EXTERNAL ENABLE INPUT IS DE-ACTIVATED.

BOTTOM 2 PINS (POSITION B) POWER SUPPLY MODULE IS ENABLED WHENEVER
(STANDARD SETTING) INPUT POWER IS APPLIED AND NO POWER SUPPLY
MODULE FAULT CONDITIONS ARE DETECTED.

External Shunt Connections 7KH8/75$3OXV3'03'0DQG%KDVDEXLOWLQVKXQW

UHJXODWRU7KHIROORZLQJWDEOHGHSLFWVWKHLQWHUQDOVKXQWVHOHFWLRQZLWKD
IDFWRU\LQVWDOOHGMXPSHUEHWZHHQWHUPLQDOVDQG5HPRYDORIWKHLQWHUQDO
VKXQWMXPSHUDQGLQVWDOODWLRQRIDODUJHUH[WHUQDOVKXQWEHWZHHQWHUPLQDOV
DQGDOORZPRUHSRZHUWREHGLVVLSDWHG
Terminal Identifier Description

1 Internal or Positive DC BUS
External
1
Internal
External Shunt
2 Internal Internal shunt
regulator resistor 2
3 External Shunt regulator 3
transistor collector TB2
+LJKYROWDJHLVSUHVHQWRQWKHWHUPLQDOVRIWKH8/75$
ATTENTION
3OXV3'0V
$IWHUUHPRYLQJSRZHUFKHFNIRUUHPDLQLQJYROWDJHEHIRUH
! PDNLQJRUUHPRYLQJDQ\FRQQHFWLRQ
5HVWULFWFDVXDOFRQWDFWWRHTXLSPHQW
ATTENTION
7KH8/75$3OXV3'0VDQGH[WHUQDOVKXQWGHYLFHVVKRXOG
EHLQVWDOOHGLQDQLQGXVWULDOO\UDWHGFDELQHWWRSURYLGHVDIH
! FRQWDLQPHQWDQGUHVWULFWHGDFFHVV
H[SRVXUHWRHOHFWULFDOKD]DUGVDQGGDPDJHWRHTXLSPHQW
/RRVHKLJKYROWDJHZLUHVFDQFDXVHDILUH
ATTENTION
'RQRWWLQVROGHUH[SRVHGOHDGVRQFDEOHVJRLQJWRKLJK
YROWDJHWHUPLQDOV6ROGHUHGFRQWUDFWVPD\ORRVHQRYHUWLPH
! )DLOXUHWRREVHUYHWKLVVDIHW\SUDFWLFHFRXOGUHVXOWLQ
LQWHUPLWWHQWVHUYLFHDQGGDPDJHWRHTXLSPHQW

7KHH[WHUQDOVKXQWLVHQDEOHGZKHQWKH'&%86LQFUHDVHVWRDVSHFLILFYDOXH
9'&$QLQFUHDVHLQ'&%86YROWDJHPD\RFFXUZKHQWKHDPSOLILHU
GHFHOHUDWHVWKHPRWRUDQGLWVORDG7KLVLVGXHWRWKHHQHUJ\IORZIURPWKH
PRWRUWRWKH'&%86:KHQWKHHQHUJ\WUDQVIHUUHGIURPWKHURWDWLQJLQHUWLD
FDXVHVWKH'&%86YROWDJHWRH[FHHG9'&WKHVKXQWLVHQDEOHGDQG
H[FHVVHQHUJ\LVGLVVLSDWHGDVKHDW
Internal Shunt Dissipation Ratings
Shunt Rating 1398 1398 1398 1398 1398

PDM PDM PDM PDM PDM
10 20 30 75 150b
Continuous (W) 50.0 180.0
Peak (kW) 4.5 10.0 19.0
,IWKHDSSOLFDWLRQUHTXLUHVDKLJKHUFRQWLQXRXVSRZHUGLVVLSDWLRQWKH8/75$
3OXV3'0SURYLGHVHDV\DFFHVVIRUDQH[WHUQDOVKXQWFRQQHFWLRQ,IDQ
H[WHUQDOVKXQWLVFRQQHFWHGWKHVKXQWMXPSHUEHWZHHQWHUPLQDOVDQG
VKRXOGEHUHPRYHG)DFWRU\DYDLODEOH([WHUQDO6KXQW.LW:RUD([WHUQDO
6KXQW.LW:FDQEHXVHG7KHVHH[WHUQDOVKXQWVFDQEHDUUDQJHGWR
SURYLGHPD[LPXPSRZHUGLVVLSDWLRQDVORQJDVWKHPLQLPXPUHVLVWDQFH
UHTXLUHPHQWLVPHW5HIHUWR ´([WHUQDO6KXQW:LULQJ([DPSOHVµRQSDJH
IRUGLIIHUHQWFRQILJXUDWLRQV
External Shunt Dissipation Power Ratings
Shunt Rating 1398 1398 1398 1398 1398

PDM PDM PDM PDM PDM
10 20 30 75 150b
Minimum Resistance 30.0 18.0 9.0
(Ohms ±10%) (1)
Continuous Power 0.8 1.8 2.4 4.0 8.0
(kW)2
Peak Power (kW) (2) 6.0 10.0 19.0
(1)
For sizing purposes, approximately 420 Vpeak will drop across any given resistor assembly.
(2)
Continuous and Peak Power Ratings are given measured with a minimum resistance shunt. Higher Resistances
will decrease Power Rating.

Figure 3.9
External Shunt Wiring Examples
200 Watts 800 Watts 1800 Watts

1 - 200W Unit Configuration* 4 - 200W Unit Configuration* 9 - 200W Unit Configuration*
TB2-1 TB2-1 TB2-1
R1
TB2-3 R1 R2 R3
R1 R2
R4 R5 R6
R3 R4
NOTES: TB2-3 R7 R8 R9
Uses 200W units p/n 9101-1079
*Configuration good for all ULTRA Plus PDMs
TB2-3
900 Watts 1800 Watts

1 - 900W Unit Configuration* 2 - 900W Unit Configuration**
TB2-1 TB2-1
R1
TB2-3 R1 R2
TB2-3
NOTES:
Uses 900W units p/n 9101-1674
*Configuration good for 1398-PDM-075,150, and 150B units
**Configuration good for 1398-PDM-150 and 150B units only

Replacing the PSM Shunt Fuse
7KH'&%XVVKXQWIXVHLVORFDWHGLQWKH3RZHU6XSSO\0RGXOH7RFKHFNDQG
RUUHSODFHWKLVIXVH
0HDVXUHYROWDJHVDW//DQG/SKDVHWRSKDVHWRHQVXUHLQFRPLQJ
SRZHULV2))0DNHVXUHWKDWWKHJUHHQ3605($'</('LV2))
5HPRYHWKH360FRYHU
5HPRYHWKHVKXQWIXVHDQGWHVWZLWKDQRKPPHWHU
IMPORTANT :KHQUHSODFLQJWKH360DQG360
VKXQWIXVHD'&UDWHGIXVHPXVWEHXVHG
5HSODFHWKHVKXQWIXVH
Figure 3.10
Shunt Fuse location
Shunt Resistor
Power Supply Module

(1398 PDM-25, 50, 100, and 150)
Shunt Fuse
PSM - 50
8 Ampere KLKD-8 or KLM-8
PSM - 125
PSM - 125 (with external shunt)

DC Bus Terminals
,QVWDOOWKH360FRYHU

Operator Terminals Power Connections (1398-HMI-002)
)LJXUHLOOXVWUDWHVWKHSRZHUFRQQHFWLRQVWRWKH2SHUDWRU7HUPLQDO
9$&VLQJOHSKDVH,WPXVWEHSURSHUO\JURXQGHGWR
SUHYHQWUDGLDWLQJUDGLRIUHTXHQF\QRLVH
Figure 3.11
Operator Terminal power connections
GROUND (EARTH)
115/230 VAC (NEUTRAL)
115/230 VAC (HOT)

Power Connections (1398-HMI-003)
7KH8/75$3OXV+0,2SHUDWRU7HUPLQDOUHTXLUHVDYROWSRZHU
VXSSO\UDWHGDWDPSVXQOHVVRWKHUZLVHVWDWHGRQWKHODEHO
Figure 3.12
Operator Terminal connections (on back of unit)
SUPPLY
COMMON
+24v
1 2
24 VDC (DC+)
COMMON
1 2 3 4 5 6 7 8 9 10
not
24 VDC RS-232 connector
used
• 7KH2SHUDWRU7HUPLQDOUHTXLUHVDSRZHUVXSSO\FDSDEOHRIVXSSO\LQJD
FXUUHQWRIP$DWDUHJXODWHGYROWDJHRIYROWV6XSSOLHVSURYLGLQJ
EHWZHHQYROWVDQGYROWVDUHDOVRVXLWDEOH
• 7KHWHUPLQDOPD\WDNHDVOLWWOHDVP$LQFHUWDLQFLUFXPVWDQFHVVREH
VXUHWKDWWKHFKRVHQSRZHUVXSSO\FDQRSHUDWHFRUUHFWO\ZLWKWKLVORDG
/DUJHVZLWFKPRGHVXSSOLHVWHQGWRQHHGDFHUWDLQPLQLPXPORDGEHIRUH
WKH\ZLOORSHUDWHFRUUHFWO\
,WLVYHU\LPSRUWDQWKRZWKHSRZHUVXSSO\LVPRXQWHGLQUHODWLRQWRWKH
2SHUDWLQJ7HUPLQDO2EVHUYHWKHIROORZLQJSRLQWV
• 7KHSRZHUVXSSO\PXVWEHPRXQWHGFORVHWRWKHXQLWZLWKXVXDOO\QRWPRUH
WKDQIHHWRIFDEOHEHWZHHQWKHVXSSO\DQGWKH2SHUDWRU7HUPLQDO,GHDOO\
DVVKRUWDOHQJWKDVLVSRVVLEOHVKRXOGEHXVH,QSDUWLFXODUWKHSRZHUVXSSO\
VKRXOGQRWEHPRXQWHGRQWKHEDFNRIWKHSDQHOZKHQWKH2SHUDWRU
7HUPLQDOLVLQVWDOOHGLQWKHSDQHOGRRUXQOHVVDVKRUWFDEOHUXQFDQEH
DFKLHYHG
• 7KHZLUHXVHGWRFRQQHFWWKH2SHUDWRU7HUPLQDOWRLWVSRZHUVXSSO\VKRXOG
EHDWOHDVWJDXJHZLUH,IDORQJHUFDEOHUXQLVXVHG\RXZLOOQHHGWR
LQFUHDVHWKHFDEOHJDXJH7KHURXWLQJRIWKHFDEOHVKRXOGEHNHSWDZD\IURP
FRQWDFWRUVLQYHUWHUVDQGRWKHUGHYLFHVWKDWJHQHUDWHVLJQLILFDQWHOHFWULFDO
QRLVH

Motors Power Connections
3KDVLQJRIWKHWKUHHSKDVHGULYHPRGXOHRXWSXWV56DQG7PXVWFRQIRUPWR
WKHPRWRU56DQG7OHDGVIRUSURSHURSHUDWLRQ&RQQHFWWKHHDUWKJURXQGWR
HQVXUHDVDIHLQVWDOODWLRQDQGSURSHURSHUDWLRQ6HH)LJXUHIRUFRQQHFWRU
SLQDQGVLJQDOLGHQWLILFDWLRQRI+DQG)6HULHVPRWRUV
Figure 3.13
Motor power connections for H, and F-Series motors
1. Do not interchange any connection in the cable

2. Ground connections:
1398-PDM-10, 20, 30, 75, and 150B – screw terminal
1398-PDM-25, 50, 100, and 150 – M6 stud
3. Wire colors shown reflect cables supplied by Rockwell Automation/
Allen-Bradley
6HH )LJXUHRQSDJH IRUFRQQHFWRUSLQDQGVLJQDOLGHQWLILFDWLRQRI

16HULHVPRWRUV
Figure 3.14 Motor power connections N-Series motors

BROWN
A R
BLACK
B S
BLUE
C T
GRN/YEL
D
E N/C
SHIELD
1. Do not interchange any connection in the cable

2. Ground connections:
1398-PDM-10, 20, 30, 75, and 150B – screw terminal
1398-PDM-25, 50, 100, and 150 – M6 stud
3. Wire colors shown reflect cables supplied by Rockwell Automation/
Allen-Bradley
+LJKYROWDJHPD\EHSUHVHQWRQWHUPLQDOVRIWKH8/75$
ATTENTION
3OXV3'0
5HPRYHSRZHUDQGGLVFRQQHFWWKHSRZHUFDEOHEHIRUH
! PDNLQJRUUHPRYLQJDQ\FRQQHFWLRQ

&DEOHVL]HVDUHLQGLFDWHGLQWKHDSSURSULDWHGUDZLQJV
• 5HIHUWR ´3RZHU:LULQJ'LDJUDPIRU3'0DQGµRQ
SDJH
• 5HIHUWR ´3RZHU:LULQJIRU3'0µRQSDJH
• 5HIHUWR ´3RZHU:LULQJIRU3'0%µRQSDJH
• 5HIHUWR ´3RZHU:LULQJ'LDJUDP3'0DQGµRQ
SDJH
6WDQGDUGFDEOHVVXSSOLHGE\5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\DUHQRW
LQWHQGHGIRUDSSOLFDWLRQVZKHUHIUHTXHQWIOH[LQJRFFXUV
0RWRUSRZHUFRQQHFWRUVDUHIRUDVVHPEO\SXUSRVHVRQO\
ATTENTION
7KH\VKRXOGQRWEHFRQQHFWHGRUGLVFRQQHFWHGZKLOH
SRZHULVDSSOLHGWRWKHGULYH
! )DLOXUHWRREVHUYHWKLVSUHFDXWLRQFRXOGUHVXOWLQGDPDJHWR
'RQRWWLQVROGHUWKHH[SRVHGOHDGVRQFDEOHV

ATTENTION
6ROGHUFRQWUDFWVRYHUWLPHDQGPD\ORRVHQWKHFRQQHFWLRQ
! )DLOXUHWRREVHUYHWKLVSUHFDXWLRQFRXOGUHVXOWLQGDPDJHWR
Shield Termination
ATTENTION
RQHSRLQWIRUVDIHW\
! WKHHTXLSPHQWRUVHYHUHERGLO\LQMXU\
5RFNZHOO$XWRPDWLRQ$OOHQ%UDGOH\PRWRUSRZHUFDEOHVDUHVKLHOGHG7KH
SRZHUFDEOHLVGHVLJQHGWREHWHUPLQDWHGDWWKHGULYHGXULQJLQVWDOODWLRQ$
VPDOOSRUWLRQRIWKHFDEOHMDFNHWLVVWULSSHGZKLFKH[SRVHVWKHVKLHOGZLUHV
7KHH[SRVHGDUHDPXVWEHFODPSHGDWWKHOHIWIURQWRIWKHGULYHFKDVVLVXVLQJ
WKHFODPSSURYLGHGQHDUWKHERWWRP,WLVFULWLFDOIRU(0&SHUIRUPDQFHWKDW
WKHVKLHOGZLUHVEHFODPSHGDJDLQVWWKHDUHDRIWKHFKDVVLVZKLFKLVQRWSDLQWHG
7KLVVHFWLRQRIWKHFKDVVLVLVODEHOHGZLWKWKHFKDVVLVJURXQGV\PERO

Figure 3.15
Motor power EMC shield connection
conductive
cable jacket shield area
5HIHUWR ´&DEOHVµRQSDJH IRUDVHOHFWLRQRIVKLHOGHGPRWRUSRZHUFDEOHV
Digital Inputs and Outputs 7KLVVHFWLRQFRYHUVWKHFRQWURODQGLQWHUIDFHFRQQHFWLRQVEHWZHHQWKH3'0

DQGWKHUHVWRIWKHV\VWHP7KLVLQFOXGHV'LJLWDO,2$QDORJ,25HOD\
2XWSXWV(QFRGHUV6WHSDQGGLUHFWLRQ,QSXWVDQG6HULDO3RUWV5HIHU
WR ´3'0FRQWUROFRQQHFWLRQVµRQSDJH LOOXVWUDWLQJDOOFRQWURO
FRQQHFWLRQVWRWKH3'0
6HH )LJXUHRQSDJH VKRZLQJWKH8/75$3OXV3'0ZKLFKSURYLGHV

RSWLFDOO\LVRODWHGLQSXWVDQGHLJKWRSWLFDOO\LVRODWHGRXWSXWVIRUPDFKLQH
FRQWURODQGLQWHUIDFH*HQHUDOSXUSRVH,2XVHVD9'&VXSSO\YROWDJH7KH
3'0KDVDQLQWHUQDO9'&#P$SRZHUVXSSO\IRUWKLVSXUSRVH
LVRODWHGIURPWKHORJLFFRPPRQ7KH9'&&RPPRQPXVWEHWLHGWR
PDFKLQHJURXQGWRSURYLGHDFRPPRQJURXQGUHIHUHQFH7KH$IXVH)RQ
WKH3'0SURWHFWVWKHLQWHUQDO9'&VXSSO\3LQRIWKHLQWHUIDFH
FRQQHFWRUV33DQG3LVORFDWHGDWWKHERWWRPRIWKHFRQQHFWRUDQGLV
PDUNHGRQWKHIURQWRIWKH3'0
IMPORTANT 7KHXVHUPD\VXSSO\H[WHUQDO9'&SRZHUE\UHPRYLQJ
ZLUHMXPSHUV:DQG:RQWKH3'0ORJLFERDUGDQG
FRQQHFWLQJWKHH[WHUQDOVXSSO\WRWKH9'&DQGYROW
FRPPRQRQFRQQHFWRUV3DQG3

Figure 3.16
PDM control connections
Operator Terminal
F1 F2 F3 F4
X1 STATUS
1 2 3 YES
X2 MODE
4 5 6 NO
X3 CLEAR
7 8 9 -
X4 0 ENTER
GML PC Compatible
Software Personal Computer
SHIELD
R P5-15
S +5 VDC
P5-14
T ANALOG
P5-13
TS+
G P5-12
TS-
P5-11
I-
P5-10
+5 VDC
P5-9
NC
P5-8
COMMON
P5-7
COMMON
P5-6
I+
Brushless Motor P5-5
B-
P5-4
B+
P5-3
A-
P5-2
A+
P5-1
SHIELD
P4-15
+5 VDC
P4-14
DIR-
P4-13
STEP-
P4-12
STEP+
P4-11
I-
P4-10
+5 VDC
P4-9
DIR+
P4-8
Master Encoder P4-7
COMMON
COMMON
P4-6
I+
P4-5
B-
P4-4
B+
P4-3
A-
P4-2
A+
P4-1
P2
OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM +24 VDC
12
ERROR OUTPUT 8
11
IN POSITION OUTPUT 7
10
HOME SEQUENCE COMPLETE OUTPUT 6
9
8
AT HOME OUTPUT 5
PROGRAM RUNNING OUTPUT 4
7
GENERAL PURPOSE OUTPUT OUTPUT 3
6
5
4
3
GENERAL PURPOSE INPUT INPUT 16
2
1
P1
14 GENERAL PURPOSE INPUT INPUT 13
13
INTERRUPT #2 INPUT 12
12
11
ERETURN INPUT 10
10
PAUSE INPUT 9
9
JOG FORWARD INPUT 8
8 JOG REVERSE INPUT 7
7
HOME COMMAND INPUT 6
6
HOME SWITCH INPUT 5
5
START INPUT 4
4
ENABLE INPUT 3
REVERSE LIMIT INPUT 2
3
FORWARD LIMIT INPUT 1
2
1
24 VOLT COMMON
INPUT SWITCHES: RESISTANCE IS 3000 OHM MAXIMUM

Figure 3.17
Typical Digital I/O wiring
INTERNAL
P2
OUTPUT LOADS: RESISTANCE IS 330 OHM MINIMUM +24 VDC
12 W3 INTERNAL 24 VDC SUPPLY
ERROR OUTPUT 8
11
10
IN POSITION OUTPUT 7
TYPICAL OUTPUT
9
HOME SEQUENCE COMPLETE OUTPUT 6
AT HOME OUTPUT 5 75mA MAX PER OUTPUT
8 500mA TOTAL
PROGRAM RUNNING OUTPUT 4
7
6
5
24 VOLT COMMON
4
3
2
1
P1
14 GENERAL PURPOSE INPUT INPUT 13
13
12
11
ERETURN INPUT 10
10
PAUSE INPUT 9
JOG FORWARD INPUT 8 3.3 K
9
8 JOG REVERSE INPUT 7 TYPICAL INPUT
7
HOME COMMAND INPUT 6
6
HOME SWITCH INPUT 5
5
START INPUT 4
4
ENABLE INPUT 3
REVERSE LIMIT INPUT 2
3
FORWARD LIMIT INPUT 1
2
24 VOLT COMMON W4
1 INTERNAL 24 VDC SUPPLY
INPUT SWITCHES: RESISTANCE IS 3000 OHM MAXIMUM

I/F 24V Sourcing
7KH8/75$3OXV3'0KDVVLQNLQJDFWLYHORZ,2ZKLFKLVFRPPRQLQWKH

86EXWVRXUFLQJDFWLYHKLJK,2LVSUHIHUUHGLQ(XURSH5RFNZHOO
$XWRPDWLRQ$OOHQ%UDGOH\RIIHUVD',1UDLOPRXQWHGLQWHUIDFHFDUGZKLFK
FRQYHUWVWKH,2IURPVLQNLQJWRVRXUFLQJDFWLYHKLJK7KLVLQWHUIDFHFDUG
PXVWEHPRXQWHGLQWKHVDPHHQFORVXUHDVWKHGULYH
PDM pin connection with the IF 24V Conversion Card
7KHLQWHUIDFHFDUGLVD',1UDLOPRXQWLQJXQLWWKDWKDVDWHUPLQDOVWULS
PPVFUHZFODPSW\SHGRZQHDFKVLGH7KH3'0VLGHRIWKHFDUG
FRQQHFWVWR3DQG3FRQQHFWRUVRQWKH3'0
PDM Connector PDM Pin Wire IF Card Pin Cable

Number Color Number Pair
P1 General purpose inputs 1 (24 volt common) GREEN 1 Pair 1
2 (Input) RED 2 Pair 1
3 (Input) ORANGE 3 Pair 2
4 (Input) BLACK 4 Pair 2
6 (Input) WHITE 6 Pair 3
9 (Input) BLUE 9 Pair 5
12 (Input) YELLOW 12 Pair 6
14 (Input) YELLOW 14 Pair 7

(Continued)
PDM Connector PDM Pin Wire IF Card Pin Cable

Number Color Number Pair
P2 General purpose inputs 1 (Input) WHITE 1 Pair 8
and outputs
3 (Input) BLUE 3 Pair 9
4 (Output) BLACK 4 Pair 9
5 (Output) GREEN 5 Pair 10
7 (Output) BROWN 7 Pair 11
9 (Output) GREEN 9 Pair 12
10 (Output) BLUE 10 Pair 12
11 (Output) WHITE 11 Pair 13
12 (+24 volts) GREEN 12 Pair 13
N/A RED N/A Pair 14
N/A ORANGE N/A Pair 14
N/A RED N/A Pair 15
N/A BROWN N/A Pair 15
2QWKHXVHULQSXWVLGHRIWKH,)FDUGWKH,2UHTXLUHVDVHSDUDWHFOHDQ
9'&QRPLQDOVXSSO\7KHUHLVQRJDOYDQLFFRQQHFWLRQIURPRQHVLGHRIWKH
,)FDUGWRWKHRWKHUDQGWKH9'&XVHUVXSSO\PXVWEHJURXQGHGRQWKH
QHJDWLYHVLGHWRWKHSURWHFWLYHHDUWKV\VWHP7KHVXSSO\VKRXOGEHEHWZHHQ
WR9'&DQGFDSDEOHRIVXSSO\LQJWKHORDGVLPSRVHGE\WKHRXWSXWORDGLQJ
SOXVP$IRUHDFKLQSXWXVHG7KHVXSSO\PXVWEHIXVHGDGHTXDWHO\WRSURWHFW
WKHFDEOHVXVHG2XWSXWORDGVPXVWEHFRQQHFWHGEHWZHHQWKHRXWSXWDQG
YROWJURXQGDQGPXVWEHRKPVRUPRUHLPSHGDQFH7KHLQWHUIDFHRXWSXWV
DUHUDWHGDWP$&DEOLQJVKRXOGEHPPPD[LPXP7KHLQSXWVPXVWEH
VXSSOLHGE\WKHXVHUVLQSXWFLUFXLWIURPWKHXVHUYROWSRVLWLYHDQGHDFKLQSXW
ZLOOVLQNP$ZKHQDFWLYH
5HIHUWR ´,)&RQYHUVLRQ&DUGµRQSDJH %IRUWKHLQWHUIDFHFDUGDQGFDEOH

PDQXIDFWXULQJQXPEHUV

Digital Inputs
7KHRSWLFDOO\LVRODWHGLQSXWVDUHFRQQHFWHGZLWKDQLQWHUQDOSXOOXSUHVLVWRUWR
9'&0DNLQJDFRQQHFWLRQWRWKHYROWFRPPRQFORVLQJDVZLWFKZLOO
DOORZFXUUHQWWRIORZWKURXJKWKHRSWRLVRODWRUWXUQLQJLWRQ,QJHQHUDO
LQSXWVDUHFRQVLGHUHG21LQWKLVVWDWHDQG2))ZKHQWKHUHLVQRFRQQHFWLRQ
IURPWKHLQSXWWRYROWFRPPRQ7KH)RUZDUGDQG5HYHUVH/LPLWVZLWFKHV
DUHH[FHSWLRQVZLWKWKHVZLWFKRSHQLQGLFDWLQJWKDWDOLPLWKDVEHHQKLW7KH
+RPH6ZLWFKLQSXWSDUDPHWHUGHILQHVWKH+RPHVZLWFKLQSXWWREHRSHQRU
FORVHGWRLQGLFDWHWKHKRPHSRVLWLRQDQGWKH3$86(SDUDPHWHUFDQVHOHFWWKH
3DXVHLQSXWDVDFWLYHRSHQRUDFWLYHFORVHG
7KHJHQHUDOSXUSRVHLQSXWVRQWKH3'0DUHUHIHUUHGWRDV,WKURXJK,LQ
SURJUDPVWDWHPHQWV,QSXWV,WKURXJK,FDQEHDVVLJQHGWKHSUHGHILQHG
IXQFWLRQVVKRZQLQWKHWDEOHEHORZ,QSXWV,DQG,PD\EHXVHGDV
,QWHUUXSWLQSXWV,QSXWV,WR,PD\EHXVHGDVSURJUDPVHOHFWLQSXWV$Q\
RIWKHVHLQSXWIXQFWLRQVPD\EHGLVDEOHGDQGWKHLQSXWVXVHGDVJHQHUDO
SXUSRVHLQSXWV
,QDGGLWLRQWRWKHLQSXWIXQFWLRQVGHILQHGEHORZRWKHUIXQFWLRQVPD\EH
DVVLJQHGWRDQ\DYDLODEOHLQSXW2SWLRQDOLQSXWIXQFWLRQVDUH+DUGZDUH5HVHW
6WRS3URJUDP'HILQH+RPH
Connector Pin Signal Name Assignable

Function (1)
P2 General purpose 12 +24 VDC
inputs and outputs
3 Input 16 Program Select MSB
2 Input 15 Program Select
1 Input 14 Program Select

(Continued)
Connector Pin Signal Name Assignable

Function (1)
P1 General purpose 14 Input 13 Program Select
inputs
13 Input 12 Int2 / Program
Select
12 Input 11 Int1 / Program
Select
11 Input 10 Emergency Return
10 Input 9 Pause
9 Input 8 Jog Forward
8 Input 7 Jog Reverse
7 Input 6 Home Command
6 Input 5 Home Switch
5 Input 4 Start Program
4 Input 3 Enable
3 Input 2 Reverse Limit
2 Input 1 Forward Limit
1 24 VDC Common
(1)
Even if an input is assigned a function, it may be used as a general purpose input.

Digital Outputs
7KHJHQHUDOSXUSRVHRXWSXWVDUHUHIHUUHGWRDV2WKURXJK2LQSURJUDP
VWDWHPHQWV7KHRXWSXWVDUHRSWLFDOO\LVRODWHGDQGRSHUDWHRQWKHVDPHYROW
VXSSO\XVHGE\WKHJHQHUDOSXUSRVHLQSXWV
Digital outputs and assignable functions
7KHVHRXWSXWVDUHDOOFDSDEOHRIVLQNLQJP$FRQWLQXRXVO\GULYHQWROHVV
WKDQYROW2XWSXWV22DQG2DUHGHILQHGUHVSHFWLYHO\DV+RPH
6HTXHQFH&RPSOHWH,Q3RVLWLRQDQG(UURU2XWSXWVKRZHYHUIXQFWLRQVPD\
EHGLVDEOHGDQGWKHRXWSXWVXVHGDVJHQHUDOSXUSRVHRXWSXWV2SWLRQDOO\
2XWSXW2PD\EHHQDEOHGDVD3URJUDP5XQQLQJRXWSXWDQGRXWSXW2PD\
EHHQDEOHGDVDQ$W+RPHRXWSXW
7KH8/75$3OXV3'0ZLOOQRWDXWRPDWLFDOO\WXUQRXWSXWV
ATTENTION
2))
([WHUQDOFLUFXLWU\PXVWEHXVHGWRHQVXUHWKHVWDWHRIGLJLWDO
! RXWSXWVLQDQHPHUJHQF\VWRSVLWXDWLRQ
Connector Pin Signal Name Assignable Function

P3 Analog I/O and status 12 +24 VDC +24 VDC
11 Output 8 Error
10 Output 7 In Position
9 Output 6 Home Sequence Complete
8 Output 5 At Home
7 Output 4 Program Running
6 Output 3
5 Output 2
4 Output 1 P2
Connecting Inputs and Outputs Together
$GLJLWDORXWSXWIURPD3'0PD\EHFRQQHFWHGWRDQLQSXWRQWKHVDPH3'0
RUDQRWKHU3'0$VLQJOHZLUHFRQQHFWLRQEHWZHHQWKHRXWSXWSLQDQGWKH
LQSXWSLQLVDOOWKDWLVUHTXLUHG,IFRQQHFWLQJ,2EHWZHHQFRQWUROOHUVWKH
9'&FRPPRQ3SLQDOVRQHHGVWREHFRQQHFWHGEHWZHHQHDFKFRQWUROOHU
0XOWLSOHGLJLWDORXWSXWVPD\EHZLUHGWRJHWKHUWRIRUPDZLUH25FRQQHFWLRQ
,IDQ\RQHRIWKHRXWSXWVWXUQVRQWKHOLQHLVSXOOHGORZRQ7KLVLVXVHIXOIRU

FRQQHFWLQJWKH(UURURXWSXWVIURPHDFKD[LVRIDV\VWHPWRDKRVW3/&RU
PDFKLQHFRQWUROOHUWRLQGLFDWHDQHUURULQDQ\RIWKHD[HV
0XOWLSOHGLJLWDOLQSXWVPD\EHZLUHGWRJHWKHU,IWKHOLQHLVSXOOHGORZDOO
FRQQHFWHGLQSXWVZLOOWXUQRQ7KLVLVXVHIXOIRUFRQQHFWLQJDQLQSXWRQHDFK
D[LVRIDV\VWHPWRDQRXWSXWIURPDKRVW3/&RUPDFKLQHFRQWUROOHUWR
V\QFKURQL]HHYHQWV
Analog Input
)LJXUHLOOXVWUDWHVWKH$QDORJWR'LJLWDOFRQYHUWHU$'&LQSXW$'&

/RFDWHGRQ3LWPD\EHXVHGWRUHDGDQ\DQDORJVLJQDOZLWKDUDQJHRI
9
Analog inputs and signal names
7KHDQDORJVLJQDOJURXQGPXVWEHFRQQHFWHGWRWKH$QDORJ&RPPRQRQ
FRQQHFWRU37KH$QDORJ&RPPRQLVWLHGWRHDUWKJURXQGLQWHUQDOO\7KH
ELW$'&KDVDUHVROXWLRQRIDSSUR[LPDWHO\P97KLVDQDORJLQSXWPD\
EHXVHGDVDJHQHUDOSXUSRVHDQDORJLQSXWRUDVWKHIHHGUDWHLQSXW5HIHUWRWKH
*0/8OWUD6RIWZDUHPDQXDOVIRULQIRUPDWLRQDERXWWKHXVHRIWKLVLQSXW
Connector Pin Signal Name

P3 Analog I/O and status 4 Analog Common
5 Analog Input (ADC1)
Figure 3.18
Analog input and output - typical internal circuits
+15 VDC
-15 VDC
+15 VDC
P3 -
+15 VDC
8
MONITOR ANALOG OUTPUT +
7
DAC1 ANALOG OUTPUT
6 +15 VDC
ADC1 ANALOG INPUT -15 VDC
5
ANALOG COMMON +15 VDC
4
RELAY COMMON -
3
ENABLED RELAY
2
READY RELAY +
1
-15 VDC
-15 VDC

Analog Output
7KH'LJLWDOWR$QDORJ&RQYHUWHU'$&RXWSXW'$&RQSLQ3RXWSXWV

DQDQDORJVLJQDOZLWKDUDQJHRIYROW
Analog output and signal names
7KHDQDORJVLJQDOJURXQGPXVWEHFRQQHFWHGWRWKH$QDORJ&RPPRQRQSLQ
37KHELW'$&KDVDUHVROXWLRQRIDSSUR[LPDWHO\P95HIHUWRWKH
*0/8OWUD6RIWZDUHIRULQIRUPDWLRQDERXWWKHXVHRIWKLVRXWSXW

3$QDORJ,2DQGVWDWXV 4 $QDORJ&RPPRQ
6 $QDORJ2XWSXW'$&
Monitor Output
7KH3URJUDPPDEOH0RQLWRURXWSXWDOORZVDV\VWHPYDULDEOHWREHPRQLWRUHG
7KHYDULDEOHWREHPRQLWRUHGLVVHOHFWHGLQWKH0RQLWRUPHQX9DULDEOH
0RQLWRU6HW8SGLDORJER[
Monitor output an signal names
7KHPRQLWRURXWSXWLVDYROWDQDORJVLJQDOZLWKELWUHVROXWLRQ5HIHUWR
WKH*0/8OWUD6RIWZDUHIRULQIRUPDWLRQDERXWWKHXVHRIWKLVRXWSXW

P3 Analog I/O and status 4 Analog Common
7 Programmable Monitor

Ready Relay Output
6HH )LJXUHRQSDJH LOOXVWUDWLQJWKH5HDG\RXWSXW3ZKLFKLVD

QRUPDOO\RSHQUHOD\FRQWDFWWKDWFORVHVZKHQWKH3'0LVSRZHUHGXSLIQR
IDXOWVH[LVWZLWKLQWKH3'0
Ready relay output and signal names
5HOD\&RPPRQ3LVWKHFRPPRQRIWKLVFRQWDFW7KLVFRQWDFWLVUDWHG

$DW9'&7KH5HDG\RXWSXWZLOORSHQLIDV\VWHPIDXOWRFFXUV

P3 Analog I/O and status 1 Ready (Relay output)
3 Relay Common
Figure 3.19
Enable and Ready Relay - Typical Internal Circuits
P3
+15 VDC
8
8 BIT DAC OUT (MONITOR)
7
12 BIT DAC OUT
6
10 BIT A/D IN
5
ANALOG COMMON
4
RELAY COMMON
3
ENABLED
2
READY NORMALLY NORMALLY
1 OPEN OPEN

Enabled Relay Output
7KH(QDEOHGRXWSXW3LVDQRUPDOO\RSHQUHOD\FRQWDFW7KH(QDEOHG

RXWSXWFORVHVZKHQWKH3'0LVHQDEOHGDQGRSHQVZKHQWKH3'0LVGLVDEOHG
Enabled relay output and signal names
5HOD\&RPPRQ3LVWKHFRPPRQRIWKLVFRQWDFW7KLVFRQWDFWLVUDWHG

$DW9'&
7KH8/75$3OXV3'0ZLOOQRWDXWRPDWLFDOO\WXUQRXWSXWV
ATTENTION
2))
([WHUQDOFLUFXLWU\PXVWEHXVHGWRHQVXUHWKHVWDWHRIGLJLWDO
! RXWSXWVLQDQHPHUJHQF\VWRSVLWXDWLRQ

P3 Analog I/O and status 2 Enabled (Relay output)
3 Relay Common
7KH3'0SURYLGHVLQWHUIDFHVIRUWZRVHSDUDWHHQFRGHUIHHGEDFNFRQQHFWLRQV
7KH3'0ZLOODFFHSWHQFRGHULQSXWVDWDPD[LPXPIUHTXHQF\RIN+]RQ
DVLQJOHFKDQQHO$RU%IRUHQFRGHUVZLWKSKDVHHUURURIOHVVWKDQRUHTXDOWR
GHJUHHV7KHUHLVDIRXUWLPHVPXOWLSOLHURQWKHHQFRGHULQSXWWRWKH3'0
RQERWKWKHHQFRGHUDQGHQFRGHULQSXWVVRIRXUHQFRGHUFRXQWVLV
HTXLYDOHQWWRRQHHQFRGHUOLQH:LWKDVWDQGDUGOLQHHQFRGHUWKH3'0
ZLOOFRXQWHQFRGHUSXOVHVSHUUHYROXWLRQ
7KH3'0ZLOODFFHSWGLIIHUHQWLDOOLQHGULYHUTXDGUDWXUHVLJQDOVIURPDYROW

LQFUHPHQWDOHQFRGHU$VLOOXVWUDWHGLQ)LJXUHWKH3'0DFFHSWV$%DQG,
,QGH[VLJQDOVIURPWKHHQFRGHUZLWK$OHDGLQJ%IRUFORFNZLVHURWDWLRQ
IDFLQJWKHPRWRUGULYHVKDIW&RQQHFWLRQVDUHSURYLGHGIRU$$%%,
,9'&DQGFRPPRQVLJQDOV

Figure 3.20
Encoder input circuitry example

Encoder 1
)LJXUHLOOXVWUDWHVWKHFRQQHFWLRQVRI(QFRGHUZKLFKPXVWFRQQHFWWR
WKHHQFRGHUPRXQWHGWRWKHPRWRU7KLVLVWKHRQO\PRWRUPRXQWHGIHHGEDFN
QHFHVVDU\IRUFRQWURORIWKHPRWRUYHORFLW\7KLVHQFRGHULVDOVRQRUPDOO\XVHG
IRUSRVLWLRQIHHGEDFN
Encoder 1 and signal names
7KH(QFRGHULQWHUIDFHDOVRLQFOXGHVFRQQHFWLRQVIRUWKHQRUPDOO\FORVHG
WKHUPRVWDWLQWKHPRWRUZLQGLQJVDQGIRUDQDQDORJVWDUWXSVLJQDOUHTXLUHG
IRUSURSHURSHUDWLRQ

P5 Encoder input 1 1 A+
2 A-
3 B+
4 B-
5 I+ (Index)
6 Common
7 Common
8 No connection
9 +5 VDC
10 I- (Index)
11 TS- (thermostat)
12 TS+ (thermostat)
13 Analog (absolute position)
14 +5 VDC
15 Shield

Figure 3.21
Encoder 1 connections
SHIELD
R P5-15
S +5 VDC
P5-14
T ANALOG
P5-13
TS+
G P5-12
TS-
P5-11
I-
P5-10
+5 VDC
P5-9
NC
P5-8
COMMON
P5-7
COMMON
P5-6
BRUSHLESS MOTOR I+
P5-5
B-
P5-4
B+
P5-3
A-
P5-2
A+
P5-1

Encoder 2
6HH )LJXUHRQSDJH VKRZLQJWKHFRQQHFWLRQVRI(QFRGHUZKLFK

SURYLGHVDQRSWLRQDOVHFRQGHQFRGHU,WFDQEHXVHGDVSRVLWLRQIHHGEDFN
GLUHFWO\IURPWKHORDGRUDVDPDVWHULQSXWIRUUHODWLYHSRVLWLRQLQJ
PDVWHUIROORZHUV\VWHPVRUIRUHOHFWURQLFJHDULQJ
$VDQDOWHUQDWLYHWKH(QFRGHUSRUWPD\DOVREHXVHGWRRXWSXWHQFRGHU
VLJQDOVZKHQRQO\WKHPRWRUPRXQWHGHQFRGHULVXVHG7KHIXQFWLRQRIWKH
(QFRGHUSRUWLVVHOHFWHGDVLQSXWRURXWSXW
Encoder 2 and signal names
7KH3'0ZLOODFFHSWGLIIHUHQWLDOOLQHGULYHUTXDGUDWXUHVLJQDOVIURPDYROW

LQFUHPHQWDOHQFRGHU7KH3'0DFFHSWV$%DQG,,QGH[VLJQDOVIURPWKH
HQFRGHUZLWK$OHDGLQJ%IRUFORFNZLVHURWDWLRQ&RQQHFWLRQVDUHSURYLGHG
IRU$$%%,,YROWVDQGFRPPRQVLJQDOV7KH,DQG,
VLJQDOVGRQRWQHHGWREHFRQQHFWHGLIQRWQHHGHG
7KH(QFRGHUVLJQDOZLUHVWRWKH3'0VKRXOGEHVKLHOGHG7KHVKLHOGVKRXOG
EHFRQQHFWHGRQO\DWWKHHQFRGHUHQG+RZHYHULQVRPHDSSOLFDWLRQVLWPD\
EHQHFHVVDU\WRFRQQHFWWKHVKLHOGDWWKH3'0HQGRIWKHFDEOHDOVR
&RQQHFWRU3LQFOXGHVDVHSDUDWHSLQ3LQIRUWKLVSXUSRVH5HIHU
WR ´8/75$3OXV3'03RU3WR$X[LOLDU\(QFRGHU8QWHUPLQDWHG31
µRQSDJH

P4 Encoder input 2 1 A+
2 A-
3 B+
4 B-
5 I+ (Index)
6 Common
7 Common
9 +5 VDC
P$PD[LPXP
10 I- (Index)
15 Shield

Figure 3.22
Encoder 2 connections
SHIELD
P4-15
+5 VDC
P4-14
DIR-
P4-13
STEP-
P4-12
STEP+
P4-11
I-
P4-10
+5 VDC
P4-9
DIR+
P4-8
MASTER ENCODER COMMON
P4-7
COMMON
P4-6
I+
P4-5
B-
P4-4
B+
P4-3
A-
P4-2
A+
P4-1
Slaving an ULTRA Plus PDM to Another
,QDSSOLFDWLRQVZKHUHDQ8/75$3OXV3'0QHHGVWR´IROORZµDQRWKHU
8/75$3OXV3'0XVLQJHOHFWURQLFJHDULQJWKH3FRQQHFWLRQVPD\EHXVHG
WRSURYLGHDVLPSOHPHWKRGRIZLULQJWKHPRWRUHQFRGHUVLJQDOVIURPWKH
PDVWHU8/75$3OXV3'0WRWKH(QFRGHULQSXWRIWKHIROORZHUVODYH
8/75$3OXV3'07KHPDVWHU8/75$3OXV3'0QHHGVWREHFRQILJXUHGWR
RXWSXWLWVPRWRUHQFRGHUVLJQDOVRQ3$VWDQGDUGFDEOHLVDYDLODEOHIRUWKLV
SXUSRVH5HIHUWR ´8/75$3OXV3'03WR3IRRW31µRQ
SDJH

Step and Direction Inputs
)LJXUHLOOXVWUDWHVFRQQHFWLRQVRIWKH3'0ZKLFKFDQDFFHSWVWHSDQG
GLUHFWLRQLQSXWVRQ37KHVHLQSXWVSURYLGHDVWDQGDUGLQWHUIDFHWRDQLQGH[HU
,IWKHVWHSDQGGLUHFWLRQLQSXWVRQ3DUHXVHGWKH(QFRGHUSRUWPD\VWLOOEH
XVHGDV(QFRGHURXWEXWQRWIRUFRQQHFWLRQVWRDQDX[LOLDU\HQFRGHULQSXW
Step and direction inputs and signal names
7KHVWHSDQGGLUHFWLRQLQSXWVUHTXLUHDVRXUFHWRGULYHDP$ORDGDW9'&
77/OHYHOVDUHFRPSDWLEOHDVORQJDVWKHLQSXWFXUUHQWLVVXIILFLHQW7KHVH
RSWLFDOO\LVRODWHGLQSXWVDUHVXLWDEOHIRURSHQFROOHFWRUGULYHUVRQWKHLQSXWV
7KHVRXUFHRIWKHVWHSDQGGLUHFWLRQVLJQDOVPXVWSURYLGHSRZHUIRUWKH
RSWRLVRODWRUVDVZHOODVVWHSDQGGLUHFWLRQVLJQDOV7KHILJXUHEHORZLOOXVWUDWHV
WKHFRQQHFWLRQVIRUDFWLYHKLJKDQGDFWLYHORZVLJQDOVWRWKHVWHSDQGGLUHFWLRQ
LQSXWV

P4 Encoder input 2 8 DIR+
11 STEP+
12 STEP-
13 DIR-
15 Shield
Figure 3.23
Step and direction input connections
Step and Direction Step and Direction

Active Low Active High
Indexer POSITIONING MODULE Indexer POSITIONING MODULE

+5V
P4-11 Step + 470 P4-11 Step + 470
Step
P4-12 Step - P4-12 Step -

Step
P4-8 Dir + 470 P4-8 Dir + 470

Dir
P4-13 Dir - Indexer P4-13 Dir -

Dir Common

7KHLQSXWUHVLVWDQFHSURYLGHVWKHSURSHUFXUUHQWOLPLWIRUD9'&VLJQDO
([WHUQDOUHVLVWDQFHLQVHULHVZLWKWKHVWHSDQGGLUHFWLRQOLQHVWROLPLWFXUUHQWWR
P$DOORZVRSHUDWLRQZLWKYROWDJHVJUHDWHUWKDQ9'&
Vcc – 1.8
RE = ----------------------- – 0.470
10
RE = External resistance ( k Ω )
Vcc = Signal Voltage
7KHVWHSLQSXWLVDFWLYHORZDQGZLOODFFHSWDVTXDUHZDYHLQSXWZLWKD
PD[LPXPIUHTXHQF\RIN+]7KHGLUHFWLRQLQSXWLVKLJKIRUPRWLRQLQWKH
IRUZDUGGLUHFWLRQ7KHGLUHFWLRQLQSXWVKRXOGFKDQJHDPLQLPXPRI
PLFURVHFRQGVEHIRUHWKHILUVWVWHSSXOVHLQWKDWGLUHFWLRQ
7KHGLVWDQFHPRYHGJLYHQDQLQSXWRI1VWHSSXOVHVLVDIXQFWLRQRIWKH
VRIWZDUHJHDUUDWLRVHWLQWKH3'07KHQXPEHURIHQFRGHUFRXQWVPRYHGLV
Motor Encoder Counts = ( N step pulses )  ---
a
 b
Motor Encoder Counts = The distance the motor moves
N step pulses = The number of pulses from an indexer
a
--- = The software gear ratio
b
7KHVLJQDOZLUHVIURPWKHLQGH[HUVKRXOGEHVKLHOGHGDQGWKHVKLHOGFRQQHFWHG
WRWKHFKDVVLVRIWKHGHYLFHJHQHUDWLQJWKHVLJQDOV,QVRPHFDVHVLWPD\EH
QHFHVVDU\WRFRQQHFWWKHVKLHOGDWWKH3'0HQGRIWKHFDEOHDW3

Serial Port Connections 7KHUHDUHWZRVHULDOSRUWVRQD3'06HULDO$X[LOLDU\3DQG6HULDO

&RPSXWHU37KH2SHUDWRU7HUPLQDOLVFRQQHFWHGWRWKH3'0WKURXJK
6HULDOSRUW36HULDOSRUW3LVXVHGDVWKHSURJUDPPLQJSRUWIRUD3&WKDWLV
UXQQLQJ*0/8OWUD6RIWZDUH63LVDOVRWKHVHULDOSRUWXVHGIRU+RVW
FRPPXQLFDWLRQV
'DWDPD\EHVHQWWRRUUHFHLYHGIURPHLWKHUVHULDOSRUWE\DQDSSOLFDWLRQ
SURJUDP7KHDSSOLFDWLRQPD\XVHD35,17VWDWHPHQWWRVHQGGDWDDQGD
5($'VWDWHPHQWWRUHFHLYHGDWD5HIHUWRWKH*0/8OWUD6RIWZDUHPDQXDOV
IRUGHWDLOHGLQIRUPDWLRQ
6HYHUDOSDUDPHWHUVVHOHFWWKHRSHUDWLQJPRGHIRUVHULDOFRPPXQLFDWLRQV%RWK
SRUWVVXSSRUWHLWKHU56&RU56FRPPXQLFDWLRQV7KHSRUWVRSHUDWH
DWEDXGUDWHVRIRU5HIHUWRWKH*0/8OWUD
6RIWZDUHPDQXDOVIRUGHWDLOHGLQIRUPDWLRQ
7KHGHIDXOWVHWXSIRUWKHVHULDOSRUWVLV
• EDXG
• 1RSDULW\
• GDWDELWV
• VWRSELW
• +DQGVKDNLQJ21
• 56&SURWRFRO
Host Computer
6HULDO&RPSXWHU3SURYLGHVWKHFRPPXQLFDWLRQLQWHUIDFHEHWZHHQWKH
3'0DQGWKHSHUVRQDOFRPSXWHUXVHGIRUSURJUDPPLQJDQGFRQILJXUDWLRQ
7KLVLVDOVRWKHVHULDOSRUWWKDWPXVWEHXVHGIRU+RVWFRPPXQLFDWLRQV
Host computer and signal names
2QHRUPRUH8/75$3OXV3'0VPD\EHLQVWDOOHGRQDQ56PXOWLGURS
QHWZRUNRUDQ56GDLV\FKDLQQHWZRUN,IPRUHWKDQRQH8/75$3OXV

3'0LVLQWKHQHWZRUNHDFKPXVWKDYHDXQLTXHDGGUHVVVHOHFWHGRQWKH6:
GLSVZLWFK5HIHUWR ´1HWZRUNLQJµRQSDJH IRUPRUHLQIRUPDWLRQ

RS-232 RS-422
P6 Serial Port 2 1 No connection RXD+
2 RXD RXD-
3 TXD TXD-
4 No connection TXD+
5 Common Common
6 Shield Shield
)LJXUHVKRZVW\SLFDO56FRQQHFWLRQVEHWZHHQDSHUVRQDOFRPSXWHU
3&DQGWKH6HULDOSRUW3RQWKH3'07KHVHGLDJUDPVLOOXVWUDWHVWKH
FRQQHFWLRQVUHTXLUHGIRUSURJUDPPLQJDVLQJOH3'0
Figure 3.24
Personal Computer RS-232 connections
ULTRA Plus Personal Computer

Serial Port (P6) 9-pin Serial
Connector Connector
RXD- P6-2 2 RXD

TXD- P6-3 3 TXD
COM P6-5 5 GND
Shield P6-6
ULTRA Plus Personal Computer

Serial Port (P6) 25-pin Serial
Connector Connector
RXD- P6-2 2 TXD

TXD- P6-3 3 RXD
COM P6-5 7 GND
Shield P6-6
5HIHUWR ´1HWZRUNLQJµRQSDJH IRU56FRQQHFWLRQVEHWZHHQDQ

8/75$3OXV3'0DQGWKHKRVWFRPSXWHU

Operator Terminal
1398-HMI-002
7KHRSWLRQDO2SHUDWRU7HUPLQDOFRQQHFWVWRWKH3'0WKURXJK6HULDOSRUW
37KHFDEOHFRQQHFWVWRWKH&20FRQQHFWRURQWKHEDFNRIWKH2SHUDWRU
WHUPLQDO
P7 at Serial Port 1 on PDM
,QWKHGHIDXOWFRQILJXUDWLRQWKH3'0H[SHFWVDQ+0,;2SHUDWRU
7HUPLQDOWREHFRQQHFWHGVRLIDDQRWKHUWHUPLQDOLVXVHGWKH3'0PXVWEH
FRQILJXUHGSURSHUO\5HIHUWRWKH*0/8OWUD6RIWZDUHPDQXDOV
PDM Connector Pin Signal Name

RS-232 RS-422
P7, Serial Port 1 1 No connection RXD+
2 RXD RXD-
3 TXD TXD-
4 No connection TXD+
5 Common Common
COM1 connector on the back of the Operator Terminal
7KH&20FRQQHFWRULVDWZHQW\ILYHSLQPDOH'FRQQHFWRU7KH2SHUDWRU
7HUPLQDOPD\EHZLUHGXVLQJ56&IRUGLVWDQFHVXSWRPHWHUVIHHW
)RUORQJHUGLVWDQFHV56VKRXOGEHXVHG5HIHUWRWKH*0/8OWUD6RIWZDUH
PDQXDOVIRUGHWDLOVRQFRQILJXULQJ6HULDOSRUW3IRU56XVH
Operator Terminal Connector Pin Signal Name

COM1 1 Chassis ground
2 TXD (RS-232 transmit)
3 RXD (RS-232 receive)
14 TXD+ (RS-422 transmit)
15 TXD- (RS-422 transmit)
16 RXD+ (RS-422 receive)
17 RXD- (RS-422 receive)
7 Signal ground

Figure 3.25
Operator Terminal RS-232 connections
ULTRA Plus PDM Operator

P7 Terminal
Connector COM1
Connector
RXD- P7-2 2 TXD

TXD- P7-3 3 RXD
COM P7-5 7 GND
Shield P7-6
Figure 3.26
Operator Terminal RS-422 connections
ULTRA Plus PDM Operator

P7 Terminal
Connector COM1
Connector
RXD+ P7-1 14 TXD+
RXD- P7-2 15 TXD-
TXD- P7-3 17 RXD-
TXD+ P7-4 16 RXD+
COM P7-5 7 COM
Shield P7-6
1398-HMI-003 ULTRA Plus PDM (P7, Serial 1 Auxiliary)
7KH8/75$3OXV3'0FRQQHFWVWRWKH2SHUDWRU7HUPLQDO7KHFRQQHFWLRQ
FDQEHZLUHGXVLQJ56IRUGLVWDQFHVXSWRPHWHUVIHHW
Pin Signal names

RS-232 RS-422
1 No connection RxD+
2 RxD RxD-
3 TxD TxD-
4 No Connection TxD+
5 Common Common
6 Shield Shield
7 No connection
8 No connection
9 No connection

Operator Terminal (screw terminal on back) .
Pin and Signal names

Pin RS-232 Pin RS-422
1 Tx 6 TxA
2 RxD 7 TxB
3 RTS 8 RxA
4 CTS 9 RxB
5 Common 10 Common
Figure 3.27
ULTRA Plus PDM connects to the Operator Terminal
ULTRA Plus
Positioning Drive Module
(1398-PDM) 9101-2205-XXX
ULTRA Plus to 1398-HMI-003
Pin 1 ULTRA Plus Operator Terminal cable
2 RxD
3 TxD
4
5 COMMON
customer supplied
6 SHIELD jumper
7
8
JUMPER
9
ULTRA Plus 1 2 3 4 5 6 7 8 9 10
Operator Terminal
(1398-HMI-003)
TxB
Tx
Rx
RTS
CTS
TxA
RxA
RxB
COMMON
COMMON
IMPORTANT $MXPSHUFXVWRPHUVXSSOLHGPXVWEHLQVWDOOHGEHWZHHQ
SLQVDQGRIWKH8/75$3OXV2SHUDWRU7HUPLQDOIRU
56RSHUDWLRQ

Networking
ULTRA Plus PDM Controls
2QHRUPRUH3'0VPD\EHLQVWDOOHGRQDQ56PXOWLGURSQHWZRUNRUDQ
56GDLV\FKDLQQHWZRUN,IPRUHWKDQRQH3'0LVRQWKHQHWZRUNHDFK
3'0PXVWKDYHDXQLTXHDGGUHVVVHOHFWHGRQWKH6:',3VZLWFKSDQHO
ZKLFKLVLOOXVWUDWHGLQ)LJXUH
Figure 3.28
Dip Switch SW1
1 2 3 4 5 6 7 8
OFF
)LJXUHLOOXVWUDWHVWKHGLSVZLWFKVHWWLQJIRUDGGUHVV6ZLWFKHV6:
WKURXJK6:DUHXVHGWRVHOHFWWKHDGGUHVV6ZLWFK6:LVWKHOHDVW
VLJQLILFDQWELWDQG6:LVWKHPRVWVLJQLILFDQWELWRIWKHELQDU\DGGUHVV,I
WKHDGGUHVVLVVHWWRDQ\WKLQJRWKHUWKDQWKH3'0ZLOOQRWFRPPXQLFDWH
XQWLOLWVDGGUHVVKDVEHHQVHOHFWHGXVH$[LV6HOHFWXQGHUWKH&RPPXQLFDWLRQV
PHQX&KDQJLQJWKHDGGUHVVRQWKHGLSVZLWFKZLOOQRWEHUHFRJQL]HGE\WKH
3'0XQWLOD+DUG5HVHWLVSHUIRUPHGRUSRZHULVUHPRYHG
Figure 3.29
Dip Switch SW1 set for address 5 example
1 2 3 4 5 6 7 8
OFF
6HH )LJXUHRQSDJH VKRZLQJWKHVHWWLQJRI6:21IRUWKH
GDLV\FKDLQPRGH6ZLWFK6:LVXVHGWRVHOHFWWKHPRGHRIRSHUDWLRQRIWKH
VHULDOSRUW,I6:LV2))VHULDOSRUWIXQFWLRQVDVDQLQGHSHQGHQWVHULDO

SRUW,I6:LV21VHULDOSRUWDQGVHULDOSRUWDUHOLQNHGWRJHWKHU
GDLV\FKDLQHG$Q\GDWDWKDWLVUHFHLYHGRQRQHVHULDOSRUWLVDXWRPDWLFDOO\
WUDQVPLWWHGRXWWKHRWKHUVHULDOSRUW
Figure 3.30
Dip Switch SW1-7 set ON for daisy-chain mode example
1 2 3 4 5 6 7 8
OFF
6ZLWFKRQWKH',3VZLWFKLVQRWXVHG7KH3'0LVVKLSSHGZLWKDOOVZLWFKHV
VHWWR2))IRULQGHSHQGHQWRSHUDWLRQRIWKHVHULDOSRUWVDQGWKHDGGUHVVVHWWR
,IWKHUHLVRQO\RQH3'0LQWKHV\VWHPDOORIWKHVZLWFKHVRQ',3VZLWFK
6:VKRXOGEH2))

RS-422 Multi-Drop
6HH )LJXUHRQSDJH LOOXVWUDWLQJWKHFRQQHFWLRQVQHHGHGIRUPXOWLSOH

3'0VZKLFKFDQEHOLQNHGZLWKDQ56PXOWLGURSFRQILJXUDWLRQ
5HPHPEHUWRVHWDGLIIHUHQWDGGUHVVRQ',3VZLWFK6:IRUHDFK3'0RQWKH
56QHWZRUN7KHFDEOHXVHGIRUWKHVHFRQQHFWLRQVVKRXOGEH$:*
WZLVWHGSDLUZLWKDQRYHUDOOVKLHOGJURXQGHGDWRQHSRLQW
Figure 3.31
RS-422 Multi-drop connections
Host
TXD+
TXD-
RXD+
RXD-
COM
AXIS 1 AXIS 2 AXIS n

Port 2 Port 2 Port 2
TXD+ P6-4 TXD+ P6-4 TXD+ P6-4
TXD- P6-3 TXD- P6-3 TXD- P6-3
RXD+ P6-1 RXD+ P6-1 RXD+ P6-1
RXD- P6-2 RXD- P6-2 RXD- P6-2
COM P6-5 COM P6-5 COM P6-5
SW1-7 OFF SW1-7 OFF SW1-7 OFF
RS-232 Daisy-Chain
7KHWZRVHULDOSRUWVFDQDOVRRSHUDWHDVRQHSRUWZLWKWKHWUDQVPLWDQGUHFHLYH
OLQHVIHGWKURXJKIRUPXOWLSOHFRQQHFWLRQV6ZLWFKRQ',3VZLWFK6:
VHOHFWVWKHLQGHSHQGHQWRUGDLV\FKDLQRSHUDWLRQRIWKHWZRVHULDOSRUWV
5HPHPEHUWRVHWDGLIIHUHQWDGGUHVVIRUHDFK3'0LQWKHFKDLQ7KHFDEOH
XVHGIRUWKHVHFRQQHFWLRQVVKRXOGEH$:*WZLVWHGSDLUZLWKDQRYHUDOO
VKLHOGJURXQGHGDWRQHSRLQW
Figure 3.32
RS-232C Daisy-chain connections
Host
TXD
RXD
GND
TXD RXD GND TXD RXD GND TXD RXD GND TXD RXD GND TXD RXD GND TXD RXD GND
(3) (2) (5) (3) (2) (5) (3) (2) (5) (3) (2) (5) (3) (2) (5) (3) (2) (5)
P6 Port #2 P7 Port #1 P6 Port #2 P7 Port #1 P6 Port #2 P7 Port #1
SW1-7 ON SW1-7 ON SW1-7 OFF
AXIS #1 AXIS #2 AXIS #n

Operator Terminal (1398-HMI-002)
)LJXUHLOOXVWUDWHVDQDGGLWLRQDORSWLRQZKLFKLVWRFRQQHFWRQH2SHUDWRU
7HUPLQDOWRPXOWLSOH3'0V7KLVPHWKRGUHTXLUHV56FRQQHFWLRQVDV
VKRZQLQWKHIROORZLQJGUDZLQJ$3'0PD\EHVHOHFWHGIURPWKHWHUPLQDOE\
XVLQJWKH12NH\IROORZHGE\WKHQXPHULFNH\FRUUHVSRQGLQJWRWKH3'0
2SHUDWRU7HUPLQDODGGUHVVZKLFKPXVWEHVHWXSLQ*0/8OWUD6RIWZDUH
Figure 3.33
Operator Terminal RS-422 multi-drop connections
Operator
Terminal
COM1
Connector
TXD+ 14
TXD- 15
RXD+ 16
RXD- 17
COM 7
AXIS 1 AXIS 2 AXIS n

Port 1 Port 1 Port 1
TXD+ P7-4 TXD+ P7-4 TXD+ P7-4
TXD- P7-3 TXD- P7-3 TXD- P7-3
RXD+ P7-1 RXD+ P7-1 RXD+ P7-1
RXD- P7-2 RXD- P7-2 RXD- P7-2
COM P7-5 COM P7-5 COM P7-5

Operator Terminal (1398-HMI-003)
2QH2SHUDWRUFDQFRQQHFWWRPXOWLSOH8/75$6HULHV'ULYHV7KLV
PHWKRGUHTXLUHVFXVWRPHUVXSSOLHG56FDEOHFRQQHFWLRQV$SDUWLFXODU
8/75$3OXV3'0PD\EHVHOHFWHGIURPWKHWHUPLQDOE\XVLQJWKH´12µNH\
IROORZHGE\WKHQXPHULFNH\FRUUHVSRQGLQJWRWKH8/75$3OXV3'0DGGUHVV
5HIHUWRWKH*0/8OWUD6RIWZDUHPDQXDOIRUIXUWKHUGHWDLOV
Figure 3.34
ULTRA Plus PDM RS-422 multiple drop connections
ULTRA Plus
Positioning Drive Modules
RS-422 Multiple Drop Connections
customer supplied cabling
Pin 1 RxD +
P7 2 RxD -
1 3 TxD -
AUXILIARY
6
SERIAL 1
4 TxD +
9 5 COMMON
5 6 SHIELD
7 Not used
8 Not used
9 Not used
Pin 1 RxD +
P7 2 RxD -
1 3 TxD -
AUXILIARY
6
SERIAL 1
4 TxD +
9 5 COMMON
5 6 SHIELD
7 Not used
8 Not used
9 Not used
Pin 1 RxD +
P7 2 RxD -
1 3 TxD -
AUXILIARY
6
SERIAL 1
4 TxD +
9 5 COMMON
5 6 SHIELD
Terminating
Resistor
7 Not used 1K
8 Not used
9 Not used
1 2 3 4 5 6 7 8 9 10
ULTRA Plus
Operator Terminal
Tx
Rx
CTS
TxA
TxB
RxA
RxB
RTS
COMMON
COMMON
IMPORTANT 7KHN:ZDWWWHUPLQDWLQJUHVLVWRULVXVHGIRUQRLVH
VXSSUHVVLRQ

Cables 5HIHUWR0RWRU&RQQHFWRUVRQSDJH%IRURUGHULQJLQIRUPDWLRQDERXWWKHVH
DQGRWKHUFDEOHV
Figure 3.35
ULTRA Plus PDM P7 to Operator Terminal (P/N 9101-2205)
OPERATOR
POSITIONING TERMINAL
MODULE SERIAL PORT
CONNECTOR CONNECTOR
P7
25 PIN FEMALE
9 PIN MALE
POSITIONING
MODULE OPERATOR TERMINAL
CONNECTOR SERIAL PORT CONNECTOR
P7
Figure 3.36
ULTRA Plus PDM P6 to PC Serial Port (9 pin) (P/N 9101-2024)
POSITIONING PC SERIAL PORT

MODULE CONNECTOR
CONNECTOR
P6 9 PIN FEMALE
9 PIN MALE
POSITIONING
MODULE
CONNECTOR PC SERIAL PORT
P6 CONNECTOR

Figure 3.37
ULTRA Plus PDM P4 or P5 to Auxiliary Encoder (Unterminated) (P/N 9101-2031)
POSITIONING
MODULE INDEXER/
CONNECTOR ENCODER
P4 CONNECTIONS
15 PIN MALE
HIGH-DENSITY
POSITIONING INDEXER
MODULE ENCODER
CONNECTOR CONNECTIONS
P4
STEP+ BLACK
P4-11 STEP+
STEP- ORANGE
P4-12 STEP-
DIR+ BROWN
P4-8 DIR+
DIR- BLACK
P4-13 DIR-
+5V WHITE
P4-14 +5V
COM BLACK
P4-7 COM
A+ GREEN
P4-1 A+
A- BLACK
P4-2 A-
B+ BLUE
P4-3 B+
B- BLACK
P4-4 B-
I+ YELLOW
P4-5 I+
I- BLACK
P4-10 I-
+5V RED
P4-9 +5V
COM BLACK
P4-6 COM
SHIELD P4-15

Figure 3.38
ULTRA Plus PDM P4 to P4, 2 foot (P/N 9101-2127)
MASTER AXIS SLAVE AXIS

CONNECTOR CONNECTOR
P4 P4
15 PIN MALE 15 PIN MALE

HIGH-DENSITY HIGH-DENSITY
MASTER AXIS SLAVE AXIS

CONNECTOR CONNECTOR
P4 P4
A+ A+
A- A-
B+ B+
B- B-
I+ I+
I- I-
SHIELD
Figure 3.39
ULTRA Plus PDM P5 to H, or F-Series Motor Encoder (P/N 9101-2027)
15 PIN MALE
HIGH DENSITY

Figure 3.40
ULTRA Plus PDM P5 to N-Series Motor Encoder (9101-1474)
™0.395
™1.16
1.96
E
(E=feet) 2
3.31 12.0±0.5
2.50
START OF BEND RADIUS
45˚
0.65
B A M
C P N L
D R V U K
E S T J
F G H
0.12 THREAD
PROTRUSION
MOLDING ADAPTER, ALUMINUM, MARKED WITH ELECTRO-CRAFT

BLACK COBALT PLATED P/N & REV, MANUFACTURERS 1.34
P/N & REV, AND DATE CODE
CONNECTOR, ITT CANNON
#KPSE05E14-19S-A71
4-40 RETRACTABLE
MACHINED THUMBSCREW
1.32
WIRING DIAGRAM
GREEN
A 1
BLACK
B 2
PIN 1
PIN 5
BLUE
C 3
BLACK
D 4
YELLOW
E 5
BLACK
F 10
B A M BROWN
C P N L
H 13
D R V U K
BLACK
E S T J
RED
F G H J 9
BLACK
M 6
WHITE
K 14
PIN 6
PIN 11
PIN 10
PIN 15
BLACK
L 7
ORANGE
R 12
BLACK
S 11
KPSE05E14-19S-A71 15 POSITION HIGH DENSITY 45˚ 'D'-SUB PLUG
CONNECTOR N N/C N/C 8 WITH MALE PIN CONTACTS
(FACE VIEW) N/C (FACE VIEW)
P N/C 15
G N/C
T N/C
U N/C
V N/C DRAIN
DENOTES TWISTED PAIR
CONNECTOR BACKSHELL SHIELDED 360˚ (BOTH ENDS)

Chapter 4
Apply Power for the First Time
2XWOLQHGEHORZDUHWKHVWHSVWKDWVKRXOGEHIROORZHGZKHQDSSO\LQJSRZHUWR
WKHHTXLSPHQWIRUWKHILUVWWLPH7KLVSURFHGXUHFRYHUVWKH8/75$3OXV3'0
0RWRUDQG2SHUDWRU7HUPLQDO5HIHUWRDQGEHFRPHIDPLOLDUZLWKWKH
IROORZLQJSXEOLFDWLRQVEHIRUHLQVWDOOLQJDQGXVLQJ*0/8OWUD6RIWZDUH
• *0/8OWUD*HWWLQJ6WDUWHG0DQXDO
• *0/8OWUD8VHU0DQXDODQG
• *0/8OWUD5HIHUHQFH0DQXDO
7KHVHVWDUWXSSURFHGXUHVDVVXPHWKDWWKHHTXLSPHQWLVSURSHUO\PRXQWHG
DQGZLUHGEXWSRZHUKDVQRWEHHQDSSOLHG7KHLQVWUXFWLRQVDOVRDVVXPHWKDWD
3&ZLWK*0/8OWUDORDGHGLQWRWKHGHIDXOWGLUHFWRU\F?XOWLVFRQQHFWHGWR
WKHXQLW
<RXFDQVWDUW*0/8OWUD6RIWZDUHE\GRXEOHFOLFNLQJRQWKH*0/8OWUD
6RIWZDUHLFRQ
1398-PDM-10, 20, 30, 75, and

150B
+LJKYROWDJHLVSUHVHQWRQWKHWHUPLQDOVRIWKH8/75$
ATTENTION
3OXV3'0
! $IWHUUHPRYLQJSRZHUFKHFNIRUUHPDLQLQJYROWDJHEHIRUH
PDNLQJRUUHPRYLQJDQ\FRQQHFWLRQ

4-2 Apply Power for the First Time
3ULRUWRDSSO\LQJSRZHUWRWKH8/75$3OXV3'0HQVXUHWKDWWKHVXSSO\
YROWDJHLVLQWKHSURSHUUDQJH²9$&
:LWKSRZHURIIHQVXUHWKDWSURSHUFRQQHFWLRQVDUHPDGHDVOLVWHGEHORZ
ULTRA Plus PDM Phasing of Phasing Connections

Power Source
1398-PDM-10, 20, and 30 Single Arbitrary between L1 and L2/N
1398-PDM-075 Single Arbitrary between L1 and L2/N
1398-PDM-075 and 150 Three Arbitrary between L1, L2/N and L3
,IDX[LOLDU\SRZHULVXVHGHQVXUHSURSHUFRQQHFWLRQVDUHPDGHWRWHUPLQDOV/
$8;DQG/1$8;
:LWKLQSXWSRZHUVWLOORIIGLVFRQQHFWPRWRUOHDGVIURP8/75$3OXV
3'0WHUPLQDOV56DQG79HULI\ZLWKDQRKPPHWHUWKDWWKHUHVLVWDQFH
EHWZHHQ8/75$3OXV3'0WHUPLQDOV5WR*1'6WR*1'DQG7WR
*1'LVDERYHNRKPV,IWKHUHVLVWDQFHLVDFFHSWDEOHUHFRQQHFWWKH
PRWRUOHDGVWRWKH8/75$3OXV3'0WHUPLQDOVPDUNHG56DQG7
&RQQHFWDOOLQWHUIDFHFDEOHV3²3WRWKH3'0
3HUIRUPWKHLQLWLDOSRZHUXSZLWKWKHPRWRUVKDIW
ATTENTION
GLVFRQQHFWHGIURPDORDGDQGWKHVKDIWNH\UHPRYHG
,PSURSHUZLULQJRUXQGLVFRYHUHGVKLSSLQJGDPDJHFRXOG
! UHVXOWLQXQGHVLUHGPRWRUPRWLRQ%HSUHSDUHGWRUHPRYH
SRZHULIH[FHVVLYHPRWLRQRFFXUV
0DNHVXUHWKDWWKHPRWRULVGLVFRQQHFWHGIURPWKHORDGEHIRUHDSSO\LQJ
SRZHU7KLVSUHYHQWVPHFKDQLFDOGDPDJHVKRXOGDIDXOWRFFXU
$SSO\LQSXWSRZHUDQGFKHFNWKH/('V
D 7KHJUHHQ'&%86/('VKRXOGWXUQRQWRLQGLFDWHSRZHULVDSSOLHG
E 7KHELFRORU67$786/('VKRXOGWXUQJUHHQ
IMPORTANT 7KH3'0LVLQDIDXOWFRQGLWLRQLIWKH67$786/('LV
UHG&RQWLQXHZLWKWKHIROORZLQJLQVWUXFWLRQVDQGSHUIRUP
6WHSWRFOHDUDQ\IDXOWV
6HOHFW2QOLQHIURPWKH'LDJUDPPHQXWRGLVSOD\WKH2QOLQH0DQDJHU
ZLQGRZ
,QLWLDOL]HDQGORDGWKHDSSURSULDWH3HUVRQDOLW\0RGXOHILOHVIRUWKH3'0

Apply Power for the First Time 4-3
DQGPRWRUFRPELQDWLRQDVIROORZV
D 6HOHFW(QWHU6HWXSVIURPWKH2QOLQH0DQDJHUZLQGRZWRGLVSOD\WKH$[LV
6HWXSVGLDORJ
E 6HOHFW,QLWLDOL]H30DQG([HFXWHWRGLVSOD\WKH,QLWLDOL]H30GLDORJ
F 6HOHFWWKHDSSURSULDWH8/75$3OXV3'0W\SHIURPWKH'ULYHOLVW
G 6HOHFWWKHDSSURSULDWHPRWRUW\SHIURPWKH0RWRUOLVW
H 9HULI\WKH(QFRGHUOLVWGLVSOD\VWKHFRUUHFWOLQHFRXQWIRUWKHPRWRU
,IQHFHVVDU\VHOHFWWKHSURSHUHQFRGHUUHVROXWLRQYDOXH
I 6HOHFW8SGDWH30WRLQLWLDOL]HWKH3HUVRQDOLW\0RGXOHZLWKWKHVSHFLILHG
GULYHDQGPRWRUSDUDPHWHUV
J $IWHUWKH3HUVRQDOLW\0RGXOHLVSURSHUO\LQLWLDOL]HGVHOHFW<HVWRUHVHWWKH
3'0DQGH[LWWKH8SGDWH30GLDORJ
K 6HOHFW&DQFHOWRH[LWWKH$[LV6HWXSVGLDORJ
,IWKH67$786/('LVUHGSHUIRUPWKHIROORZLQJVWHSV
D 6HOHFW(QWHU6HWXSVWRDFFHVVWKH$[LV6HWXSVGLDORJ
E 6HOHFW,26WDWXV0RQLWRUDQGSUHVV([HFXWHWRYLHZWKH,26WDWXV
0RQLWRUZKLFKGLVSOD\VWKHIDXOW
F &RUUHFWDQ\IDXOWFRQGLWLRQV5HIHUWR (UURU0HVVDJHVDQG(UURU2XWSXW
RQSDJH IRUGLDJQRVWLFDVVLVWDQFH
G &ORVHWKH,26WDWXV0RQLWRU
H 6HOHFW&DQFHOWRH[LWWKH$[LV6HWXSVGLDORJ
I 'RXEOHFOLFNWKH5HVHW'ULYHEORFNLQWKH2QOLQH0DQDJHUFRPPDQG
ZLQGRZWRUHVHWWKH8/75$3OXV3'0
J 9HULI\WKH67$786/('LVJUHHQ
,IWKH67$786/('LVUHGUHWXUQWR6WHSD
9HULI\WKHIDQLVRSHUDWLQJE\FKHFNLQJWKDWDLULVEORZLQJIURPWKHWRSRI
WKH8/75$3OXV3'0
'LVDEOHWKH8/75$3OXV3'0E\SHUIRUPLQJRQHRIWKHIROORZLQJ
D 7XUQWKH(QDEOHLQSXW2))RU
E 'RXEOHFOLFNRQWKH)HHGEDFNEORFNWRDFFHVVWKH)HHGEDFNGLDORJ
6HW6WDWH 2))DQGVHOHFW([HFXWH6HOHFW&DQFHOWRH[LWWKHGLDORJ
6HOHFW(QWHU6HWXSVWRDFFHVVWKH$[LV6HWXSVGLDORJIURPWKH2QOLQH
0DQDJHUZLQGRZ
9HULI\WKHHQFRGHULQFUHPHQWVDQGGHFUHPHQWVSURSHUO\DVIROORZV
D 6HOHFW(QFRGHU7HVWDQG([HFXWHIURPWKH$[LV6HWXSVGLDORJWRGLVSOD\
WKH(QFRGHU7HVWGLDORJ
E 6HOHFW=HUR&RXQWVWRUHVHWWKH&RXQWYDOXHWR
F 5RWDWHWKHPRWRUVKDIWFORFNZLVHDQGYHULI\WKDWWKH&RXQWYDOXHLQFUHDVHV
G 5RWDWHWKHPRWRUVKDIWFRXQWHUFORFNZLVHDQGYHULI\WKDWWKH&RXQWYDOXH
GHFUHDVHV

H 6HOHFW&DQFHOWRH[LWWKH(QFRGHUGLDORJ
6HOHFW&ORVHWRH[LWWKH$[LV6HWXSVZLQGRZ
(QDEOHWKH8/75$3OXV3'0E\SHUIRUPLQJRQHRIWKHIROORZLQJ
• 7XUQWKH(QDEOHLQSXW21RU
• 'RXEOHFOLFNRQWKH)HHGEDFNEORFNVHW6WDWH 21DQGVHOHFW([HFXWH
6HOHFW&DQFHOWRH[LWWKHGLDORJ
9HULI\WKHPRWRULVVWDWLRQDU\DQGKDVKROGLQJWRUTXH
&RPPDQGPRWLRQDQGYHULI\WKHPRWRUURWDWHVLQWKHSURSHUGLUHFWLRQE\
SHUIRUPLQJRQHRIWKHIROORZLQJVWHSV
• (QDEOHWKHMRJLQSXWVRU
• 'RXEOHFOLFNRQWKH-RJ$[LVEORFNLQWKH2QOLQH0DQDJHUZLQGRZWRDFFHVV
WKH-RJ$[LVGLDORJ6HOHFW([HFXWHIURPWKH-RJ$[LVGLDORJWRURWDWHWKH
PRWRU7KHGLUHFWLRQDQGVSHHGRIURWDWLRQPD\EHFKDQJHGLQWKH-RJ$[LV
EORFN6HOHFW&DQFHOWRH[LWWKH-RJ$[LVGLDORJ
• 6HOHFW(6723LQWKH2QOLQH0DQDJHUFRPPDQGZLQGRZWRKDOWPRWLRQ
VWRSSURJUDPH[HFXWLRQDQGVHW)HHGEDFN 2))
• 5HPRYHLQSXWSRZHU7KH/('VVKRXOGWXUQRIIZLWKLQWHQVHFRQGV
1398-PDM-25, 50, 100, and 6WDUWXSRIDQ8/75$3OXV3'0V\VWHPLQYROYHVVWDUWLQJD3RZHU6XSSO\

0RGXOH360DQGDWOHDVWRQH8/75$3OXV3'07KH360LVFKHFNHGILUVW
150 DQGWKHQWKH3'0V3HUIRUPWKHVWDUWXSSURFHGXUHRQDOOWKH3'0VDWWDFKHG
WRWKH360DWWKHVDPHWLPH
'DQJHURXVYROWDJHVPD\H[LVWDIWHUSRZHULVUHPRYHG
ATTENTION
&KHFN'&EXVYROWDJHHDFKWLPHSRZHULVUHPRYHGEHIRUH
ZRUNLQJRQWKH3RZHU6XSSO\0RGXOHRU8/75$3OXV
! 3'0

Power Supply Module
3ULRUWRDSSO\LQJSRZHUWRWKH360HQVXUHWKDWWKHVXSSO\YROWDJHLVLQ
WKHSURSHUUDQJH9$&SKDVH
:LWKSRZHURIIUHPRYHWKH360FRYHUDQGHQVXUHSURSHUFRQQHFWLRQV
KDYHEHHQPDGHWRWHUPLQDOV//DQG/DQGWKDWDSURSHUJURXQGLV
FRQQHFWHG3KDVLQJRIWKHLQSXWSRZHUFRQQHFWLRQVLVDUELWUDU\
'LVFRQQHFWDOOZLUHVIURPWKH360'&EXVWHUPLQDOSRVWVPDUNHGDQG
,QVWDOOWKH360FRYHUWKHQWXUQRQLQSXWSRZHU9HULI\WKDW'&EXV
YROWDJHLVLQWKHSURSHUUDQJH9'&QRPLQDOZLWK9$&LQSXW
&KHFNWKDWWKHJUHHQ3605($'</('LVRQDQGWKDWDOOWKUHHUHG/('V
DUHRIIDQGWKDWWKH360IDQVDUHRSHUDWLQJ
'LVFRQQHFWLQSXWSRZHUDQGFKHFNWKDWWKHJUHHQ/('JRHVRIIDQGWKH
'&EXVYROWDJHIDOOVWROHVVWKDQ9'&ZLWKLQRQHVHFRQG
5HPRYH360FRYHU5HFRQQHFWWKH'&EXVZLUHVWRWKH360WHUPLQDOV
PDUNHGDQGHQVXULQJWKDWSURSHUSRODULW\LVPDLQWDLQHG,QVWDOOWKH
360FRYHU
'RQRWVXEVWLWXWHWKH'&EXVZLUHVSURYLGHGZLWKZLUHVRI
ATTENTION
DGLIIHUHQWOHQJWKRUJDXJH
)DLOXUHWRREVHUYHWKLVSUHFDXWLRQPD\UHVXOWLQGDPDJHWR
! RUGHVWUXFWLRQRIWKH8/75$3OXV3'0

Start-up Procedure for PDM
(QVXUHLQSXWSRZHUWRWKH360LVRII
'LVFRQQHFWDOOLQWHUIDFHFDEOHV33IURPHDFK8/75$3OXV3'0
:LWKLQSXWSRZHUVWLOORIIGLVFRQQHFWPRWRUOHDGVIURP8/75$3OXV
3'0WHUPLQDOV56DQG79HULI\ZLWKDQRKPPHWHUWKDWWKHUHVLVWDQFH
EHWZHHQ8/75$3OXV3'0WHUPLQDOV5WR*1'6WR*1'DQG7WR
*1'LVDERYHNRKPV,IWKHUHVLVWDQFHLVDFFHSWDEOHUHFRQQHFWWKH
PRWRUOHDGVWRWKH8/75$3OXV3'0WHUPLQDOVPDUNHG56DQG7
9HULI\WKDWWKH'&EXVZLUHVDUHFRQQHFWHGWRHDFK8/75$3OXV3'0
ZLWKSURSHUSRODULW\
&RQQHFWDOOLQWHUIDFHFDEOHV3²3WRWKH8/75$3OXV3'0V
ATTENTION
0DNHVXUHWKDWWKHPRWRULVGLVFRQQHFWHGIURPWKHORDGEHIRUHDSSO\LQJ
SRZHU7KLVSUHYHQWVPHFKDQLFDOGDPDJHVKRXOGDIDXOWRFFXU
$SSO\LQSXWSRZHUDQGFKHFNWKH/('V
D 7KHJUHHQ'&%86/('VKRXOGWXUQRQWRLQGLFDWHSRZHULVDSSOLHG
E 7KHELFRORU67$786/('VKRXOGWXUQJUHHQ
7KH8/75$3OXV3'0LVLQDIDXOWFRQGLWLRQLIWKH67$786/('LV
UHG&RQWLQXHZLWKWKHIROORZLQJLQVWUXFWLRQVDQGSHUIRUP6WHSWR
FOHDUDQ\IDXOWV
6HOHFW2QOLQHIURPWKH'LDJUDPPHQXWRGLVSOD\WKH2QOLQH0DQDJHU
ZLQGRZ
,QLWLDOL]HDQGORDGWKHDSSURSULDWHWKH3HUVRQDOLW\0RGXOHILOHVIRUWKH
8/75$3OXV3'0DQGPRWRUFRPELQDWLRQDVIROORZV
D 6HOHFW(QWHU6HWXSVIURPWKH2QOLQH0DQDJHUZLQGRZWRGLVSOD\WKH$[LV
6HWXSVGLDORJ
E 6HOHFW,QLWLDOL]H30DQG([HFXWHWRGLVSOD\WKH,QLWLDOL]H30GLDORJ
F 6HOHFWWKHDSSURSULDWH8/75$3OXV3'0IURPWKH'ULYHOLVW
G 6HOHFWWKHDSSURSULDWHPRWRUW\SHIURPWKH0RWRUOLVW
H 9HULI\WKH(QFRGHUOLVWGLVSOD\VWKHFRUUHFWOLQHFRXQWIRUWKHPRWRU

,IQHFHVVDU\VHOHFWWKHSURSHUHQFRGHUUHVROXWLRQYDOXH
I 6HOHFW8SGDWH30WRLQLWLDOL]HWKH3HUVRQDOLW\0RGXOHZLWKWKHVSHFLILHG
GULYHDQGPRWRUSDUDPHWHUV
J $IWHUWKH3HUVRQDOLW\0RGXOHLVSURSHUO\LQLWLDOL]HGVHOHFW<HVWRUHVHWWKH
8/75$3OXV3'0DQGH[LWWKH8SGDWH30GLDORJ
K 6HOHFW&DQFHOWRH[LWWKH$[LV6HWXSVGLDORJ
,IWKH67$786/('LVUHGSHUIRUPWKHIROORZLQJVWHSV
D 6HOHFW(QWHU6HWXSVWRDFFHVVWKH$[LV6HWXSVGLDORJ
E 6HOHFW,26WDWXV0RQLWRUDQGSUHVV([HFXWHWRYLHZWKH,26WDWXV
0RQLWRUZKLFKGLVSOD\VWKHIDXOW
F &RUUHFWDQ\IDXOWFRQGLWLRQV5HIHUWR (UURU0HVVDJHVDQG(UURU2XWSXW
RQSDJH IRUGLDJQRVWLFDVVLVWDQFH
G &ORVHWKH,26WDWXV0RQLWRU
H 6HOHFW&DQFHOWRH[LWWKH$[LV6HWXSVGLDORJ
I 'RXEOHFOLFNWKH5HVHW'ULYHEORFNLQWKH2QOLQH0DQDJHUFRPPDQG
ZLQGRZWRUHVHWWKH8/75$3OXV
J 9HULI\WKH67$786/('LVJUHHQ
,IWKH67$786/('LVUHGUHWXUQWR6WHSD
9HULI\WKHIDQLVRSHUDWLQJE\FKHFNLQJWKDWDLULVEORZLQJIURPWKHWRSRI
WKH8/75$3OXV3'0
'LVDEOHWKH8/75$3OXV3'0E\SHUIRUPLQJRQHRIWKHIROORZLQJ
• 7XUQWKH(QDEOHLQSXW2))RU
• 'RXEOHFOLFNRQWKH)HHGEDFNEORFNWRDFFHVVWKH)HHGEDFNGLDORJ
6HOHFW(QWHU6HWXSVWRDFFHVVWKH$[LV6HWXSVGLDORJIURPWKH2QOLQH
0DQDJHUZLQGRZ
9HULI\WKHHQFRGHULQFUHPHQWVDQGGHFUHPHQWVSURSHUO\DVIROORZV
D 6HOHFW(QFRGHU7HVWDQG([HFXWHIURPWKH$[LV6HWXSVGLDORJWRGLVSOD\
WKH(QFRGHU7HVWGLDORJ
E 6HOHFW=HUR&RXQWVWRUHVHWWKH&RXQWYDOXHWR
F 5RWDWHWKHPRWRUVKDIWFORFNZLVHDQGYHULI\WKDWWKH&RXQWYDOXHLQFUHDVHV
G 5RWDWHWKHPRWRUVKDIWFRXQWHUFORFNZLVHDQGYHULI\WKDWWKH&RXQWYDOXH
GHFUHDVHV
H 6HOHFW&DQFHOWRH[LWWKH(QFRGHUGLDORJ
(QDEOHWKH8/75$3OXV3'0E\SHUIRUPLQJRQHRIWKHIROORZLQJ
• 7XUQWKH(QDEOHLQSXW21RU
• 'RXEOHFOLFNRQWKH)HHGEDFNEORFNVHW6WDWH 21DQGVHOHFW([HFXWH

6HOHFW&DQFHOWRH[LWWKHGLDORJ
9HULI\WKHPRWRULVVWDWLRQDU\DQGKDVKROGLQJWRUTXH
&RPPDQGPRWLRQDQGYHULI\WKHPRWRUURWDWHVLQWKHSURSHUGLUHFWLRQE\
PRWRU7KHGLUHFWLRQDQGVSHHGRIURWDWLRQPD\EHFKDQJHGLQWKH-RJ$[LV
EORFN6HOHFW&DQFHOWRH[LWWKH-RJ$[LVGLDORJ
6HOHFW(6723LQWKH2QOLQH0DQDJHUFRPPDQGZLQGRZWRKDOWPRWLRQ
5HPRYHLQSXWSRZHU7KH/('VVKRXOGWXUQRIIZLWKLQWHQVHFRQGV
5HSHDW6WHSWKURXJK6WHSIRUHDFKDGGLWLRQDO8/75$3OXV3'0
Motors
0RWRUSRZHUFRQQHFWRUVDUHIRUDVVHPEO\SXUSRVHVRQO\
ATTENTION
7KH\VKRXOGQRWEHFRQQHFWHGRUGLVFRQQHFWHGZKLOH
SRZHULVDSSOLHGWRWKHGULYH
!
ATTENTION
5RWDWLQJPRWRUVKDIWVFDQFDXVHH[WHQVLYHGDPDJHDQG
ATTENTION
LQMXU\
0RWRUVPXVWEHSURSHUO\JXDUGHGGXULQJWHVWLQJDQGLQWKH
! ILQDOLQVWDOODWLRQ

'LVFRQQHFWPRWRUVIURPWKHORDGEHIRUHDSSO\LQJSRZHU7KLVSUHYHQWV
PHFKDQLFDOGDPDJHVKRXOGDIDXOWRFFXU,IWKLVLVQRWSRVVLEOHWDNH
DGHTXDWHSUHFDXWLRQVLQFDVHRIDIDXOW
'LVFRQQHFWDOOLQWHUIDFHFDEOHVIURPWKH8/75$3OXV3'0DQGUHPRYH
WKHLWVFRYHU3'0RURQO\&RQQHFWWKHPRWRU
ZLUHV567DQGJURXQGWRWKHSURSHU8/75$3OXV3'0,QVWDOODOO
8/75$3OXV3'0FRYHUVDQGFRQQHFWDOOLQWHUIDFHFDEOHVWRWKH8/75$
3OXV3'0
'LVDEOHHDFK8/75$3OXV3'0E\SHUIRUPLQJRQHRIWKHIROORZLQJ
• 7XUQWKH(QDEOHLQSXW2))RU
• 'RXEOHFOLFNRQWKH)HHGEDFNEORFNWRDFFHVVWKH)HHGEDFNGLDORJ
5HDSSO\LQSXWSRZHUDQGFKHFNIRUSURSHUSRZHUXSGLDJQRVWLFVDVVKRZQ
E\WKH67$786/('RQHDFKXQLW
/LPLWWKHFXUUHQWWRWKHPRWRUDVIROORZV
D 'RXEOHFOLFNWKH(TXDWLRQEORFNLQWKH2QOLQH0DQDJHUFRPPDQG
ZLQGRZWRDFFHVVXVHUDQGV\VWHPYDULDEOHVDQGWKHJHQHUDOSXUSRVH
RXWSXWV
E 6HOHFW6\VWHP9DULDEOH)ODJVIURPWKHPHQX
F &KHFN&XUUHQW/LPLWLQWKHVFUROOOLVWDQGHQWHUDFXUUHQWOLPLWYDOXHWKDWLV
ORZRISHDNFXUUHQWLVDORZYDOXH
G 6HOHFW([HFXWHWRPDNHWKHVHOHFWLRQ
H 6HOHFW&DQFHOWRH[LWWKH(TXDWLRQGLDORJ
&RPPDQGPRWLRQDQGYHULI\HDFKPRWRUURWDWHVLQWKHSURSHUGLUHFWLRQE\
PRWRU6HOHFW&DQFHOWRH[LWWKH-RJ$[LVGLDORJ
6HOHFW(6723LQWKH2QOLQH0DQDJHUFRPPDQGZLQGRZWRKDOWPRWLRQ
,IWKHPRWRUGRHVQRWWXUQFORFNZLVHWKHSRZHUZLUHVDQGHQFRGHUZLUHV
VKRXOGEHLQVSHFWHGWRHQVXUHSURSHUFRQQHFWLRQWRWKH8/75$3OXV
3'0
'LVDEOHDOO8/75$3OXV3'0VDQGWXUQ2))LQSXWSRZHU0HDVXUHWKH
'&EXVYROWDJHWREHVXUHWKDWLWLVEHORZ9'&

1RZWKDWWKHV\VWHPLQVWDOODWLRQLVYHULILHGUHWXUQWKH,OLPLWSDUDPHWHUWR
DYDOXHDSSURSULDWHIRUWKHDSSOLFDWLRQ

Operator Terminal 7KH2SHUDWRU7HUPLQDOUHTXLUHVQRVSHFLDOVWDUWXSSURFHGXUH5HIHU

WR 2SHUDWRU7HUPLQDOVRQSDJH IRUZLULQJLQVWUXFWLRQV7KHRSHUDWRU
WHUPLQDOGLVSOD\/('VKRXOGEHOLW1RPHVVDJHZLOODSSHDURQWKHVFUHHQ
XQOHVVWKHRSHUDWRUWHUPLQDOLVFRQQHFWHGWRWKH8/75$3OXV3'0VHULDOSRUW
DQGWKH8/75$3OXV3'0VHQGVDPHVVDJHWRWKHRSHUDWRUWHUPLQDO:KHQ
WKH2SHUDWRU7HUPLQDOLVFRQQHFWHGWRD8/75$3OXV3'0SUHVVWKH6WDWXV
NH\WRYHULI\WKH2SHUDWRU7HUPLQDOLVFRPPXQLFDWLQJSURSHUO\
Personality Module 5HIHUWRWKH*0/8OWUD8VHU0DQXDOVIRUVDYLQJWKH3HUVRQDOLW\GDWDLQD

FRPSXWHUILOHDQGORDGLQJLWLQWRWKH8/75$3OXVFRQWUROOHUXVLQJWKHXSORDG
RSWLRQVLQWKH*0/2QOLQH0DQDJHU


Chapter 5
Check for Problems in the System
7KH8/75$3OXV3'0V\VWHPLVGHVLJQHGWRSURYLGHGLDJQRVWLFDLGVWKDWKHOS
LVRODWHDQ\SUREOHPVWRD´PRGXOHµLQWKHV\VWHP$PRGXOHPD\EHD8/75$
3OXV3'03RZHU6XSSO\3'0DQG3HUVRQDOLW\
0RGXOHPRWRUDQGHQFRGHUFDEOHVRUWKHPHFKDQLFDOV\VWHP7KH8/75$
3OXV3'0FLUFXLWU\LVGHVLJQHGWRSUHYHQWSUREOHPVLQDQ\RQHPRGXOHIURP
GDPDJLQJDQ\RWKHUPRGXOH7KHPRGXODUSDFNDJHDOORZVYHU\VLPSOHILHOG
UHSODFHPHQW,ID*0/LVUHSODFHGWKHSHUVRQDOLW\PRGXOHLVWUDQVIHUUHGWRWKH
UHSODFHPHQWPRGXOHDQGDOOSURJUDPVSDUDPHWHUVDQGRWKHULQIRUPDWLRQDUH
PRYHGWRWKH3'07KH3HUVRQDOLW\0RGXOHV\VWHPILUPZDUHDQGIXVHVDUH
WKHRQO\ILHOGUHSODFHDEOHLWHPVLQWKHV\VWHP
0DLQWHQDQFHRIWKH8/75$3OXV3'0V\VWHPLVYLUWXDOO\XQQHFHVVDU\7KH
SULPDU\FRQVLGHUDWLRQLVWRHQVXUHWKDWWKHIDQVDUHRSHUDWLRQDODQG8/75$
3OXV3'0LVRSHUDWHGLQDSURSHUO\VL]HGDQGYHQWLODWHGHQFORVXUHZLWKSURSHU
IXVLQJ
Light Emitting Diodes (LED) 7KH*0/DQG360HDFKKDYH/('VRQWKHIURQW7KHVH/('VSURYLGHDILUVW

OHYHORIGLDJQRVWLFV
Positioning Drive Module STATUS LED
$OO*0/VKDYHD67$786/('RQWKHWRSIURQWULJKWKDQGFRUQHU7KLV
/('PD\DSSHDUJUHHQUHGRURSDTXH2))
Green
7KH/('RQWKH8/75$3OXV3'0LQGLFDWHVWKHSUHVHQWVWDWXVRIWKH*0/
'XULQJQRUPDORSHUDWLRQZKHQQRIDXOWFRQGLWLRQVH[LVWWKLV/('LVJUHHQ
7KLV/('WXUQVUHGWRLQGLFDWHWKDWWKH*0/KDVGHWHFWHGDIDXOW
Red
,IDIDXOWLVGHWHFWHGWKH/('WXUQLQJUHGLQGLFDWHVWKHUHLVDIDXOWLQWKH
V\VWHP7KLVGRHVQRWLQGLFDWHWKDWWKH*0/VKRXOGEHUHSODFHGLPPHGLDWHO\
PDQ\IDXOWFRQGLWLRQVDUHFDXVHGE\SUREOHPVH[WHUQDOWRWKH*0/7KH
VSHFLILFIDXOWLQIRUPDWLRQLVDYDLODEOHIURPWKHVHULDOSRUWV)DXOWPHVVDJHVDUH

5-2 Check for Problems in the System
GLVSOD\HGRQWKHRSHUDWRUWHUPLQDOVFUHHQLIWKHRSHUDWRUWHUPLQDOLVSUHVHQW
7KH/('ODEHOHG6<6)$8/7RQWKHRSHUDWRUWHUPLQDODOVRZLOOWXUQRQUHG
WRLQGLFDWHWKDWDIDXOWKDVRFFXUUHG
Not lit (OFF)
:KHQSRZHUWRWKH*0/LVRIIWKH67$786/('LVQRWOLW,IWKH*0/'&
%86/('LV21DQGWKH67$786/('LV2))WKHUHPD\EHDIDLOXUHLQWKH
ORJLFSRZHUVXSSO\
DC Bus Power (1398-PDM-25, 50, 100, and 150)
$ERYH7HUPLQDO%ORFNLVD'&%86/('7KLV/('LQGLFDWHVWKDWWKH'&
%XVLVFKDUJHG
LED Label LED Color Description

PHASE LOSS RED OFF = OK (Normal Operation)
ON = Loss of one phase of incoming AC power. The PSM will
continue to run on two phases and the fault LED ON.
OVERTEMP RED OFF = OK (Normal Operation
ON = Excessive main heatsink temperature
DISABLED RED OFF = Not disabled (Normal Operation)
ON = DC bus disabled by external enable input
PSM READY GREEN OFF = No DC bus voltage
ON = DC bus charged (Normal Operation
,IQRQHRIWKH/('VDUH21HLWKHUUHGRUJUHHQDQGLQFRPLQJOLQHYROWDJHV

DUHIRXQGWREHFRUUHFWWKHUHPD\EHD360IDLOXUH5HSODFHWKH360ZLWK
DQRWKHUPRGXOH

Check for Problems in the System 5-3
Operator Terminal Status 7KH8/75$3OXV3'0KDVVWDWXVVFUHHQVWKDWPD\EHDFFHVVHGE\SUHVVLQJ

WKH67$786NH\(DFKWLPHWKH67$786NH\LVSUHVVHGWKHQH[WVWDWXVVFUHHQ
Screens LVGLVSOD\HG7KH%$&.63$&(NH\FDQEHXVHGWRVFUROOEDFNZDUGVWKURXJK
WKHVWDWXVVFUHHQV7KH&/($5.H\ZLOOUHPRYHWKHVWDWXVGLVSOD\RUFOHDUWKH
SHDNYDOXHV
Variable Name Description

Refer to the GML Programming Reference for detailed information
about each flag and variable
Status Flags ATHOME, HSEQCPL, INPOSN, ERROR, XFER, READY, ENABLED,
PAUSE
Program Status Program Number. If compiled with the debug option ON, the
instruction that is executing will also be displayed.
Position Status PCMD, POSN, FE
Velocity Status VCMD, FVEL1, VEL2
Input Status Inputs 1 through 16. Inputs 17 through 48 if an Expansion I/O or
Memory and Expansion I/O card is installed.
Output Status Outputs 1 through 8. Outputs 9 through 24 if an Expansion I/O or
Memory and Expansion I/O card is installed.
Current Status ICMD, IAVE, IN PEAK CURRENT
Commanded PGEN, PJOG, PEXT
Position Status
Peak Status PFE, PVEL1, PICMD
$OOSRVLWLRQYDOXHVGLVSOD\HGRQWKH2SHUDWRU7HUPLQDOVWDWXVVFUHHQVDUHLQ
XVHUXQLWVYHORFLW\YDOXHVDUHLQXVHUXQLWVSHUWLPHEDVHDQGFXUUHQWWRUTXH
YDULDEOHVDUHLQDPSV
Personality Module Default An inoperable NVRAM may be recovered by initializing the PM to the
factory default settings. This command zeroes the NVRAM and performs a
Initialization series of NVRAM integrity tests before installing factory default NVRAM
settings.
IMPORTANT This selection erases the existing Personality Module

parameters and motion programs. If the PM was
programmed, be prepared to restore the PM settings and
motion programs from your backup files. See section
“Apply Power for the First Time” for instructions to
initialize the PM with PDM and motor configuration
data.

7RUHLQLWLDOL]HD3HUVRQDOLW\0RGXOHWRWKHIDFWRU\GHIDXOWVHWWLQJVSHUIRUPWKH
IROORZLQJ
6HOHFW,QLWLDOL]H8/75$3OXV3'0IURPWKH)LOHPHQX7KH,QLWLDOL]H
3HUVRQDOLW\0RGXOHZLQGRZZLOODSSHDU
&OLFNWKH)DFWRU\'HIDXOW,QLWLDOL]DWLRQWDE
&OLFNWKH)DFWRU\,QLWLDOL]H30EXWWRQWRLQLWLDOL]HWKH307KH3HUFHQW
&RPSOHWHLQGLFDWRUGLVSOD\VWKHVWDWXVRIWKHLQLWLDOL]DWLRQ
Error Messages and Error ,IWKHUHLVDIDXOW*0/8OWUD6RIWZDUHFDQSURYLGHVSHFLILFHUURUPHVVDJHV,I

DSHUVRQDOFRPSXWHUUXQQLQJ*0/VRIWZDUHLVFRQQHFWHGWRWKH3FRQQHFWRU
Output WKHHUURUPHVVDJHFDQEHGLVSOD\HGLQWKH0RQLWRUPHQX6WDWXVGLDORJER[
7KHHUURUPHVVDJHVDUHDOVRGLVSOD\HGRQWKHRSWLRQDO2SHUDWRU7HUPLQDO
7KH(UURURXWSXWPD\EHGLVDEOHGDQGXVHGDVDJHQHUDOSXUSRVHRXWSXW
7KHUHIRUHWKLVRXWSXWPD\QRWEHDYDLODEOHIRUGLDJQRVWLFSXUSRVHV7KH
UHPDLQGHURIWKHGLVFXVVLRQDERXWWKH(UURURXWSXWDVVXPHVWKDWRXWSXWLV
DVVLJQHGDVWKH(UURURXWSXW7KHRXWSXWFDQEHDVVLJQHGLQWKH3DUDPHWHU
PHQX
7KH(UURURXWSXWEHFRPHVDFWLYHZKHQHYHUWKH8/75$3OXV3'0GHWHFWVD
IDXOW7KH8/75$3OXV3'0ZLOOQRWEHJLQWRH[HFXWHPRWLRQSURJUDPVZKLOH
DIDXOWLVSUHVHQW$IWHUUHPRYLQJWKHFDXVHRIWKHIDXOWWRJJOLQJWKH(1$%/(
LQSXW2))DQGEDFN21RULVVXLQJD5(6(7FRPPDQGZLOOFOHDUWKHIDXOW
DQGDOORZH[HFXWLRQRIPRWLRQSURJUDPV6RPHIDXOWVKRZHYHUFDQRQO\EH
FOHDUHGE\DQ+5(6(7FRPPDQG7KHVHIDXOWVLQFOXGHQXPEHUV²
DQG5HIHUWR´(UURU0HVVDJHVµRQSDJH IRUDGHVFULSWLRQRI
HDFKIDXOW
2QVRPHPDFKLQHV\RXPD\ZDQWWKH8/75$3OXV3'0WRFRQWLQXHUXQQLQJ
HYHQDIWHUVRPHIDXOWVRFFXU7KLVLVDFFRPSOLVKHGE\VHWWLQJ'LVDEOHRQ)DXOW
WR3DUWLDO,QWKLVFDVHWKHIROORZLQJIDXOWVDUHGLVDEOHG,DYJIDXOW0RWRU
2YHUWHPSHUDWXUH6RIW)RUZDUG/LPLWDQG6RIW5HYHUVH/LPLW$OOIDXOWVZLOO
FDXVHWKH(UURURXWSXWWRWXUQ21LIHQDEOHG+RZHYHULI'LVDEOHRQ)DXOW
LVVHWWR3DUWLDODQGDIDXOWOLVWHGDERYHRFFXUVWKH8/75$3OXV3'0ZLOO
UHPDLQHQDEOHGDQGH[HFXWHPRWLRQSURJUDPVQRUPDOO\7KH(UURURXWSXWLQ
WKLVFDVHVHUYHVDVDQDODUPDQGDSURJUDPPDEOHORJLFFRQWUROOHU3/&RU
RWKHUFRQWUROOHUFDQWKHQJUDFHIXOO\VKXWGRZQWKHPDFKLQHZLWKRXWGDPDJLQJ
WKHWRROLQJRUZRUNSLHFH

7KHIROORZLQJWDEOHOLVWVWKHIDXOWVWKDWDFWLYDWHWKH(UURURXWSXW7KHQXPEHU
SUHFHGLQJWKHIDXOWLVWKHHUURUQXPEHU
No. Error Messages Description

3 2ms Reentrancy Fault The system did not finish the required calculations in
the previous 2ms position loop update in time for the
next position loop update.
4 Math Overflow A math overflow occurred (a calculation exceeded the
internal system limit). Check the values of the
variables used in the program.
5 Divide by Zero A division by zero calculation was attempted. Check
the values of the variables used in the program.
6 LOOP variable range A variable used as the count for a LOOP statement
was out of range. The valid range of a LOOP count is 0
to 65535.
8 PRECISION Out of Range Decimal point precision is not within the range of 0 to
4.
9 BCD Input Range A number larger than 9 was read in as a BCD number
in a BCD statement in a program. Check the inputs that
are being used for the BCD input.
12 LOOP Count Out of Range Loop constant value is not within the range of 0 to
65535.
13 Profile Calculation The move cannot be made based on the parameters
for the move: distance, velocity, acceleration, or time.
Possible causes are variable values used for the move
parameters that result in an acceleration or time of 0.
16 Invalid Opcode The GML tried to execute a program opcode that was
not valid (programs are compiled into opcodes that the
GML executes). Compile the program again to make
sure it compiles correctly.
17 Home Not Defined Home has not been defined when trying to execute a
MOVP (absolute) move. Run the Home program or
Define Home and execute the MOVP command again.
19 Delay Out of Range Time value for a Delay statement is greater than
65,535 seconds.
20 KP Out of Range The parameter listed has exceeded the internal system
21 KFF Out of Range limit. The limit is determined at run time based on the
22 KI Out of Range Scale parameter. Check the gain values under the
23 KPZ Out of Range Parameter menu.
24 Gear Out Of Range The calculated value for the gear ratio denominator is
greater than 32,767. Check that the value is correct.
Calculations: The calculation listed has exceeded the internal
30 S-Curve system limit. The limit is determined at run time based
31 Accel on the Scale parameter. Check the velocity and
32 Velocity acceleration values under the Parameter menu.

(Continued)

33 Iavg Fault The average current output of the GML exceeded safe
levels for the motor or GML. Check for correct
connection of the motor encoder to the GML or of the
motor leads to the GML. Other possible causes are
motor stall or end of travel condition, excessive duty
cycle, or no DC bus voltage. This can also occur if the
drive is enabled and there is power supplied to the L1
and L2/N AC AUX inputs, but not to the L1 and L2/N
AC main inputs (this provides logic voltage, but no DC
bus voltage).
34 Excessive FE The following error has exceeded the Following Error
Limit for a time greater than the Following Error Time.
Possible causes are loss of encoder feedback, low
gain settings, a commanded velocity or acceleration
that exceeds system capabilities, or entries for
Following Error Limit and/or Following Error Time that
are beyond system capabilities.
35 Excessive Speed Commanded velocity of a move exceeded the
Overspeed value set under Velocity / Acceleration in
the Parameter menu.
36 Cam Profile Overflow The target follower position in a cam profile could not
be calculated.
37 POS Track Overflow The target follower position with tracking mode active
could not be calculated
38 Serial Port #2 Busy A PRINT or READ statement was attempted to serial
port #2 while the system was reserving the port for
other functions.
39 Drive Not Ready The Ready to Run signal from the drive indicates a
fault in the drive.
40 Motor Overtemperature The temperature sensor in the motor windings
indicated that the motor temperature has exceeded
the rating. Check for mechanical binding, undersized
motor, or duty cycle too high.
41 Power Module Fault This fault typically indicates that the amplifier is trying
or to supply currents above its rating to the motor. Check
Heat Sink for mechanical binding, excessive duty cycle, or faulty
Overtemperature motor wiring.
(1398-PDM-10, 20, 30, 75, and 150B) The power
module has detected excessive internal temperature
or excessive current to the motor. On earlier power
modules, this fault indicates the heat sink temperature
has exceeded the rated temperature.
(1398-PDM-25, 50, 100, and 100) The heat sink
temperature has exceeded the rating.
42 Bus Undervoltage The DC Bus voltage is too low, or power supplies for
or the amplifier circuitry were below the nominal output
Logic Supply Fault voltage. This indicates a problem in the GML internal
power supply.

(Continued)

43 Peak Overcurrent The GML current sensors detected a short circuit in the
motor leads. Check motor power cables for shorts.
44 Bus Overvoltage The DC bus voltage exceeded safe levels. This error
usually indicates that the power supply shunt is not
operating properly. Check the shunt fuse on the Power
Supply Module (1398 PDM-25, 50, 100, and 100).
See Figure 3.10 on page 3-15.
45 Encoder 1 Fault Incorrect encoder signals were detected by the PDM
46 Encoder 2 Fault circuitry. The encoder signals may be out of quadrature
or an encoder signal is missing (broken wire).
47 Watchdog Test Fault The Watchdog circuitry test (performed at power up)
failed. The GML should be replaced.
48 Personality Fault A checksum error was detected in the personality data
for the GML. Reload the Personality Module from a
previously saved file, or replace the Personality
Module.
49 Watchdog Reset The watchdog timer is pulsed by the microprocessor
every millisecond to ensure that the microprocessor is
running properly. If the microprocessor fails to pulse
the watchdog, a Watchdog Reset fault occurs.
50 RAM R/W Fault The static RAM failed a test. The GML should be
replaced.
51 EPROM Checksum One of the EPROMs failed the checksum test at power
up. All three EPROMs, U66, U67, and U87 should be
replaced.
52 TEXT Checksum The text EPROM failed the checksum test at power up.
The text EPROM, U57, should be replaced.


Appendix A
Specifications
1398-PDM-10, 20, 30, 75, and 7KHWDEOHVVWDUWLQJEHORZSURYLGHVSHFLILFDWLRQVIRUWKH8/75$3OXV3'0V

DQGWKHLUDFFHVVRULHV
150B
1398-PDM-10, 20, 30, 75, and 150B Specifications
Drive 1398 1398 1398 1398 1398

Module PDM-10 PDM-20 PDM-30 PDM-75 PDM-150B
Type (1Φ) (1Φ) (1Φ) (3Φ) (3Φ)
Peak Output 10 amps 20 amps 30 amps 75 amps 150 amps
Current/
Phase
Continuous 5 amps 10 amps 15 amps 35 amps 65 amps
Output
Current/
Phase
Continuous 1 kW 2 kW 3 kW 7 kW 15 kW
Output
Power
Electrical Specifications
Line Voltage 100-240 100-240 100-240 100-240 100-240 VAC
Input VAC VAC VAC VAC
(50/60 Hz)
Continuous 50 W 50 W 50 W 50 W 180W
Shunt Power
Peak Shunt 4.5 kW 4.5 kW 4.5 kW 10 kW 19 kW
Power
Continuous 2.4 kW 2.4 kW 2.4 kW 4 kW 8 kW
Shunt
External
Peak Shunt 6 kW 6 kW 6 kW 10 kW 19 kW
External
Physical Specifications
Weight 15 lb 15 lb 15 lb 21 lb 31 lb
(5 kg) (5 kg) (5 kg) 10 kg 14 kg
Operating 32° to 140°F (0° to 50°C)
Temperature
Storage -40° to 176°F (-40° to 80°C)
Temperature

A-2 Specifications
1398-PDM-10, 20, 30, 75, and 150B Specifications (Continued)
Drive 1398 1398 1398 1398 1398

Module PDM-10 PDM-20 PDM-30 PDM-75 PDM-150B
Type (1Φ) (1Φ) (1Φ) (3Φ) (3Φ)
Relative 5% to 95% non-condensing
humidity
External Shunt Resistor P/N 9101-1079
Continuous 200 W
Shunt Power
Peak Shunt 6000 W
Power
1398 PDM-25, 50, 100, and 1398-PDM-25, 50, 100, and 150 Specifications
150
Positioning 1398 1398 1398 1398
Drive Module PDM-25 PDM-50 PDM-100 PDM-150
Peak Output 25 amps 50 amps 100 amps 150 amps
Current/Phase
Continuous 20 amps 40 amps 50 amps 65 amps
Output
Current/Phase
Continuous 4 kW 8 kW 10 kW 12 kW
Output
Power
Physical Specifications
Weight 15 lb 15 lb 15 lb 21 lb
(5 kg) (5 kg) (5 kg) 10 kg
Operating 32° to 122°F (0° to 50°C)
Temperature
Storage -40° to 176°F (-40° to 80°C)
Temperature
Relative 5% to 95% non-condensing
humidity
External Shunt Modules
Continuous 200 W 900W
Shunt Power
Peak Shunt 6000 W 10kW
Power
Power Supply 1398-PSM-50 1398-PSM-125

Module
Line Voltage 100 to 240 100 to 240 VAC
Input VAC
(3Φ 50/60 Hz)

Specifications A-3
1398-PDM-25, 50, 100, and 150 Specifications (Continued)
Positioning 1398 1398 1398 1398

Drive Module PDM-25 PDM-50 PDM-100 PDM-150
Fused Class RK5 Class RK5
Disconnect 40 amps 90 amps
Output Bus 100-340 VDC 100-340 VDC
Voltage
Continuous 50 amps 100 amps
Output Current
Continuous 600 W 1200 W
Shunt
Dissipation
Peak Shunt 20 kW 40 kW
Power
Terminal Block 11.0 lb-in 24.0 lb-in
Torque (1.25 Nm) (2.75 Nm)
Operator Terminals 7KHWZRRSWLRQDORSHUDWRUWHUPLQDOVSHFLILFDWLRQVDUHFRPSDUHGLQWKH

IROORZLQJWDEOH
Operator Terminals
Terminal 1398-HMI-002 1398-HMI-003
Input voltage 110/240 VAC ±15% 24 VDC ±20% Nominal
Supply 25 Watts 0.5 Amps
Temperature
Operating 32° to 131°F (0° to 55°C) ambient 32° to 104°F (0° to 40°C) ambient
Storage -40° to 158°F (-40° to 70°C) 4° to 176°F (-20° to 80°C) ambient
ambient
Humidity 5% to 95% non-condensing 80% maximum, non-condensing
Weight 7 lb. (3 kg) 2.3 lb. (0.1 kg)
Display Vacuum Fluorescent Display, 4 Vacuum Fluorescent Display, 4
lines by 20 characters lines by 20 characters
Characters 5 mm high Characters 5 mm high
Front panel seal NEMA 4 (IP64) NEMA 4/IP65
NEMA 12 (IP66)
RS-232 cable 9101-2205 9101-2205

A-4 Specifications
Transformers 0XOWLWDSLVRODWLRQWUDQVIRUPHUVDUHDYDLODEOHIRUOLQHYROWDJHPDWFKLQJ
Single Phase Transformer specifications
7KH3'0DQGXVHDVLQJOHSKDVHWUDQVIRUPHU
Specification Value
Rating 3.0 kVA
Input 220/ 230/ 240/ 440/ 460/ 480 VAC RMS
Outputa 115/ 230 VAC RMS
Ambient temperature 32° to122°F (0° to 50°C)
Single phase input and output (50/60 Hz)
5HIHUWR 6LQJOH3KDVH7UDQVIRUPHU/RDG5HJXODWLRQ&XUYHRQSDJH DQG

5HIHUWR 6LQJOH3KDVH7UDQVIRUPHU2XWOLQH'LDJUDPRQSDJH
Three Phase Transformer specifications
7KH3'0DQGKDYHDVHSDUDWHSRZHUVXSSO\PRGXOHDQG
XVHDWKUHHSKDVHWUDQVIRUPHU5HIHUWR 7KUHH3KDVH7UDQVIRUPHU/RDG
5HJXODWLRQ&XUYHVRQSDJH DQG5HIHUWR 7KUHH3KDVH7UDQVIRUPHU2XWOLQH
'LDJUDPRQSDJH
Specification Model
TF-03 TF-06 TF-12 TF-18
Rating 3 kVA 6 kVA 12 kVA 18 kVA
Weight 86 lb 135 lb 200 lb 325 lb
31 kg 61 kg 91 kg 148 kg
Input 208/ 230/ 240/ 380/ 460/ 480 VAC RMS
Outputa 115/ 230 VAC RMS
Ambient temperature 32° to122°F (0° to 50°C)
Three phase input and output (50/60 Hz)

Appendix B
Options and Accessories
PDMs and Optional 7KHIROORZLQJWDEOHVFDQEHXVHGWRRUGHUSURGXFWV8VHWKH´,WHP1XPEHUµ

2UGHUQXPEHUZKHQHYHUSRVVLEOH7KH´$OWHUQDWH1XPEHUµ0DQXIDFWXULQJ
Accessories QXPEHULVXVHGIRURUGHULQJZKHQWKH´,WHP1XPEHUµLVQRWDYDLODEOHRU
ZKHQUHVHDUFKLQJLQIRUPDWLRQDERXWWKHFRPSRQHQWRUPRGXOH
7KLVWDEOHJLYHVWKH8/75$3OXV3'0UHIHUHQFHQXPEHUV
Item Number Description Alternate Number

1398-PDM-10 Positioning Drive Module 9101-2185
1398-PDM-25(1) Positioning Drive Module 9101-3058

1398-PDM-150B Positioning Drive Module 9101-2234
Fuse, Drive Module F1 1 Amp 9101-0228
(for 24 VDC circuits Bussman MDL 1 or
Littelfuse 313 001)
(1)
Requires use of 1398-PSM-XXX Power Supply.
7KLVWDEOHVKRZVRSWLRQDO8/75$3OXV3'0DFFHVVRULHV

1398-HMI-002 ULTRA Plus Operator Terminal, 110/240 VAC 9101-2196
1398-HMI-003 ULTRA Plus Operator Terminal, 24 VDC 9101-2209
1398-SR9P External Shunt Kit (900W) 9101-1697
External Shunt Kit (200W) 9101-1183
Personality Module Replacement Kit(1) 9101-2226
(1) The Personality Module is programmed with standard factory default settings. If replacing a previously
installed Personality Module, user programs and user selected parameters must be re-entered into the new
Personality Module memory.

B-2 Options and Accessories
I/F Conversion Card 7KLVWDEOHOLVWVWKH96RXUFLQJLQWHUIDFHFRQYHUVLRQFDUGDQGLWVFRQQHFWLRQV

FDEOHV

I/F Conversion Card, 24V Sourcing(1) 9103-0152
Cable, I/F Conversion Card 3ft (1m), 44-0141-003

Cable I/F Conversion Card 10ft (3m), 44-0141-010
(1)
Required for compliance with the European Union Low Voltage Directive (LVD). It must be mounted in the same
enclosure as ULTRA Plus PDM.
Power Supply Modules 7KLVWDEOHOLVWVWKUHHSKDVHSRZHUVXSSOLHVDQGWKHLUIXVHV

1398-PSM-50 Power Supply Module 9101-3056
1398-PSM-125 Power Supply Module 9101-3057
Auxiliary PSM 9101-0439
Connector TB1, PSM Screw Terminal 9101-0111
1398-PSM-50 Fuse 9101-0225
Bussman KLM-8 or Littelfuse KLK D 8
1398-PSM-125 Fuse 9101-1076
Bussman KLM-20 or Littelfuse KLK D 20
Fuse F1, PSM-AUX 9101-0123
Bussman MDX-7 or Littelfuse 313 007

Options and Accessories B-3
AC Line Filters 7KLVWDEOHOLVWV$&/LQH)LOWHUVUHTXLUHGIRU&((0&FRPSOLDQFH

1398-PDM-10 9101-1517
(10 Amps continuous, single phase)
1398-PDM-20 9101-1518
1398-PDM-30 9101-1387
Multiple drives (1) 9101-1388
1398-PDM-75 9101-1389
(36 Amps continuous, three phase)
1398-PDM-150B 9101-1575
Multiple drives(1) 9101-1390
(1) For multiple PDMs using one filter, the combined PDMs input current must not exceed filter ratings.

Cables 7KLVWDEOHOLVWVSRZHUFDEOHVEHWZHHQWKH3'07HUPLQDO%ORFN7%DQGWKH

0RWRU7KHODVWWKUHHGLJLWV;;;LQGLFDWHDVWDQGDUGFDEOHOHQJWK IW
P IWP IWPDQG IWP
PDM Motor Description Alternate

Number
1398-PDM-10, H-2000 or H-3000 Motor 9101-1080-XXX
20, 30 or 75
1398-PDM-10, H-4000 or F-4000 Motor 9101-1081-XXX
20, 30 or 75
ULTRA Series F-2000, 3000 or H-2000, 3000 9101-1381-XXX
ULTRA Series F-4000 or H-4000 9101-1382-XXX
ULTRA Series F-6000 or H-6000 9101-1383-XXX
ULTRA Series Programming Terminal Cable (RS-232) (P6) (1) 9101-2024-XXX
ULTRA Series Operator Terminal Cable (RS-232) 9101-2025-XXX
(P7)
ULTRA Series Motor Encoder Cable (P5 9101-2027-XXX
Connector)
ULTRA Series Control Station Cable 9101-2030-010
ULTRA Series Encoder Cable 9101-2031-XXX
1398-PDM-25, 50, 100 or 150 for H-3000 Motor 9101-0250-XXX
Power Cable with Motor Connector
1398-PDM-25, 50, 100 or 150 for H-4000/F-4000 9101-0251-XXX
Motor Power Cable
1398-PDM-25, 50, 100 or 150 for H-6000/F-6000 9101-0252-XXX
Motor Power Cable
1398-PDM-25, 50, 100 or 150 for H-8000 Motor 9101-0253-XXX
Power Cable
N-Series Motor Power Cable 9101-1676-XXX
ULTRA Series P4 to P4 Master/Follower Cable 9101-2127-002
ULTRA Series Motor Encoder Cable (P5 9101-2135-025 or
Connector) with right angle motor connector 9101-2135-050
N-Series Encoder Cable (P5 Connector) with right 9101-1677-XXX or
angle motor connector 9101-1679-XXX
1398 PDM-10, 20, 30 or 75 for H-6000/F-6000 9101-2179-XXX
Motor Power Cable
ULTRA Plus to I/O Conversion Card, 3-foot Cable 44-0141-003
ULTRA Plus to I/F 24V Conversion Card, 10-foot 44-0141-010
Cable
(1)
RS-232 cables are available in 3m and 7m (10 and 25 ft) lengths only.

Transformers 7KLVWDEOHOLVWVVLQJOHDQGWKUHHSKDVHWUDQVIRUPHUVWREHXVHGZLWKWKH
8/75$3OXV3'0V
Description Alternate
Number
3 KVA three phase transformer 0020-5091-001
Auxiliary PSM transformer 0020-5093
3 KVA single phase transformer (1398 PDM-10, 20, 30 or 75) 0020-5097
Motor Identification
H - 4 0 3 0 - Q - H 00 AA
FACTORY DESIGNATED SPECIAL OPTIONS
AA = STANDARD FLANGE
AN = NEMA56C FLANGE
OPTIONS
00 = STANDARD
01 = 90 Vdc BRAKE
04 = 24 Vdc BRAKE
OPTICAL ENCODER LINE COUNT*
F = 1000
H = 2000 (S T A N D) A R D
J = 2500
K = 5000
L = 500
M = 3000
N = 1500
MOTOR WINDING KE DESIGNATOR
NOTE: SPECIAL ORDER WINDINGS AVAILABLE
FRAME SIZE
Series DESIGNATOR
F = FERRITE MAGNET
H = LOW INERTIA
N = NEMA
* Not all line counts are available on all motors

Motor Connectors 7KLVWDEOHOLVWVPRWRUFRQQHFWRUVIRUEXLOGLQJFDEOHVIRUWKH+)DQG16HULHV

PRWRUV
Connector Motor Series Straight Right Angle

Type
Power H-Series (2000 9101-0325 9101-0398
connectors and 3000) (MS3106F18-4S) (MS3108F18-4S
Power H and F-Series 9101-0326 9101-0399
connectors (4000) (MS3106F20-4S) (MS3108F20-4S)
Power H and F-Series 9101-0327 9101-0400
connectors (6000) (MS3106F24-22S) (MS3108F24-22S)
Power H-Series (8000) 9101-0328 9101-0401
connectors (MS3106F32-17S) (MS3108F32-17S)
Power N-Series 9101-1557 (Solder)
connectors MS3116F14-5S (Solder) KPT08F14-5S (Solder) PT08E14-5S (Solder)
MS3126F14-5S (Crimp) KPSE08F14-5S (Crimp) PT08SE14-5S (Crimp)
Encoder H-Series and 9101-0329 9101-0402
connectors F-Series MS3106F20-29S MS3108F20-29S
Encoder N-Series 9101-1558 (Solder)
connectors MS3116F14-19S (Solder) KPT08F14-19S (Solder) PT08E14-19S (Solder)
Brake connectors H-Series and 9101-0330 9101-0403
F-Series MS3106F12S-3S MS3108F12S-3S
Brake connectors N-Series 9101-1698 (Solder)
MS3116F12-3S (Solder) KPT08F12-3S (Solder) PT08E12-3S (Solder)

Motor Shaft Seal Kits 7KLVWDEOHOLVWVPRWRUVKDIWVHDONLWVDYDLODEOHIRUWKH+)DQG16HULHV

PRWRUV
Description (Outside Dia x Inside Dia x Width) Alternative Number

Shaft seal kit, H-2000 motor 0041-5056
22 mm x 12 mm x 7 mm
Shaft seal kit, H-8000 motor 0041-5053-005
85 mm x 45 mm x 8 mm W
Shaft seal kit, F-4000 motor 0041-5060
1.437 inch x 0.875 inch x 0.25 inch
Shaft seal kit, F-6000 motor 0041-5061
2.125 inch x 1.438 inch x 0.31 inch
Shaft seal kit, N-2300 motor mm/in 0041-5068
0.035 x 0.001 x 0.005 / 0.875 x 0.250 x 0.125
0.044 x 0.019 x 0.010 / 1.125 x 0.500 x 0.250
0.044 x 0.025 x 0.010 / 1.125 x 0.625 x 0.250
0.054 x 0.030 x 0.010 / 1.375 x 0.750 x 0.250
Note: Shaft seals are manufactured to inch dimensions. Millimeter dimensions are
conversions from inches. Shaft seals require a lubricant to reduce wear. Lubricant is
provided with kit.


Index
A Operator Terminal power supply

Absolute positioning , PDM terminal block ,
AC Contents of manual 3
3-phase power Conventions
Coils suppressed with RC filters Conventions used in this manual 3
Line filter Conversion Card 24V Sourcing
Installation ,
Order % D
Rasmi DC
Roxburgh Coils suppressed with diode
Schaffner Multiple power installations
Power transformer DC Bus
Power wiring Power supply
Accel calculation error Delay
Analog to Digital converter Out of Range error
Resolution Diagnostics
ANSI DC Bus Power LED
C62 and C63 Error Messages
Assignable function LED
Home Sequence Complete (output) Personality Module Default Initialization
Assignable functions
Digital Outputs Diagram
At Home output Auxiliary Power Supply Connections
Assignable function External Shunt Mounting and Connection
Auxiliary power supply Diagram ,
Description Power Wiring Diagram (1398-PDM-25,
Logic power , 50, 100, and 100
Power Wiring Diagram for 1398-PDM-10,
B 20, and 30
BCD Input Range error Power Wiring for 1398-PDM-150B
Bonding Power Wiring for 1398-PDM-75
Mounting PSM AUX Outline and Connection
Sub panels Diagram
Bus Transformer Load Regulation (1398
DC Power Supply PDM-10, 20, 30, 75, and 150B)
Overvoltage error Curve
Undervoltage error Transformer Outline Diagram (1398
PDM-10, 20, 30, 75, and 150B)

C Transformer Outline Diagram
Cable (1398-PDM-25, 50, 100, 150)
Description
Order % Digital
Shielding Assignable output functions
Cam Profile Overflow error Multiple outputs
COM1 connector Digital to Analog Converter (DAC)
Connections Resolution
Motor power Dip Switch

2 Index
Jumpers Encoder

RS-232 operation Encoder Fault error
SW-1 in network Feedback , ,
SW1-1 Shield
SW1-6 EPROM Checksum error
SW1-7 EPROMs
Divide by Zero error Installation
Documentation Error
Related documentation 3 BCD Input Range
Drive Not Ready error Bus Overvoltage
Bus Undervoltage
Calculation
E
Cam Profile Overflow
Earth ground Delay Out of Range
Electrical Noise Divide by Zero
Electronic gearing Drive Not Ready
EMC Encoder Fault
Defined EPROM Checksum
European Directive Excessive FE
Noise Excessive Speed
PDM mounting requirements Gear Out Of Range
Performance Heat Sink Overtemperature
Requirements Home Not Defined
Cable shielding Iavg Fault
Requirements - Flying leads Invalid Opcode
Requirements - Lead length KFF Out of Range
System Installation KI Out of Range
Emergency Return KP Out of Range
Emergency stop contactor KPZ Out of Range
EMI Logic Supply Fault
Bonding LOOP Count Out of Range
Defined LOOP Variable Range
Model Math Overflow
Problems Motor Overtemperature
Source-Victim Model Peak Overcurrent
Standards Personality Fault
EN POS Track Overflow
60529 (IEC 529) Power Module Fault
61000-4-X series PRECISION Out of Range
Enable Profile Calculation
Assignable Function RAM R/W Fault
Enable Input Reentrancy Fault
Enabled output Serial 2 Busy
Enclosure TEXT Checksum
Faraday cage Watchdog Reset
IP4X Watchdog Test Fault
Metal Error output
NEMA Assignable function
Shielding Multiple axis
Sizing

Index 3
European Directive Compliance H

Directive Heat
Emergency Stop Contactor Heat Losses for sizing enclosures
I/O Conversion Card Heat Sink Overtemperature error
Low Voltage Directive High frequency energy
Motors and Cables Home
Excessive Home Command
Excessive FE error Home Not Defined error
Excessive Speed error Home Sequence Complete (output)
External Shunt Home Switch
Description Host
Installation PLC
Power dissipation ratings
I
F I/F Conversion Card 24VDC Sourcing ,
Faraday shield
Fault I/O
Encoder 24VDC Sourcing
Iavg Iavg Fault
Logic Supply In Position output
Personality Assignable function
Power Module Incremental encoder ,
RAM R/W Input
Reentrancy Isolating input power
Watchdog Test Step and direction
Filter types Installation
Firmware EMC Motors and Cables
Installation Installing for European Union Compliance
Flying leads ,
Motor shield termination Emergency Stop Contactor
Forward Limit I/F Conversion Card
Full Load Amperage Motor guidelines
Fuse Internal
Short Circuit Protection Internal logic power supply ,
Internal shunt
G Invalid Opcode error
Gear IP4X Enclosure
Out Of Range error
GML Ultra Software J
Description Jog
Installation Forward
Ground Reverse
Ground bus bar Jumper
Safety ground PDM internal power supply
Single Point Ground Types PDM Internal shunt connection
Torroid encoder shielding

4 Index
K Ventilation
KFF
Out of Range error N
KI National Electrical Code
Out of Range error Requirements
KP NEMA enclosure
Out of Range error Noise
KPZ Emission supression diagrams
Out of Range error Operator terminal suppression
Problems
L See Bonding
Lead length
EMC requirements O
LED Operating Environment
Limit Operator Terminal
Forward , Description
Reverse , Installation
Logic Supply Fault Mounting
LOOP Specifications $
Count Out of Range error Start-up Procedure
Variable Range error Optically isolated inputs
Ordering Information
M Cable %
Manuals Motor Mating Connectors %
Math Overflow error Motor Shaft Seal Kits %
MIL-STD-461 Motors %
Monitor Output Transformers %
Motor Output
Compatibility with PDM Control Analog Output
Description Connecting inputs and outputs
Encoder Enabled Relay output
Mating Connectors , % Monitor output
Mounting Ready Relay output
Ordering Information % Sinking signal of output
Overtemperature error
Power leads P
Shaft Seal Kits % Pause input
Shielded power cables , , , PDM
EMC mounting requirements
Thermostat PDM with integral power supply
Mounting PDM with separate power supply
Auxiliary PSM Transformer Peak Overcurrent error
Bonding Personal Computer (PC)
Environment Personality Module
Motors Description
Positioning Drive Module Factory Default Initialization
Requirements Initialization
Shunt Resistor , PDM-10, 20, 30 or 75

Index 5
PDM-25, 50, 100 or 150 Multi-drop network , ,
Installation Operator Terminal connections ,
Location
Personality Module Fault
POS Track Overflow error
S
Positioning Drive Module
LEDs Safety ground ,
Mounting Schaffner AC Line filter
Power cable S-Curve calculation error
Motor Serial 1 Auxiliary (P7) ,
Shielding Serial 2
Power losses Busy error
Power Module Fault Computer (P6)
Power supply Shielded cable
Auxiliary Encoder
Connections Motor
Digital I/O Shunt Resistor
I/F 24V Conversion Card Connection Diagram ,
Internal Logic Internal in some PDMs
Isolating input power Mounting ,
Location Single Point Ground Types
Module mounting Sinking (active low) I/O
Motor connections Sourcing (active high) I/O
Operating environment Specifications
Operator Terminal 1398 PDM-25, 50, 100, and 150 $
Power supply module 1398-PDM-10, 20, 30, 75, and 150B $
PRECISION Out of Range error Operator Terminal $
Profile Calculation error Transformers $
Program Running output Start Program
Assignable function Start-up Procedure
Programmable Monitor 1398-PDM-10, 20, 30, 75, and 150B
1398-PDM-25, 50, 100 or 150
Motors
Q Operator Terminal
Quadrature signals , Personality Module
Status outputs
Step and direction inputs
R
Storage 3
RAM R/W Fault Suitable filter types
Rasmi AC Line filter Support
Ready output Local product 3
Reentrancy Fault error Technical product assistance 3
Regulatory requirements SW1 dip switch
Related documentation 3 Nework settings
Reverse Limit Unique addresses in network
Roxburgh AC line filter Symbols and Conventions 3
RS-232 , System firmware
Daisy-chain network Location
Jumper System Overview
RS-422

6 Index
T U
Terminal block Underwriter Laboratories
Connections , Listing
TEXT Checksum error
Transformer
V
Description
Isolation Velocity calculation error
Load Regulation (1398 PDM-10, 20, 30, Ventilation
75, and 150B) Curve
Ordering % W
Outline Diagram (1398-PDM-25, 50, 100, Watchdog
150) Watchdog Reset error
Sizing Watchdog Test Fault error
Troubleshooting, see “Check for Problems in Wording Conventions 3
the System”
Typographical Conventions 3

For more information refer to our web site: www.ab.com/motion
For Rockwell Automation Technical Support information refer to: www.rockwellautomation.com/support or Tel: (1) 440.646.3434
Publication 1398-5.1 — January 2000 2 PN 0013-1048-002 Rev A

Supersedes Publication 1398-5.1 — August 1997 © 2000 Rockwell International Corporation. Printed in the U.S.A..

Instalation Manual IQ2000 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instalation Manual IQ2000 PDF

Uploaded by

Copyright:

Available Formats

1398

ULTRA Plus Series

i Publication 1398-5.1 — January 2000

,QVWDOOLQJWKH3HUVRQDOLW\0RGXOH 30  

Publication 1398-5.1 — January 2000

Publication 1398-5.1 — January 2000

Publication 1398-5.1 — January 2000

Who Should Use this 8VHWKLVPDQXDOLI\RXDUHUHVSRQVLEOHIRUGHVLJQLQJLQVWDOOLQJSURJUDPPLQJ

Purpose of this Manual 7KLVPDQXDOGHVFULEHVWKHIXQFWLRQDQGLQVWDOODWLRQRIWKH8/75$3OXV

1 Publication 1398-5.1 - January 2000

Contents of this Manual 5HIHUWRWKHIROORZLQJPDQXDOIRUWKHGHVFULSWLYHFRQWHQWVRIWKLVLQVWDOODWLRQ

Chapter Title Contents

Publication 1398-5.1 - January 2000

Related Documentation 7KHIROORZLQJGRFXPHQWVFRQWDLQDGGLWLRQDOLQIRUPDWLRQFRQFHUQLQJUHODWHG

For this information Read This Document Document Number

Conventions Used in this 7KHIROORZLQJFRQYHQWLRQVDUHXVHGWKURXJKRXWWKLVPDQXDO

Publication 1398-5.1 - January 2000

Product Receiving and <RXWKHFXVWRPHUDUHUHVSRQVLEOHIRUWKRURXJKO\LQVSHFWLQJWKHHTXLSPHQW

Allen-Bradley Support $OOHQ%UDGOH\RIIHUVVXSSRUWVHUYLFHVZRUOGZLGHZLWKRYHU6DOHV6XSSRUW

Local Product Support

Technical Product Assistance

Publication 1398-5.1 - January 2000

Overview of the ULTRA Plus PDM System

Functional Description 7KH8/75$3OXV3'0PRWLRQFRQWUROV\VWHPLVDSRVLWLRQLQJGULYHV\VWHP

Figure 1.1 ULTRA Plus PDM Product Family

1 Publication 1398-5.1 - January 2000

System Overview $Q8/75$3OXV3RVLWLRQLQJ'ULYH0RGXOH 3'0 PRWLRQFRQWUROV\VWHP

Publication 1398-5.1 - January 2000

AUXILIARY ENCODER GML ULTRA™

GML Ultra™ for Windows™

Publication 1398-5.1 - January 2000

Positioning Drive Modules

Integral Power Supply Modules

Separate Power Supply Modules

Publication 1398-5.1 - January 2000

Power Supply Module (PSM)

Personality Module (PM)

Publication 1398-5.1 - January 2000

Accessories Operator Terminal

programmable keys X1 STATUS

Publication 1398-5.1 - January 2000

Auxiliary Power Supply Module (PSM)

$QDX[LOLDU\SRZHUVXSSO\PRGXOH 360$8; LVDYDLODEOHWRVXSSO\'&

Publication 1398-5.1 - January 2000

Personal Computer (PC)

Publication 1398-5.1 - January 2000

Install the ULTRA Plus PDM Components

1 Publication 1398-5.1 — January 2000

Publication 1398-5.1 — January 2000

Maximum power losses for help in sizing enclosures

:KHUHG GHSWK Z ZLGWK DQGK KHLJKW DUHLQLQFKHV

Publication 1398-5.1 — January 2000

7UDQVIRUPHU.9$UDWLQJ 6XPRIDYHUDJHRXWSXWSRZHURIHDFKD[LV [

Speed ( RPM ) × Torque ( lb – in ) 746Watts KVA

Publication 1398-5.1 — January 2000

3000RPM × 75lb – in 746Watts KVA

Publication 1398-5.1 — January 2000

TRANSFORMER SECONDARY VOLTAGE

(VAC RMS LINE TO LINE, 3 PHASE)

1 DC BUS VOLTAGE AND CURRENT IS MEASURED AT MOTOR POWER

Publication 1398-5.1 — January 2000

TRANSFORMER SECONDARY VOLTAGE

(VAC RMS LINE TO LINE, 3 PHASE)

,QVWDOOLQJWKH3HUVRQDOLW\0RGXOH30

Who Should Use this 8VHWKLVPDQXDOLI\RXDUHUHVSRQVLEOHIRUGHVLJQLQJLQVWDOOLQJSURJUDPPLQJ

Conventions Used in this 7KHIROORZLQJFRQYHQWLRQVDUHXVHGWKURXJKRXWWKLVPDQXDO

Product Receiving and <RXWKHFXVWRPHUDUHUHVSRQVLEOHIRUWKRURXJKO\LQVSHFWLQJWKHHTXLSPHQW

Allen-Bradley Support $OOHQ%UDGOH\RIIHUVVXSSRUWVHUYLFHVZRUOGZLGHZLWKRYHU6DOHV6XSSRUW

System Overview $Q8/75$3OXV3RVLWLRQLQJ'ULYH0RGXOH3'0PRWLRQFRQWUROV\VWHP

$QDX[LOLDU\SRZHUVXSSO\PRGXOH360$8;LVDYDLODEOHWRVXSSO\'&

:KHUHGGHSWKZZLGWKDQGKKHLJKWDUHLQLQFKHV

7UDQVIRUPHU.9$UDWLQJ 6XPRIDYHUDJHRXWSXWSRZHURIHDFKD[LV[

5HIHUWR ´6SHFLILFDWLRQVµRQSDJH $IRUDGGLWLRQDOWHFKQLFDOLQIRUPDWLRQ

5HIHUWR ´3RZHU6XSSO\0RGXOHVµRQSDJH %IRUSURGXFWQXPEHUV

Personality Module 7KH3HUVRQDOLW\0RGXOHLVDOUHDG\LQVWDOOHGRQWKH8/75$3OXV3'07KH

System Firmware $OO8/75$3OXV3'0VFRPHZLWKWKHV\VWHPILUPZDUHLQVWDOOHG7KHUHIRUH

Jumper and DIP Switches -XPSHUV:DQG:PD\EHUHPRYHGLIDQH[WHUQDO9'&SRZHUVXSSO\LV