Installation Instructions

Changing System / Axis Module on 1394 GMC and

1394 GMC Turbo Controllers

Who should use this Manual?

Use this manual if you are responsible for designing, installing, programming, or troubleshooting
the Allen-Bradley 1394 family of products.
If you do not have a basic understanding of the 1394, contact your local Allen-Bradley
representative for information on available training courses before using this product.

Purpose of this Manual

The purpose of this manual is to enable the customer to successfully replace select 1394 models
that have been designated as Silver Series, with recommended alternative products (series C 1394
product family).

Conventions used in this document

Section
I. Replace / upgrade System Module
II. Replace / upgrade Axis Module

III. Appendix

1
 I. Replace / Upgrade System Module

Overview
Follow the steps in this document to replace a 1394 GMC / 1394 GMC Turbo series A or series B
System module.
These steps, which are described in detail in the succeeding sections of this document, include:

A. Tools required.
B. Note controller switch settings.
C. Connect Serial Comms.
D. Upload script.
E. Remove all power.
F. Disconnect system module – Replacement is a series A or B ONLY
G. Disconnect system module – Replacement is a series C ONLY
H. Remove system module.
I. Insert new system module.
J. Reconnect the system series A or B ONLY
K. Reconnect the system – series C ONLY
L. Download.

A. Tools required
PC running GML Commander 4.03.
Serial cable to interface with 1394 system.
Controlled GML diagram (Required if controller is not responding).
Terminal screwdriver.
Terminal tools (supplied with system module).
Philips No1 screwdriver.
4mm Hex driver or other device for fixing module to panel.
Pen.
5mm Ring Crimp and tool (Series C only).

B. Note controller switch settings

ATTENTION. This product contains stored energy devices. Only qualified personnel familiar with solid state
control equipment and safety procedures in publication NFPA 70E or applicable local codes should
attempt this procedure.

Label and remove the 380/460VAC input power from the system module.
Secure any mechanical loads that may be connected to the motor.
Switch off 24V control power to the system.
Open the system module door.
You will identify the positions of the system module configuration switches in the spaces provided
below. These will be used to set the switches on the replacement unit.
Fig 1 (Positions of switches)

Axis Link and RS-422 Multidrop Control Address

rotary switch number

System module Jumper Fitted series A and B only Fitted ( ! ) Not Fitted ( ! )

2
 Serial Port Config. Dipswitch
Bitswitch No Left ( ! ) Right ( ! )
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1

Axis Link Extended Length Position (Turbo only). Up ( ! ) Down ( ! )

C. Connect Serial Comms. (Ref.A-01)

Connect RS-232 serial cable between PC and system module.
• Ensure that correct serial port bit switches are set for RS-232.
• Apply 24V control power.

D. Upload script. (Ref.A-02)

In GML Commander set the appropriate baud rate for the controller and the comm. port for the PC.
On a new diagram configure the control options to reflect the control type, iCODE version and
multidrop address if applicable.
Go online.
In GML Commander, select Upload Options in the dialog menu. The Upload Options dialog box
opens.
In the Upload Options dialog box:
• Select All as an Upload Option,
• Accept a Lower Variable Address,
• Set the Upper Variable Address to 1999,
• Accept a Lower Cam Point,
• Set the Upper Cam Point to 12999,
• Select OK. GML Commander uploads the program, and then displays the uploaded code in
the Script Editor Window.
• Be sure to Save and note the saved name and location of the new text file.

E. Remove all power

Remove all power from the system.

ATTENTION. This product contains stored energy devices. Only qualified personnel familiar with solid state
control equipment and safety procedures in publication NFPA 70E or applicable local codes should
attempt this procedure.
Ensure that mechanical loads are secured.
Ensure that 380/460V AC input power is disconnected.
Disconnect 24V control power.

3
F. Disconnect system module (Ref.A-03)– Replacement is a Series A or
B ONLY
Ensure that all cables connected to the front and bottom of the system module motion board are
identified and removed.

G. Disconnect system module (Ref.A-04) – Replacement is a series C

ONLY

Ensure that all cables connected to the front and bottom of the system module are identified and
removed.
The 1394 5 and 10KW System Module (Series “C”) uses connectors instead of IEC terminals for
connecting power. You will wire the system using power connectors (J1, J10 and J11) that mate
with plugs (P1, P10 and P11) conveniently located on the bottom of the System Module. See below
for details of location.

Open the System Module door.

Label and remove any feedback or communication connections from the control board.
Label and remove the feedback and communication connectors from the bottom of the System module.
Remove the three connectors from the bottom of the replacement System module.

External Shunt NOT Used Go to 6.

Remove and discard link fitted to 3 way connector (J11).

Pin 1 Pin 2 Pin 3

DC+ COL

• Remove wire from COL and fit to 3 way connector (J11) pin 1.
• Remove wire from DC+ and fit to 3 way connector (J11) pin 3.
• Go to 7.
External Shunt not Used.

Ensure that a link is fitted to 3 way connector (J11).

Pin 1 Pin 2 Pin 3

Link Link

4
 Remove U, V, W and incoming PE then fit to 4 way connector (J10) pins 1-4.

Pin 1 Pin 2 Pin 3 Pin 4

U V W PE

Remove the 24V control and fit to 2 way connector (J1) pins 1&2
Fit a 5mm ring crimp to the end of the Protective Earth returning to the Earth bar.

H. Remove system module

Disconnect the slide-and-lock mechanism on all the modules to the right of the System Module.
Loosen the bottom then top fasteners that hold the module in place.
Lift the module up and pull it out

I. Insert new system module

Install the top mounting fasteners on the system panel for the system module. The heads of the fasteners
should be at least 6.5mm ( ¼” ) from the panel.
Hang the 1394 System Module on the two mounting fasteners on the left side of the panel and locate
mounting lugs.
Install the lower fasteners for the System Module, and tighten the upper fasteners.

J. Reconnect the system – Series A or B ONLY

Open the System Module door.
Connect 24V control power and 380/460V AC input power (U, V, W, PE) to the System Module.
Connect any shunt wiring (if applicable).
Reconnect the feedback and communication connectors from the bottom of the System module.
Reconnect any feedback or communication connections from the control board.
Re-attach the input wiring board by pressing it into both the motion board and the J4 connector.
Insert and tighten the two screws that attach the input wiring board to the motion board.
Close the System Module door, connect the slide-and-lock mechanism on all of the modules.
Connect PC serial cable to CHAN A / J3
Verify switch settings:
• Axis Link and RS-422 Multidrop Address rotary switch is set to value noted on previous
module.
• Serial Port Config. Bitswitch all to left
• Application Lock Keyswitch is Unlocked

K. Reconnect the system – series C ONLY

Open the System Module door.
Connect 380/460V AC input power (U, V, W, PE) via the 4 way connector (J10).
Connect the Protective Earth with attached ring crimp to the System Module Ground Bar.
Connect 3 way connector (J11).
Connect 2 way connector (J1), 24V control power.
Reconnect the feedback and communication connectors from the bottom of the System module.
Reconnect any feedback or communication connections from the control board.
Close the System Module door, connect the slide-and-lock mechanism on the System Module to all of
the modules.

5
 In the case of scheduled maintenance see appendix (Ref.A-05)
Connect PC serial cable to CHAN A / J3
Verify switch settings:
• Axis Link and RS-422 Multidrop Address rotary switch is set to value noted on previous
module.
• Serial Port Config. Bitswitch all to left
• Application Lock Keyswitch is Unlocked

L. Download
Initialise the controller. This involves setting essential drive data parameters to their default values.
• Apply 24V control power to the system module.
• Press in and Hold the INIT button. (This is the right most pushbutton switch revealed when
the front panel of the controller is open.)
• While still pressing the INIT button, press and release the RESET button on the front of the
controller.
• Continue pressing the INIT button until the system module status LED flashes red / green.
• Release the INIT button.
Clear the controller’s Application and parameter memory:
• Ensure that the controller is on line.
• Select the Terminal window (Lower right), within Diagram view with the left button of
the mouse, type the command .I and press the Enter key on the keyboard.
• Press and release the Reset button on the front of the controller.

If a Script file was uploaded from the controller go to 6.

Or
If a controlled diagram is to be downloaded

Open the appropriate controlled diagram.

Press F7 (Translate to Script).
Go to 7.

Download Script file

Open the previously uploaded script file.

Select Script, Download Script. From the menu.

Click OK to abort program. If required.
After the download is finished, switch the Application Program Lock keyswitch to the Locked position.
Remove 24V Control Power.
Verify that all switches are set to the same position as the previous System Module: (See section 3.)
Axis Link and RS-422 Multidrop Control Address rotary switch.
Serial Port Config. Bitswitch.
Axis Link Extended Length (Turbo only).
System Module Jumper Series A and B only.
Apply 24V Control Power.
Apply 380/460C AC input power to the System Module.
Verify that your system is operating properly.
End.

6
 I. Replace / Upgrade Axis Module

Overview
Follow the steps in this Section to replace / upgrade an axis. Installing the new system module
requires the following steps described in detail in the succeeding sections of this document,
include:

A. Tools required
B. Remove all power.
C. Disconnect the axis module.
D. Install a replacement axis module.

A. Tools required
Terminal screwdriver
4mm Hex driver or other device for fixing module to panel.
Pen

B. Remove all power.

ATTENTION. This product contains stored energy devices. Only qualified personnel familiar with solid state
control equipment and safety procedures in publication NFPA 70E or applicable local codes
should attempt this procedure.
Remove 24V control power and 380/460V AC input power from the system.
Allow five minutes for the DC bus to completely discharge before proceeding.

C. Disconnect the axis module

Remove connectors (TB1 and TB2) from the bottom of the axis module.
Label and remove the motor leads and ground wiring from the terminal block on the axis module.
Disconnect the Slide-and-Lock mechanism on the module you plan to remove and all modules to the
right of it.
Loosen the bottom fastener on the axis module you plan to remove.
Loosen the top fastener on the axis module you plan to remove.
Lift the axis module and pull it out.
If you are removing the right most axis module, remove the terminator.

D. Install a replacement axis module:

Install the top mounting fastener on the system panel for the axis module. The head of the fastener
should be at least 6.5 mm ( ¼” ) from the panel.
Hang the axis module on the top mounting fastener.
Engage the alignment tab and tighten fastener.
Slide the Slide-and-Lock mechanism on the axis module to the left until it locks into place on all
modules.
Install the lower fastener on the axis module.
If not already attached, attach the terminator to the last axis module.
Tighten all mounting fasteners.

7
 In the case of scheduled maintenance Series C axis only see appendix (Ref.A-
06)

Reconnect TB1 and TB2, motor and ground wires.

Terminal Description Wire Name

TB1 Pin 1 Thermal Sensor I/P from Motor Cable 9
TB1 Pin 2 Thermal Sensor I/P from Motor Cable 5
TB1 Pin 3 Brake 24V DC from Motor Cable 4
TB1 Pin 4 Brake 24V DC from Motor Cable 6
Terminal Description Wire Name (User)
TB2 Pin 1 Brake 24V DC from Fault System
TB2 Pin 2 Brake 24V DC from Fault System
TB2 Pin 3 Thermal Sensor O/P to Fault System
TB2 Pin 4 Thermal Sensor O/P to Fault System
Terminal Description Wire Name
U1 Phase A 1
V1 Phase B 2
W1 Phase C 3
PE1 Axis PE to Ground Bar PE
PE2 Motor PE 8 (PE-Motor)
PE3 Motor Cable Shield 7 (Drain)

Apply power to the system.

Verify that the system is operating properly.
End.

8
 Appendix to Changing System / Axis Module on 1394 GMC and
1394 GMC Turbo Controllers

Ref.A-01 Connect Serial Comms.

A-01-1 Connect the Serial cable from the programming terminal to the J3 serial port on the
controller.
A-01-2 Set Serial Port Bitswitch bits 1-6 to the left.
Return to Connect Serial Comms.

Ref.A-02 Upload script.

1. Start GML Commander
2. Ensure the Application Keyswitch is in the Unlocked position on the system module.
3. Select File from the menu bar. The File menu appears.
4. Select Properties. The Properties window appears.

5. Click the Configure Interface button. The Serial Interface Configuration dialog will open.

9
• Ensure that the Baud rate is set to 9600 and the appropriate port is set for your PC.
• Click OK twice to close the dialog boxes.
6. Select Configure, Control Options from the menu bar.

7. Ensure that the control type is IMC S Class 1394/1394 Turbo, and the iCODE version
represents the controller Firmware Version or lower (Located on System module left hand
side). Also select the multi-drop checkbox if multi-drop addressing was previously used. And
set the control address to match the system module. Then click OK.

10
 8. Select Diagram, Online Connection. The controller should come Online.

If the controller came online go to 11. (This may take some seconds for the controller to
respond)

OR
If the controller did not come online:

9. Repeat part 5 with increasing baud rates selected from the dropdown choice.

10. Press F8 (Online connection) Twice. If the controller does not come on line after 30 seconds.
• Repeat 9 until all available baudrates have been tried.
• Ensure that the controlled copy of the diagram is available to download to the replacement
controller.
• Go to 6. Remove all power
11. In GML Commander, select Upload Options in the dialog menu. The Upload Options dialog
box opens.
12. In the Upload Options dialog box:
• Select All as an Upload Option,
• Accept a Lower Variable Address,
• Set the Upper Variable Address to 1999,
• Accept a Lower Cam Point,
• Set the Upper Cam Point to 12999,

11
 13. Select OK. GML Commander uploads the program, then displays the uploaded code in the
Script Editor Window.
14. Select Save in the Script Editor Window File Menu. The Save As Dialog box opens.
• Save the uploaded diagram script.
• Be sure to note the saved name and location of the new text file.
• Return to Upload script.

Ref.A-03 Disconnect system module (Series A or B)

Ensure that all cables connected to the front and bottom of the system module are identified and
removed.
1. Open the System Module door.
2. Label and remove any feedback or communication connections from the control board.
3. Label and remove the feedback and communication connectors from the bottom of the
System module.
4. Label and remove the 24V control power and 380/460V AC input power (U, V, W and
PE) from the System Module.
5. Remove the two screws that hold the input wiring board to the system module.
6. Gently pull the input wiring board away from the motion board set and the J4 connector.
Be careful not to lose the shoulder washers that may be included to help hold the input
board in place.
7. Allow the input wiring board to hang loose.
8. Return to Disconnect system module

12
Ref.A-04 Disconnect system module (Series C)
Picture…Fig B2, Fig B1

# User identification Wire Termination #

-----
1. / Sys Enable Motion Input Wiring Board TB1-01 1.
2. { . 24V Input Com Motion Input Wiring Board TB1-02 2.
3. \__ Shield Motion Input Wiring Board TB1-03 3.
4. /----- Home 0 Motion Input Wiring Board TB1-04 4.
5. { . Pos Overtrav 0 Motion Input Wiring Board TB1-05 5.
6. { . Neg Overtrav 0 Motion Input Wiring Board TB1-06 6.
7. { . Therm Flt 0 Motion Input Wiring Board TB1-07 7.
8. { . 24V Input Com 0 Motion Input Wiring Board TB1-08 8.
9. \__ Shield Motion Input Wiring Board TB1-09 9.
10. /----- Home 2 Motion Input Wiring Board TB1-10 10.
11. { . Pos Overtrav 2 Motion Input Wiring Board TB1-11 11.
12. { . Neg Overtrav 2 Motion Input Wiring Board TB1-12 12.
13. { . Therm Flt 2 Motion Input Wiring Board TB1-13 13.
14. { . 24V Input Com 2 Motion Input Wiring Board TB1-14 14.
15. \__ Shield Motion Input Wiring Board TB1-15 15.
16. /----- Reg0 5V Motion Input Wiring Board TB1-16 16.
17. { . Reg0 24V Motion Input Wiring Board TB1-17 17.
18. { . Reg Com Motion Input Wiring Board TB1-18 18.
19. \__ Shield Motion Input Wiring Board TB1-19 19.
20. /----- Reg2 5V Motion Input Wiring Board TB1-20 20.
21. { . Reg2 24V Motion Input Wiring Board TB1-21 21.
22. { . Reg Com Motion Input Wiring Board TB1-22 22.
23. \__ Shield Motion Input Wiring Board TB1-23 23.
24. /----- A Test 0 Motion Input Wiring Board TB1-24 24.
25. { . A Test 1 Motion Input Wiring Board TB1-25 25.
26. { . A Test Com Motion Input Wiring Board TB1-26 26.
27. \__ Shield Motion Input Wiring Board TB1-27 27.
28. /----- Sys Enable Motion Input Wiring Board TB2-01 28.
29. { . 24V Input Com Motion Input Wiring Board TB2-02 29.
30. \__ Shield Motion Input Wiring Board TB2-03 30.
31. /----- Home 1 Motion Input Wiring Board TB2-04 31.
32. { . Pos Overtrav 1 Motion Input Wiring Board TB2-05 32.
33. { . Neg Overtrav 1 Motion Input Wiring Board TB2-06 33.
34. { . Therm Flt 1 Motion Input Wiring Board TB2-07 34.
35. { . 24V Input Com 1 Motion Input Wiring Board TB2-08 35.
36. \__ Shield Motion Input Wiring Board TB2-09 36.
37. /----- Home 3 Motion Input Wiring Board TB2-10 37.
38. { . Pos Overtrav 3 Motion Input Wiring Board TB2-11 38.
39. { . Neg Overtrav 3 Motion Input Wiring Board TB2-12 39.
40. { . Therm Flt 3 Motion Input Wiring Board TB2-13 40.
41. { . 24V Input Com 3 Motion Input Wiring Board TB2-14 41.
42. \__ Shield Motion Input Wiring Board TB2-15 42.
43. /----- Reg1 5V Motion Input Wiring Board TB2-16 43.
44. { . Reg1 24V Motion Input Wiring Board TB2-17 44.
45. { . Reg Com Motion Input Wiring Board TB2-18 45.
46. \__ Shield Motion Input Wiring Board TB2-19 46.
47. /----- Reg3 5V Motion Input Wiring Board TB2-20 47.
48. { . Reg3 24V Motion Input Wiring Board TB2-21 48.
49. { . Reg Com Motion Input Wiring Board TB2-22 49.
50. \__ Shield Motion Input Wiring Board TB2-23 50.
51. /----- Drive OK1 Motion Input Wiring Board TB2-24 51.
13
 # User identification Wire Termination #
.
52. { Drive OK2 Motion Input Wiring Board TB2-25 52.
53. \__ Chassis Motion Input Wiring Board TB2-26 53.
54. Chassis Motion Input Wiring Board TB2-27 54.
.
55. { RIO A Remote IO A 55.
.
56. { RIO B Remote IO B 56.
.
57. { SLC In SLC In (Turbo only) 57.
.
58. { SLC Out SLC Out (Turbo only) 58.
.
59. { DH485 1 DH485 1 J1 Front 59.
.
60. { DH485 2 DH485 2 J2 Front 60.
.
61. { Axis Link Axis Link J1 Underside 61.
.
62. { RS-232 / RS-422 Chan A/J3 62.
.
63. { Flex IO Flex IO J2 63.
.
64. { RS-232, RS-422 & Chan B/J4 64.
DH-485
.
65. { Axis 0 Resolver FB Axis 0 Resolver Feedback input J5 65.
.
66. { Axis 0 Encoder I/P Axis 0 Auxiliary Encoder I/P J3 66.
.
67. { Axis 1 Resolver FB Axis 1 Resolver Feedback input J6 67.
.
68. { Axis 1 Encoder I/P Axis 1 Auxiliary Encoder I/P J4 68.
.
69. { Axis 2 Resolver FB Axis 2 Resolver Feedback input J7 69.
.
70. { Axis 2 Encoder I/P Axis 2 Auxiliary Encoder I/P J5 70.
.
71. { Axis 3 Resolver FB Axis 2 Resolver Feedback input J10 71.
.
72. { Axis 3 Encoder I/P Axis 2 Auxiliary Encoder I/P J10 72.
.
73. { PE Power Terminal Block PE 73.

Return to Disconnect system module

Ref.A-05 Reconnect System –Series C only - In the case of scheduled

maintenance:
To improve the bond between feedback cable shield and the System Module PE ground, cable shield clamps are
included with the series “C” System Modules.
Ensure that an appropriate amount of cable shielding is removed from the feedback cable to exposes the braid underneath.
Place the exposed cable braid into the cable shield clamp and tighten the clamp. Then screw the clamp to the bottom of
the System Module.

1 2 3 4

5
Return to scheduled maintenance.
14
Ref.A-06 Replace / Upgrade Axis Module

In the case of scheduled maintenance Series C only:

To improve the bond between motor cable shield and the System Module PE ground, cable shield clamps are
included with the series “C” System Modules.

1. Series ‘A’ non-flex cables produced before 1998 have a foil shield instead of braid. In order to
bond these shields to ground it is necessary to affect the following procedure.
• Remove approximately 25mm of insulation. Care must be taken not to cut the foil or inner
insulation.
• Fold back the foil to reveal its conductive side. Note that the outer of the foil is non-conductive.
• Insert copper tape, ensuring that a good connection is made with the drain wire.

• Go to 3
2. Braided shield type motor power cable.
• Remove approximately 25mm of insulation to exposes the braid underneath.
3. Place the exposed cable shield into the cable shield clamp and tighten the clamp. Then screw the clamp
to the bottom of the axis module.
4. Return to scheduled maintenance Series C axis.

15