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42 Reference lnstallation Drawings. Outline Drawings

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Wiring

System Power Connections

Wiring. System Power Connections 43

DANGER

The user is responsible for conforming to NEC and all other applicable local codes. Wiring, grounding, disconnects and overcurrent protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.

IQ-2OOO PCM

The PCM-10, PCM-20 and PCM-30 require single phase AC power, lo}-24o vAC. The pcM-75

requires single or three phase AC power, 100-U.O VAC. The input power may be optionally isolated

through a transformer. Field wiring must be copper, with a minimum rating of 60"C. The phasing of L1

and L2lI.{ to the PCM-10, PCM-20 and PCM-30 is arbitrary. The phasing of rhe PCM-75 is Ll, L2A.{

and L3 The earth ground connection is required for safe and proper system operation. Terminal block

connections should be torqued to 11 lb-in (1.25 Nm). The IQ-2000 does not contain supply fuses or dis-

connecting devices. These must be supplied by the machine builder and co¡nected externally for safety

and maintenance pu4)oses.

Refer to üe following drawings for complete power wiring details.

.

.

PCM-10, -2O ar:Ld -30 Power Wiring Diagram, drawing 9l0l-Zlg5 on page 76

PCM-75 Power Wiring Diagram, drawing 9LOI-1453 onpageTT

These drawings show an optional AC line filter, and shielded motor cable. These can be used in con-

junction with the grounded metal enclosure to meet tle Electromagnetic Compatibiüty requirements of the European Machinery Directive. A discussion of EMC can be found in "system Installation for Elec-

lQ 2000/5000 lnstallation Manual

44

Wiring. System Power Connections

tromagnetic Clmpatibili ty" otpage 25.

DANGER

Shielded power cables must be grounded at a minimum of one point for safety. Failure to ground a shield power cable will result in potentially lethal voltages on the shield and anything connected to it.

Auxiliary Logic Power

Single phase AC power, IOO-240 VAC, may be supplied to the internal logic supply through Ll ALIX

and L2lN ALIX.

Supply power to the logic supply is useful if the PCM logic must stay ON when üe motor power must be turned OFF. Absolute positioning is one example of when üis would be useful, since position infor- mation is maintained as long as logic power is on. Another example would be mahtaining PCM logic power so the PCM serial interface could be used for troubleshooting and diagnostics.

IQ.5OOO PCM

Power Supply Module (PSM)

The Power Supply Module (PSM) can supply DC power to as many as six PCM modules. Three phase AC power, ll5l23Ü VAC, is the only required input power for the PSM. The input power may be optionally isolated through a transformer. Field wiring must be copper, with a minimum rating of 60"C. The phasing of üe input power L1, L2, andL3, is arbitrary. The earth ground connection is required for safe and proper system operation. Terminal block connections should be torqued to 11 lb-in (1.25 Nm). on the PSM-50 ard24lb-rn (2.75 Nm) on the PSM-125. The IQ-5000 does not contain supply fuses or

disconnecting deüces. These must be supplied by the machine builder and connected externally for safety and maintenance purposes. The Power Suppty Modules will continue to operate with reduced capacity with the loss of one phase. The red phase loss LED on the front of the PSM will turn ON to

indicate the loss of the phase.

CAUTION

The power supply module allows for operation to continue even in the event of loss of one phase or during power disruption on the three phase AC inputs. Under these conditions, the Phase Loss LED will light, but the power

supply is not disabled. Extended operation of this product

with an AC phase input missing will reduce the life of the product.

Refer to drawing 9101-0411 on page 74 for details. This drawing shows an optional AC line filter, and shielded motor cable. These can be used in conjunction with the grounded metal enclosure to meet the Electromagnetic Compatibility requirements of the European Machinery Directive. A discussion of

EMC can be fouud in "System Installation for Electromagnetic Compatibiüty' otpage 25.

Positioning Drive Modules (DC Bus Power)

The DC bus from the PSM supptes power to the IQ-5000 PCMs. The DC bus must be connected as

shown in drawing 9101-0411 on page T4,wifhthe PSM in the center, ¡¡sing the connection wires pro-

vided.

lQ 2000/5000 lnstallation Manual

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Wiring. System Power Connections 45

CAUTION

Do nof substitute the DC bus wires provided with other wires. Failure to observe this precaution may result in damage to or destruction of the equipment.

Auxiliary Logic Supply

An auxiliary power supply module (PSM-AUX) is available to supply DC power to the logic supplies of up to four PCMs if the PSM is OFF. The PSM-ALIX uses single phase 115 VAC power as the input.

The PSM-AUX option is usefrrl if PCM logic power must stay on even when the motor supply (the

PSM) is off. Absolute positioning is one example of when the PSM-AIIX would be useful, since posi- tion i¡formation is maintained as long as logic power is on. Another example would be maintaining PCM logic power so the PCM serial interface could be used for troubleshooting and diagnostics. Refer

to the drawing 9l0l-OL34 on page 75 for wiring information on the PSM-AUX and optional PSM-ALX

isolation ffansformer.

PSM Interface logic

The Status signal and the Enable signal on the PSM are proüded to interface the PSM wiü the PCM or

another control. The following drawings illustrate typical internal circuitry for the interface connec-

tions, and sample external connections of the PCMs.

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POI.IE R SU?PLY XODULT

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lQ 2000/5000 lnstallation Manual

46

Wiring . System Power Connections

SAIYPTE E XTE RNAL

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PSM Interface - External Connection Examples

PSM Connector

P1

General

Purpose

Inputs/Outputs

Pin #

Signal Name

I

Status-

2

Status +

J

PSM Enable-

4

PSM Enable +

lQ 2000/5000 lnstallation Manual

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Wiring'System PowerConnections 47

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Status

The Status outputs are the contacts of a normally open relay, which closes to indicate that the PSM is operating properly. An open relay signals that no AC power is applied to the PSM or that a PSM fault has occurred. Refer to the above drawing for connection examples.

Enable

The PSM Enable input is an optically isolated input which controls the power output of the power sup-

ply module. The PSM Enable input is turned on by sourcing current through the opto-isolator. Refer to

the above drawing for connection examples. The position, A (see figure below).

With the jumper in the enable input activated position (optional Position A), the PSM is enabled if the

input is only functional ifjumper Wl is il the optional

enable input is ON. With the enable input OFF, üe PSM DC bus is turned OFF and the dissipative shunt

is turned ON to quickly discharge the DC bus capacitors and dynamically brake synchronous motors.

This is to allow time for the PCMs to power-up and apply the enable signal to the PSM if the PSM is to remain on.

WARNING

lf the PSM is disabled during a power up, the DC bus voltage will be present for at least two (2) seconds before returning to a zerc (0) Volt condition.

With the jumper in the enable input deactivated position (standard Position B), the enable input has no effect on the PSM operation and the PSM activates itself when tkee phase voltage in the proper voltage range is connected to the input.

POWER SUPPLY MODULE

CIRCUIT BOARD

(COMPONENTSIDE)

a I DIAGNOSTTC

INDICATOR

LIGHTS

TB1

INTERFACE

CONNECTOR

W1 JUMPER SETTING

SHORTING

JUMPER ACROSS

TOP 2 PINS (POS|T|ON

A)

SHORTING JUMPER ACROSS BOTTOM 2 P|NS (POSTTTON B)

(STANDARD

SETTING)

SELECTS:

EXTERNAL ENABLE INPUT IS SELECTED.

EXTERNAL

CONNECTION

IS REQUIRED

TO CONNECTOR

TB1 SIGNALS ENABLE+

AND ENABLE-. REFERTO INSTRUCTION

MANUAL

FOR SIGNAL SPECIFICATION

AND DETAILS OF OPERATION USING POSITION A,

BEFORE

EXTERNAL ENABLE INPUT IS DE.ACTIVATED, POWER SUPPLY I\4ODULE IS ENABLED WHENEVER INPUT POWER IS APPLIED AND NO POWER SUPPLY

I\4ODULE FAULT CONDITIONS

ARE DETECTED,

Power Supply Module Jumper Location

lQ 2000/5000 lnstallation Manual

48 Wiring r System Power C"onnections

Replacing the PSM Shunt Fuse (IQ-5000 only)

The DC Bus shunt fuse is located in the Power Supply Module. To check anÜor replace this fuse:

1. Measure voltages atLl,L2,and L3 phase to phase to ensure incoming power is OFF Make sure

that the green PSM READY LED is OFF Remove the PSM cover' Remove the shunt fuse and test with an ohmmeter'

L

WARNING

when replacing the PSM 50 and PSM 125 s-hunt fuse a DC rated fuse must be used'

J. Replace the shunt fuse.

4. Install the PSM cover.

Shunt Resistor

DC Bus Terminals

lQ 2000/5000 lnstallation Manual

Power SuPPIY Modulg

(lQ 5000 OnlY)

PSM-125

.

20 AmpeE KLKD-2o or KLitr2O

PSM - 50

I Ampere KLKD-8 or KLM{

' PSlr-125 wiih exterml shuot

3OAmPeeKLKD-1OorKLl,.30

Shunt Fuse Location

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Wiring'System PowerConnections 49

Opárator Termina!

The Operator Terminal may be powered from 115/230 VAC single phase or optionally, *om24 VDC or

24yAC. The Operator Terminal must be properly grounded to prevent it from radiating radio frequency

noise.

The following diagram illustrates the power connections to the operator Terminal.

I

2/\ PL

GROUND (EARTH)

115/230 VAC (NEUTBAL)

11s1230 VAC HOT)

Operator lbrminal Power Connections (1.15/230 \4\C Version)

L1 L2lN Pt

GROUND (EARTH)

24 VDC (DC-), 24 VAC (NEUTRAL)

24vDC (DC+), 24 VAC (HOT)

Operator Terminal Power Connections (24 VDC, 24VAC Version)

lQ 2000/5000 lnstallation Manual

50

Wiring. System Power Connections

t

Motor Power Connections

The phasing of the three phase drive module outputs R, S, and T must conform to the motor R, S, and T

leads for proper operation. Connect the earth ground to ensure a safe installation and proper operation.

Refer to the following motor connection üagrams for connector, pin, and signal identification.

nnIvr yoou-r

I

TERY I NALS

R

DR IVE [,]ODULE

CFASS ] 5

Notes:

2. 1.

.r.

IlOTOR PCi./ER

IlAT.NG

CONNECTOR

A

C

D

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S-SER]E5 AND

F-5ERIE5 IIOTORS

fi0T0R P0\"iE a

CONNE CTOR

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l'40T0R CASE

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Do not interchange any connections in this cable.

Ground Connections:

lQ-2000 - Screw Terminal IQ-5000 - MG Stud Wire colors shown are for cables supplied by Electro-Craft

Motor Power Connections

I-5300 AND

.6600

l'10T0R5

14OTOR POIiER

TERI,IINAL STR IP

R

MoToR .ASE

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WARNING

High voltage may be present on the terminals of the lQ-Series Positioning Control Module. Remove power and disconnect the power cable before making or removing any connection.

Cab1e sizes are inücated in the appropriate drawings:

.

.

.

910l-2195 on page 76 for the PCM-10, PCM-20 and PCM-30 (IQ-2000)

910l-1453 on page 77 for the PCM-75 (IQ-2000)

9101-0411 on page 74 for the IQ-5000.

L

Standard cables supplied by Electro-Craft are not intended for applications where frequent flexing occurs. The motor connectors are intended to be connected or disconnected only when the system

power is off, and must zol be used to disconnect live equipment.

WARNING

Motor power connectors are for assembly purposes only.

They should notbe connected or disconnected while power

is applied to the drive.

lQ 2000/5000 lnstallation Manual

Wiring. System Power Connections 51

CAUTION

Do nottin (solder) the exposed leads on cables. Solder contracts over time and may loosen the connection.

Shield Termination of Power Cables

DANGER

Shielded power cables must be grounded at a minimum of one point for safety. Failure to ground a shielded power cable

will result in potentially lethal voltages on the shield and

anything connected to it.

F-, H-, N- and S-Series Power Cables

Electro-Craft motor power cables are shielded. The power cable is designed to be terminated at the drive during ilstallation. A small portion of the cable jacket is stripped, which exposes the shield wires.

The exposed area must be clamped at the left front of the drive chassis using the clamp provided near the bottom. It is critical for EMC performance that the shield wires be clamped against the area of the chassis which is not painted. This section of thp chassis is labeled with the chassis ground symbol.

Cable Jacket

Motor Power EMC Shield Connection

Drawings which illustrate the power connections for specifi.c F-Series, H-Series, N-Series, S-Series, W- Series, and I-Series motors are supplied with the motors and are available in the Electro-Craft catalog or

via the Electro-Craft BBS.

i

lQ 2000/5000 lnstallation Manual

52 Wiring . Control Connections

a

Control Connect¡ons

This section covers the control and interface connections between the PCM and the rest of üe system.

This includes: Digital VO, Analog VO, Relay Outputs, Encoders, Step and direction Inputs, and Serial

Ports.

The following diagram illustrates all control connections to the PCM.

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OPERATER

STATlO\

10 Moster

PRO6RAMMI

TERMI NAL

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MA§TER ENCODER

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Wiring. Control Connections Sg

Oigital lnputs and Outputs

Each IQ-Series PCM provides

confol and interface. The general

16 optically isolated inputs and 8 optically isolated outputs fo¡ machine

purpose VO uses a24 voltDCsuppty voltage. rire pcvt has an inter-

üis pu{pose, isolated rrom t¡e logic common. The 24 volt

provide a corrrmon ground reference. The 1A fuse, Fl, on

nal24YDC @ 500 mA power supply for

common must be tied to machine ground to

the PCM protecrs the hternal 24VDC supply.

Note:

The user may supply

externar 24vDcpower by removing wire jumpÁ w3 and w4 on

connecting the external supply to t¡e iz+únc *¿ 24 volt com_

the PCM logic board, and

mon on connectors P1 and p2.

Pin 1 of the interface

connectors P1,P2, and P3 is located at the bottom of the connector and is indi-

cated on the front of the pCM.

RESTSTTANCE

[S 330 oxlM Mlt{tMtiM

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IN|ITERNAL

INTEFÍ{AL 24 VDC §UFPLY

24 VOú eO,MMOit

75M mS PER OLrmr

56emA

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INPLf SW:'rq,lEg:,qES|STAN6E

tS aoo! úHkl MIAX|MIUM

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24 V]DE SUgFIY

Typical Digital VO Wiring

CAUTION

The lQ-series uses sinking (NpN) styre

inputs and outputs.

¡n the usA. rf a

This is the most common interface used

ground fault occurs on an input, it can become active and may result in a potentially hazardous unanticipated machine state. Contact Electro-Craft for more information.

The IQ 2000/5000 has sinking (active low) vo

which is common in the uS, but sourchg (active high) V

rail mounted interface board which converts the vo

board must be mounted in the same enclosure as

o is preferred in Europe. Electro-craft offers a DIN

from sinking to sourcing (active high). This hterface

the drive. The interface board and cables are listed below:

.

.

.

9103-0t52

44-0t41_o03

44-0141-OLO

24YDC Sourcing VO Conversion Card

IQ-Series to VO Conversion Card, 3-foot Cable

IQ-Series to VO Conversion Card, l0-foot Cable

IQ 2000/5000 lnstallation Manuat

54

Wiring . Control Connections

Digital tnpirts

The opücally isolated inputs are connected with an internal pu[-up resistor to +24 YDC. Making a con- nection fo the 24 volt common (closing a switch) will allow curent to flow through üe opto-isolator,

turning it on. In general, inputs are considered ON in this state, and OFF when there is no connection from the nputto )4 volt common. The Forward and Reverse Limit switches are exceptions, with the

switch open indicating that a limit has been hit. The Home Switch input parameter defi.nes the Home

switch input to be open or closed to indicate the home position, and the PAUSE parameter can select the

Pause input as active open or active closed.

The general purpose inputs on the PCM are referred to as I1 through 116 in program statemetrts. Inputs

11 through I10 can be assigned the predefined functions shown in the table below. Inputs I11 andll2

may be used as Intemrpt inputs. Inputs I12 to 116 may be used as program select inputs. Any of these

input functions may be üsabled and the inputs used as general purpose inputs.

,

In adütion to the input functions defined below, other functions may be assigned to any available input. These optional input functions are Hardware Reset, Kill program, and Define Home

Connector

P1

General

Purpose Inputs

lQ 2000/5000 lnstallation Manual

Pin

1

Signal Name

24YDC Common

Assignable Function

2

Input 1 (I1)

Forward Limit

J

Input

2 (I2)

Reverse Limit

4

Input

3 (I3)

Enable

5

Input

4 (I4)

Start Program

6

Input

5 (5)

Home Switch

7

Input

6 (16)

Home Command

8

Input

7 (I7)

Jog Reverse

9

Input

8 Q8)

Jog Forward

10

Input

9 (9)

Pause

11

Input 10 (I10)

Emergency Return

t2

Input

11 (I11)

Intl / Program Select

t3

Input

12 (I12)

Int2 / Program Select

T4

Input 13 (I13)

Program Select

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Wiring ' Control Connections

Connector

Pin

Signal Name

Assignable Function

 

P2

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2

and Outputs

 

3

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Input

14 (I14)

Program Select

Input

15 (I15)

Program Select

Input

16 (I16)

Program Select MSB

+24YDC

Note: Even if an input is assigned a function it may be used as a general purpose

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lQ 2000/5000 lnstallation Manual

56

Wiring'ControlConnections

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Digital OutPuts

The general purpose outputs are referred to as 01 through 08 in progfam statements' The outputs are

optiáIy isolated and operate

on the same 24 volt supply used by the general purpose inputs. These

ootprrt.-*" all capable of

08 are defined respectively these output functions may

Output O+^uy be enabled Home output.

sinking 75 mA continuously, driven to less than 1 volt. Outputs 06, 07, and

as Home Sequence Complete, In Position, and Error outputs, however,

be disabled and the outputs used as general purpo§e ouQuts' Optionally'

as a Program Running output, and Output 05 may be enabled as an At

External circuitry

outputs in an

must be used to ensure the state of digital

emergency stop situation. The lQ-series will nof automaticallY turn outputs off.

Connector

P2

General

Purpose Inputs

and Outputs

Pin

Signal Name

4

Output

1 (O1)

5

Output 2(O2)

6

Output 3 (O3)

1

Output 4 (O4)

8

Output 5 (O5)

9

Ouput 6 (06)

10

Output 7 (O7)

11

Output 8 (O8)

t2

+24YDC

Assignable Function

P2

Program Running

At Home

Home Sequence Com- plete

In Position

Error

+24YDC

Connecting Inputs and Outputs Tbgether

A digital output from a PCM may be connected to an input on the same controller or another controller.

A single

wire connection between

the output pin and the input pin is all that is required. If conaecting V

. O between controllers, the 24 VDC common (Pl pin 1) also needs to be connected between each con-

troller.

Multiple digital outputs

may be wired together to form a wire OR connection. If any one of the outputs

pulled low (on). This is useful for connecting the Error output§ (O8) from each axis

turns on, tfre me is

of a system to a host PLC or