Allen-Bradley 9/Series 230, 260, 290, 440, 440HR CNC Hardware User Manual

The 9/Series 230, 9/Series 260, 9/Series 290, 9/Series 440, and 9/Series 440HR CNC Hardware are used to control the motion of machines in a variety of applications. They offer a range of features and benefits to meet the needs of different users. These systems are designed for high performance, reliability, and ease of use. They are also designed to be easy to integrate into existing systems.

PDF Download

Document

Allen-Bradley

9/Series CNC

Hardware

Integration and

Maintenance

Manual

P--1

Publication XXXX-XX.X -- September 1995

TAB 9

TAB 10

TAB 11

TAB 12

TAB 13

TAB 14

TAB 15

TAB 16

TAB 17

TAB 18

TAB 1

TAB 2

TAB 3

TAB 4

TAB 5

TAB 6

TAB 7

TAB 8

9/Series Hardware

Using this Manual and System Overview

System Layout and Dimensions

9/230 CNC Systems

9/260 and 9/290 CNC Systems

9/440 CNC Systems

Emergency Stop Design

Making Cables and Noise Prevention Techniques

Communications

Operator Interface

I/O Interface

1394 Digital Drive Systems

Analog Servo Drive Connection

8520 Digital Drive Systems

System Startup

Troubleshooting and Replacement Procedures

Error and System Messages

Installing 9/Series Hardware for CE Compliance

Manual Index

852062--RM025A--EN--P -- November 2000 PN--176965

Important User Information

Because of the variety of uses for this product and because of the differences between solid state products and electromechanical products, those responsible for applying and using this product must satisfy themselves as to the acceptability of each application and use of this product. For more information, refer to publication SGI-1.1 (Safety Guidelines For The Application,

Installation and Maintenance of Solid State Control).

The illustrations, charts, and layout examples shown in this manual are intended solely to illustrate the text of this manual. Because of the many variables and requirements associated with any particular installation, Allen-Bradley

Company cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.

No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment or software described in this text.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen-Bradley Company is prohibited.

Throughout this manual we make notes to alert you to possible injury to people or damage to equipment under specific circumstances.

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

Attention helps you:

- Identify a hazard

- Avoid the hazard

- recognize the consequences

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

New Information

Revision Bars

Summary of Changes

9/Series hardware

Integration and Maintenance Manual

October 2000

The following is a list of the larger changes made to this manual since its last printing. Other less significant changes were also made throughout.

2 new versions of the MTB panel ; 24 Volt direct I/O and LED lamp version. (chapter 9A)

New contact information (chapter 14)

Enhanced servo tuning screens (chapter 15A)

Enhanced servo diagnostic screens (chapter 15A)

New Error Messages for the above features (chapter 16)

We use revision bars to call your attention to new or revised information.

A revision bar appears as a thick black line on the outside edge of the page as indicated here.

Chapter

1-2

Table of Contents

9/Series Integration and Maintenance Manual

TAB 1

TAB 2

TAB 3

Using This Manual

1A.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A.1

Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A.2

Terms and Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A.3

Attention and Important Information

1A.4

Related Publications

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A-1

1A-2

1A-3

System Overview

1B.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B.1

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B.2

9/230 Component Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . .

1B.3

9/260 and 9/290 Component Enclosure . . . . . . . . . . . . . . . . . .

1B.4

Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B.5

Operator Interface Components . . . . . . . . . . . . . . . . . . . . . . . .

1B.6

Drives Interface

1B.7

I/O Interface

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B.8

Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B.9

Offline Development System (ODS) . . . . . . . . . . . . . . . . . . . . .

1B.10 Adjustable Machine Parameters (AMP)

1B.11 Programmable Application Logic (PAL)

1B.12 Fiber Optic I/O Ring

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B-11

1B-12

1B-15

1B-16

1B-1

1B-6

1B-7

1B-8

Planning Your System Layout

2A.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2A.1

Determining Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . .

2A.2

Meeting Environmental Conditions . . . . . . . . . . . . . . . . . . . . . .

2A.3

Designing the Cabinet for your System’s Environment . . . . . . . .

2A.4

Maintaining Cabinet Temperature

2A.5

Reducing Noise

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2A.6

Installing the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2A-1

2A-3

2A-4

2A-8

Mounting Dimensions

2B.0

Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2B.1

Common System Component Dimensions . . . . . . . . . . . . . . . . .

2B-1

2B-10

Primary 9/230 Components

3A.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.1

The Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.1.1 Connections on the Processor Board

3A.1.2 Reading LEDs

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A-1

3A-2

3A-3

3A-5 i

Table of Contents

9/Series Integration and Maintenance Manual

3A.1.3 Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.1.4 Main Power Supply (PS2A) . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.2

Servo Axis Connectors on the 9/230 Analog

3A.2.1 Connecting Axes to Analog Servo Interface

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

3A.2.2 Analog Servo Operation and Specifications . . . . . . . . . . . . . . . .

3A.2.3 Analog Servo Connectors and Pin Assignments . . . . . . . . . . . .

3A.3

Analog Servo Amplifiers

3A.4

Analog Servo Motors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.5

Encoder Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.6

9/230 Compatible Feedback Devices . . . . . . . . . . . . . . . . . . . .

3A.6.1 Wiring an Incremental Feedback Device . . . . . . . . . . . . . . . . . .

3A.7

Servo Axis Connectors on the 9/230 Digital CNC . . . . . . . . . . .

3A.7.1 Connecting Axes to Digital Servo Interface

3A.7.2 Digital Servo Operation and Specifications

. . . . . . . . . . . . . . . .

3A.7.3 9/230 Digital Connectors and Pin Assignments

3A.7.4 Digital Servo Amplifiers

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.7.5 Digital Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.8

Using Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A.9

Wiring a Touch Probe to the Processor Module . . . . . . . . . . . . .

3A.10 Adaptive Depth Probing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3A-16

3A-17

3A-18

3A-21

3A-24

3A-6

3A-7

3A-8

3A-9

3A-12

3A-13

3A-24

3A-26

3A-27

3A-30

3A-31

3A-32

3A-33

3A-36

Power Distribution

3B.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3B.1

Connecting the PS2 Main Power Supply . . . . . . . . . . . . . . . . . .

3B.2

Main and Operator Panel Power Supply Input

Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3B.3

Protective Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3B-1

3B-2

3B-4

3B-9

TAB 4

Primary 9/260 and 9/290 Components

4A.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A.1

The Motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A.2

Connections on the Motherboard . . . . . . . . . . . . . . . . . . . . . . .

4A.3

CPU Board for 9/260 and 9/290

4A.4

Reading LEDs

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A.5

Battery Backup for the 9/260 and 9/290

4A.6

Main Power Supply

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A-1

4A-3

4A-4

4A-6

4A-7

4A-9

4A-10

Connecting the 3-axis Servo Module

4B.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B.1

How the 8520 Digital Servo Card Works

4B.2

8520 Digital Servo Module (8520-ENC3)

. . . . . . . . . . . . . . . . . .

4B.2.1 Servo Module Connectors and Pin Assignments . . . . . . . . . . . .

4B-1

4B-3

4B-6

4B-7

Table of Contents

9/Series Integration and Maintenance Manual

4B.2.2 Digital Servo Module Specifications

4B.2.3 Servo Module Battery Replacement

. . . . . . . . . . . . . . . . . . . . .

4B.3

Optional Feedback Module . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B.3.1 Optional Feedback Module Power Requirements . . . . . . . . . . . .

4B.3.2 Optional Feedback Module Connectors and Pin Assignments

4B.3.3 Optional Feedback Module Jumper (JP1)

. . .

. . . . . . . . . . . . . . . . .

4B.3.4 Optional Feedback Module Variable Resistors (Pots)

4B.3.5 Optional Feedback Module Test Points

. . . . . . . . .

. . . . . . . . . . . . . . . . . . .

4B.4

Wiring a Touch Probe to the Digital Servo Module

4B.5

Adaptive Depth Probing

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B.6

How the Analog Servo Module Works

4B.6.1 Analog Servo Module

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B.6.2 Analog Servo Module Connectors and Pin Assignments

4B.6.3 Analog Servo Module Specifications

. . . . . . .

. . . . . . . . . . . . . . . . . . . . .

4B.6.4 Connecting Axes to Analog Servo Module

4B.6.5 Analog Servo Module LED Indicators

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

4B.6.6 Analog Servo Module Test Points . . . . . . . . . . . . . . . . . . . . . . .

4B.7

Encoder Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B.8

Compatible Feedback Devices . . . . . . . . . . . . . . . . . . . . . . . . .

4B.8.1 Wiring an Incremental Feedback Device . . . . . . . . . . . . . . . . . .

4B.9

Wiring a Touch Probe to the Analog Servo Module

4B.10 Adaptive Depth Probing

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B-22

4B-23

4B-25

4B-28

4B-29

4B-32

4B-14

4B-15

4B-16

4B-17

4B-18

4B-21

4B-33

4B-37

4B-38

4B-39

4B-41

4B-42

4B-45

4B-48

4B-51

Connecting the 4-axis Servo Module

4C.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4C.1

How the Digital Servo Card Works . . . . . . . . . . . . . . . . . . . . . .

4C.2

Digital Servo Module (8520-ENC4) . . . . . . . . . . . . . . . . . . . . . .

4C.3

How the Analog/1394 Servo Module Works . . . . . . . . . . . . . . . .

4C.4

Analog/1394 Servo Module (8520-SM4) . . . . . . . . . . . . . . . . . .

4C.5

Connecting Axes to the Servo Module . . . . . . . . . . . . . . . . . . . .

4C.5.1 Servo Module Connectors and Pin Assignments . . . . . . . . . . . .

4C.5.2 8520-ENC4 Servo Module Specifications . . . . . . . . . . . . . . . . .

4C.5.3 8520-SM4 Servo Module Specifications . . . . . . . . . . . . . . . . . .

4C.5.4 Digital Servo Module Battery Replacement . . . . . . . . . . . . . . . .

4C.5.5 Servo Module LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . .

4C.5.6 Servo Module Test Points

4C.6

Encoder Termination Panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

4C.7

Compatible Feedback Devices . . . . . . . . . . . . . . . . . . . . . . . . .

4C.7.1 Wiring an Incremental Feedback Device . . . . . . . . . . . . . . . . . .

4C.8

Wiring a Touch Probe to the Servo Module

4C.9

Adaptive Depth Probing

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4C-9

4C-15

4C-16

4C-17

4C-19

4C-1

4C-4

4C-5

4C-8

4C-19

4C-20

4C-21

4C-24

4C-27

4C-31 iii

Table of Contents

9/Series Integration and Maintenance Manual

TAB 5

Power Distribution

4D.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4D.1

Connecting the Main Power Supply . . . . . . . . . . . . . . . . . . . . .

4D.2

Main and Operator Panel Power Supply

Input Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4D.3

Protective Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4D-1

4D-2

4D-5

4D-10

The 9/440 Resolver- based CNC/Drive System

5A.0

Section Overview

5A.1

Hardware Overview

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A.2

CNC Processor Board

5A.3

Connecting Feedback

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A.3.1 Connecting Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . .

5A.3.2 Encoder Feedback (Optional Feedback)

5A.4

9/440 Resolver--based CNC Wiring Board

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

5A.4.1 Wiring a Touch Probe to the 9/440 . . . . . . . . . . . . . . . . . . . . . .

5A.4.2 9/440 Resolver--based Control Remote I/O Connection

5A.4.3 9/440 Resolver--based Analog Out (TB2 and TB3)

. . . . . . .

. . . . . . . . . . .

5A.4.4 Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A.5

Power Terminal Block Connection

5A.5.1 On/Off Control and 24V Logic Power

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

5A.5.2 Drive Power 3 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A.6

Connecting Axis Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A.7

9/440 Resolver--based LEDs . . . . . . . . . . . . . . . . . . . . . . . . . .

5A.8

General Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A-1

5A-6

5A-10

5A-12

5A-14

5A-19

5A-20

5A-25

5A-26

5A-27

5A-28

5A-29

5A-32

5A-36

5A-39

5A-40

The 9/440HR CNC/Drive System

5B.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B.1

Hardware Overview

5B.2

CNC Processor Board

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B.3

Connecting Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B.3.1 Connecting the 1326AB Motor--mounted Feedback Device . . . . .

5B.3.2 Connecting A Quad B Optional Feedback Ports

5B.4

9/440HR CNC Wiring Board

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

5B.4.1 Wiring a Touch Probe to the 9/440

5B.4.2 9/440HR Remote I/O Connection

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

5B.4.3 9/440HR Analog Out (TB2 and TB3)

5B.4.4 Battery Backup

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B.5

Power Terminal Block Connection

5B.5.1 On/Off Control and 24V Logic Power

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

5B.5.2 Drive Power Three--phase

5B.6

Connecting Axis Modules

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B-1

5B-6

5B-10

5B-12

5B-15

5B-20

5B-21

5B-26

5B-27

5B-28

5B-29

5B-30

5B-32

5B-35

Table of Contents

9/Series Integration and Maintenance Manual

TAB 6

TAB 7

TAB 8

5B.7

9/440HR LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B.8

General Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B-38

5B-39

Emergency Stop Design

6.0

6.1

6.2

6.3

6.4

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-Stop Connections

E-Stop String

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-Stop Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Events When E-Stop Occurs . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-2

6-5

6-6

Cable Diagrams

7A.0

Connecting the Components and Modules

7A.1

System Cabling Diagrams

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A.2

Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A-1

7A-13

Fiber Optic Connections

7B.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B.1

Fiber Optic Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . .

7B.2

Fiber Optic Cable Construction . . . . . . . . . . . . . . . . . . . . . . . . .

7B-1

7B-4

Noise Prevention

7C.0

Section Overview

7C.1

Preventing Noise

7C.2

Reducing Noise

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7C-1

7C-10

Communication Interface

8.0

8.1

8.2

8.3

8.4

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RS-232 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RS-232 Signal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection of Peripherals

RS-422 Interface

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5

8.6

RS-422 Signal Description

Connection of Peripherals

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7

Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7.1

RS-491 Level 1 Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7.2

RS-491 Level II Protocol

8.8

Peripherals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9

Remote I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9.1

9/290 Remote I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11

8-15

8-19

8-20

8-7

8-8

8-9

8-1

8-2

8-3

8-6 v

Table of Contents

9/Series Integration and Maintenance Manual

TAB 9

8.9.2

9/260 Remote I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9.3

9/230 Remote I/O Connection . . . . . . . . . . . . . . . . . . . . . . . . .

8.9.4

9/440 Remote I/O Connection

8.10

MMS Ethernet Communications

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

8.11

DH+ Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-23

8-27

8-28

8-29

8-30

Operator Interface

9A.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A.1

Operator Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A.2

Mounted Operator Panel Installation . . . . . . . . . . . . . . . . . . . .

9A.2.1 Mounted Operator Panel Video Connector . . . . . . . . . . . . . . . .

9A.2.2 Mounted Operator Panel Power Supply . . . . . . . . . . . . . . . . . .

9A.2.3 Mounted Operator Panel Fiber Optic Connection . . . . . . . . . . . .

9A.2.4 Mounted Operator Panel Node Address Setting . . . . . . . . . . . . .

9A.2.5 Flat Panel Horizontal Adjustment

9A.2.6 Keyboard Interface Jumper JP3

9A.2.7 Adjusting Monitor Intensity

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A.3

Removable Operator Panel Installation . . . . . . . . . . . . . . . . . . .

9A.3.1 Installing the Removable Operator Panel Interface Assembly . . .

9A.3.2 Connecting/Disconnecting the Removable Operator Panel . . . . .

9A.3.3 Multiple Removable Operator Panel Assemblies

9A.4

MTB Panels

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A-23

9A-26

9A.4.1 MTB Panel Connectors and Pin Assignments (fiber--optic versions)9A-28

9A.4.1.1 MTB I/O Module Specifications . . . . . . . . . . . . . . . . . . . . . . . .

9A.4.1.2 MTB Panel I/O Module Fiber Optic Connection . . . . . . . . . . . . .

9A.4.1.3 MTB I/O Module Mode Setting . . . . . . . . . . . . . . . . . . . . . . . . .

9A-33

9A-35

9A-36

9A.4.1.4 MTB I/O Module Node Address Setting . . . . . . . . . . . . . . . . . . .

9A-36

9A.4.2 MTB Panel Connectors and Pin Assignments (Direct I/O version) 9A-37

9A.5

HPG (Hand Pulse Generator) . . . . . . . . . . . . . . . . . . . . . . . . . .

9A-41

9A.5.1 HPG Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A.5.2 HPG Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A.5.3 HPG Node Address Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .

9A-41

9A-43

9A-11

9A-12

9A-14

9A-15

9A-21

9A-1

9A-4

9A-6

9A-7

9A-9

9A-10

Integrating Your Teach Pendant

9B.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9B.1

Connecting the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . .

9B-1

9B.2

Using DF1 Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9B-2

9B.3

Programming the Teach Pendant to Send and Receive Messages 9B-2

9B.4

Sending Commands to PAL (CMD=60 hex) . . . . . . . . . . . . . . . .

9B-4

9B.5

Sending Commands to the Application Software (CMD=61 hex) .

9B-5

9B.6

Receiving Unsolicited Messages from the Control (CMD=62 hex) 9B-7

Table of Contents

9/Series Integration and Maintenance Manual

TAB 10

9B.7

Receiving the Illegal Request Message from the CNC

(CMD=63 hex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9B-8

I/O Interface

10A.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.1 Fiber Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.1.1 Fiber Optic Ring Device Fault Indicators . . . . . . . . . . . . . . . . . .

10A.2 Push-Button MTB Panel I/O Module . . . . . . . . . . . . . . . . . . . . .

10A.2.1 Push-Button MTB Panel I/O Module Pin Assignments . . . . . . . .

10A.2.2 Push-Button MTB Panel I/O Module Specifications . . . . . . . . . . .

10A.2.3 Push-Button MTB Panel I/O Module Fiber Optic Connection . . . .

10A.2.4 Push-Button MTB Panel I/O Module Node Address Setting . . . . .

10A.2.5 Setting the Push-Button MTB Panel I/O Module for a Custom MTB Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.3 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.3.1 Digital I/O Connection

10A.3.2 Digital I/O Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.3.3 Digital I/O Fiber Optic Connections . . . . . . . . . . . . . . . . . . . . . .

10A.3.4 Digital I/O Node Address Setting

10A.4 High--density I/O Module

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.4.1 High Density I/O Module Connection . . . . . . . . . . . . . . . . . . . . .

10A.4.2 High Density I/O Module Specifications . . . . . . . . . . . . . . . . . . .

10A.4.3 High--density I/O Module Fiber Optic Connection . . . . . . . . . . . .

10A.4.4 High Density I/O Module Node Address Setting . . . . . . . . . . . . .

10A.5 E--Series Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.5.1 E--Series Analog I/O Specifications . . . . . . . . . . . . . . . . . . . . . .

10A.5.3 E--Series Analog I/O Fiber Optic Connection . . . . . . . . . . . . . . .

10A.5.4 E--Series Analog I/O Node Address Setting . . . . . . . . . . . . . . . .

10A.5.5 E--Series Analog I/O Bipolar/Unipolar Configuration . . . . . . . . . .

10A.6 1746 I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.6.1 Removing/Installing 1746 Modules . . . . . . . . . . . . . . . . . . . . . .

10A.6.2 1746I I/O Ring Adapter Node Address Setting . . . . . . . . . . . . . .

10A.6.3 1746P1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.6.4 1746 I/O Ring Adapter Fiber Optic Connection

10A.7 1746 Discrete I/O Racks

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.7.1 Wiring 1746 Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.8 1746 Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.8.1 Analog I/O Specifications (1746-NIO4V) . . . . . . . . . . . . . . . . . .

10A.9 1746 I/O Fault Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A.9.1 Troubleshooting the 1746I Communication Module

10A.10 Fast I/O (9/260 and 9/290 only)

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

10A.11 Wiring I/O Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A-1

10A-4

10A-7

10A-8

10A-12

10A-15

10A-16

10A-46

10A-48

10A-49

10A-50

10A-52

10A-54

10A-56

10A-57

10A-61

10A-62

10A-63

10A-66

10A-17

10A-18

10A-19

10A-26

10A-32

10A-33

10A-34

10A-38

10A-40

10A-41

10A-42

10A-43

10A-46 vii

viii

Table of Contents

9/Series Integration and Maintenance Manual

TAB 11

9/Series Adapter Modules for 1771 and 1746 I/O Devices

10B.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10B.1 1771 I/O Ring Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . .

10B.1.1 1771 I/O Ring Adapter Fiber Optic Connection . . . . . . . . . . . . . .

10B.1.2 1771 I/O Ring Adapter Node Address Setting . . . . . . . . . . . . . .

10B.2 1746 I/O Ring Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . .

10B.2.1 1746I I/O Ring Adapter Node Address Setting . . . . . . . . . . . . . .

10B.2.2 1746 I/O Fault Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10B.2.3 9/Series 1746 I/O Catalogs . . . . . . . . . . . . . . . . . . . . . . . . . . .

10B.2.4 Other Compatible 1746 I/O Modules . . . . . . . . . . . . . . . . . . . . .

10B.2.5 Troubleshooting the 1746I Communication Module

10B.3 1771 and 1746 I/O adapter ASRN Use

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

10B-1

10B-2

10B-3

10B-5

10B-7

10B-8

10B-10

Connecting 1394 Digital Drive Systems

11.0

Section Overview

11.1

Hardware Overview

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2

Resolver Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3

Connecting the 9/Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4

1394 Addressing and Fiber Optic Connections

11.5

1394 Drive E-Stop Connection (TB1)

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

11.6

1394 Low Voltage Test Points (TB3)

11.7

1394 LEDs

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.8

General Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1

11-3

11-5

11-8

11-10

11-12

11-13

11-14

TAB 12 Wiring A-B Analog Drives

12.0

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1

TAB 13 Connecting 8520 Digital Drive Systems

13A.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13A.1 8520 Digital Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . .

13A.2 8520 Digital Servo Amplifier Options Specifications . . . . . . . . . .

13A.2.1 1AX-D Servo Amplifier Connectors and Pin Assignments

13A.2.2 2AX-D Servo Amplifier Connectors and Pin Assignments

. . . . . .

13A.2.3 3AX-D Servo Amplifier Connectors and Pin Assignments . . . . . .

13A.3 Selecting an A-B 1389 Transformer for 8520 Digital Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . .

13A.4 8520 Digital Servo Amplifier Fault Indicators

13A.5 8520 Digital Servo Amplifier Jumper Settings

. . . . . . . . . . . . . . .

13A.6 8520 Digital Servo Amplifier Shunt Specifications

13A.7 8520 Drive Power Distribution

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

13A-1

13A-2

13A-4

13A-6

13A-9

13A-11

13A-14

13A-16

13A-19

13A-22

Table of Contents

9/Series Integration and Maintenance Manual

TAB 14

TAB 15

13A.8 8500 Digital Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13A.8.1 8500 Digital Servo Motor Options . . . . . . . . . . . . . . . . . . . . . . .

13A.8.2 8500 Digital Servo Motor Connector and Pin Assignments

13A.9 Feedback Devices

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13A.9.1 Incremental Encoder Feedback Interface

13A.9.2 Absolute Encoder Feedback Interface

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

13A.9.3 Resetting Absolute Encoders on an 8500 Digital Servo Motor

13A.9.4 Using a Second Feedback Device

. . .

. . . . . . . . . . . . . . . . . . . . . .

13A-24

13A-27

13A-28

13A-31

13A-32

13A-33

13A-37

8500 Digital Motor Dimensions

13B.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13B.1 8500 Digital Servo Motors With Holding Brake . . . . . . . . . . . . . .

13B.2 8500 Digital Servo Motors Without Holding Brake . . . . . . . . . . .

13B-1

13B-3

13B-8

System Start-Up

14A.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14A.1 Initial Control Power Up and Servo Start-Up Procedures . . . . . . .

14A-1

Integrating a Split Axis with Deskew

14B.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14B.1 Split Axis Servo Connections

14B.2 Split Axis Start up Procedure

14B.3 Split Axis Marker Alignment

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

14B.4 Replacing an Absolute Encoder with Deskew

14B.5 Split Axis Motion

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14B-1

14B-2

14B-3

14B-10

14B-11

Troubleshooting the Control

15A.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.1 System Initialization Software . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.1.1 Loading the Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.1.2 Using the Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.2 Search Monitor (online) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.2.1 Selecting Search Monitor

15A.2.2 Using Search Functions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.2.3 Displaying Symbol Comments

15A.2.4 Adjusting View

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.2.5 Timer Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.2.6 Using the Search Monitor Hotkey [SHIFT] + {”}

15A.3 Setup Diagnostics

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.4 I/O Ring Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A-1

15A-2

15A-3

15A-4

15A-7

15A-10

15A-11

15A-12

15A-14 ix

Table of Contents

9/Series Integration and Maintenance Manual

15A.4.1 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.4.2 High Density I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.4.3 1746 I/O Ring Adapter

15A.4.4 1771 I/O Ring Adapter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.4.5 MTB Panel I/O Diagnostics Screen . . . . . . . . . . . . . . . . . . . . . .

15A.4.6 Operator Panel Keyboard Diagnostics Screen . . . . . . . . . . . . . .

15A.4.7 HPG Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.4.8 Analog I/O Diagnostics Screen

15A.4.9 1394 Drives Diagnostics Screen

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

15A.5 Remote I/O Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.6 Fast I/O Diagnostics (9/260 and 9/290 Only) . . . . . . . . . . . . . . .

15A.7 Servo Diagnostic Displays

15A.7.1 Axis Monitor Diagnostics

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A.7.2 1394 Drives Diagnostics Screen

15A.8 Serial I/O Diagnostics

15A.9 Data Scope Monitor

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15A-15

15A-16

15A-17

15A-19

15A-22

15A-26

15A-27

15A-28

15A-29

15A-31

15A-34

15A-35

15A-39

15A-43

15A-45

Replacement Procedures

15B.0 Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B.1 Updating the Executive Firmware . . . . . . . . . . . . . . . . . . . . . . .

15B.2 Replacing the Lithium Battery . . . . . . . . . . . . . . . . . . . . . . . . . .

15B.3 Replacing the CPU Board on the 9/260 and 9/290

15B.4 Replacing the Motherboard on the 9/260 and 9/290

. . . . . . . . . . .

. . . . . . . . . .

15B.5 Replacing the Processor Board on the 9/230 Analog

15B.6 Replacing the Processor Board on the 9/230 Digital

. . . . . . . . .

. . . . . . . . . .

15B.7 Replacing the Main Power Supply on the 9/260 and 9/290 . . . . .

15B.8 Replacing the Main Power Supply on the 9/230

15B.9 Replacing the Monochrome CRT

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

15B.10 Replacing the Color CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B.11 Replacing the Keyboard Assembly for the Monochrome

Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B-26

15B-1

15B-2

15B-8

15B-10

15B-13

15B-15

15B-17

15B-22

15B-23

15B-25

15B.13 Replacing the I/O Ring Interface for the Keyboard

15B.14 Replacing the Fuse in the Monochrome CRT

. . . . . . . . . . .

. . . . . . . . . . . . . . .

15B.15 Replacing the Fuse in the Color CRT . . . . . . . . . . . . . . . . . . . .

15B-30

15B.16 Replacing the Power Supply for Monochrome Operator Panel . . .

15B-31

15B.17 Replacing the Power Supply for the Color Operator Panel . . . . .

15B-31

15B.18 Replacing the Rotary MTB Panel . . . . . . . . . . . . . . . . . . . . . . .

15B.19 Replacing the Push-button MTB Panel . . . . . . . . . . . . . . . . . . .

15B-32

15B-33

15B.20 Replacing the Push-button Light Bulbs . . . . . . . . . . . . . . . . . . .

15B.21 Replacing the Hand Pulse Generator and Interface Board . . . . .

15B.22 Replacing the Battery Backup for Absolute Encoders on the Servo Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B-27

15B-29

15B-34

15B-36

15B-37

Table of Contents

9/Series Integration and Maintenance Manual

TAB 16

TAB 17

TAB 18

15B.23 Replacing the 3-axis Digital Servo Module

15B.24 Replacing the Digital Servo Amplifier

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

15B.25 Replacing the Logic Board on the Digital Servo Amplifier

15B.26 Replacing the Power Section on the Digital Servo Amplifier

. . . . . .

. . . . .

15B-38

15B-40

15B-41

15B-42

15B.27 Replacing the Optional Feedback Module . . . . . . . . . . . . . . . . .

15B-43

15B.28 Replacing the 3-axis Analog Servo Module (9/260 and 9/290 only) 15B-44

15B.29 Replacing the 4-axis Servo Module (9/260 and 9/290 only)

15B.30 Replacing an Analog Servo Amplifier

. . . . .

. . . . . . . . . . . . . . . . . . . .

15B.31 Replacing the Rotary MTB Panel I/O Module . . . . . . . . . . . . . . .

15B.32 Replacing the Push-Button MTB Panel I/O Module . . . . . . . . . . .

15B.33 Replacing Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B.34 Replacing the Power Fuse on Digital I/O and Analog I/O . . . . . . .

15B-45

15B-46

15B-47

15B-49

15B-50

15B-52

15B.35 Replacing the High Density I/O

15B.36 Replacing the Analog I/O

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B-53

15B-54

15B.37 Replacing the Removable Operator Panel (ROP) Interface Module 15B-55

15B.38 Replacing the ROP Module in the Removable Operator Panel

Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B-56

15B.39 Replacing the Removable Operator Panel CRT or Keyboard Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15B-57

15B.40 Replacing the 9/440 System Module or CNC Assembly

15B.41 Replacing the 9/440 E-STOP String Fuse

. . . . . . .

. . . . . . . . . . . . . . . . .

15B-58

15B-60

Error and System Messages

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16-1

Installing 9/Series Hardware for CE Compliance

17.0

Complying with European Union Directives . . . . . . . . . . . . . . . .

17.1

Wiring AC Power for a CE Compliant System . . . . . . . . . . . . . .

17.2

Wiring a High-Density I/O Module for CE Compliance . . . . . . . . .

17.3

Wiring E-stop for CE Compliance . . . . . . . . . . . . . . . . . . . . . . .

17.4

Modifying the Video Cable for CE Compliance

17.5

1394 and 9/440 CE Requirements

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

17-1

17-2

17-4

17-5

17-7

17-9

Manual Index

xii

Table of Contents

9/Series Integration and Maintenance Manual

Publication 852062--RM025A--EN--P November 2000

Supercedes Publication 8520--6.2.25 -- August 1998

PN 176965

8520-6.2.1 -- February 1996

9/Series Hardware

TAB 1

Using This Manual and System Overview

Enclosure

Remote

I/O

9/230 ac power video

+5V dc

+12V dc

E--stop reset

E --stop string

1746 I/O

High

I/O Module to servo amplifiers from encoders ac/dc power dc power

66 inputs

36 outputs

PN--160474

Important User Information

Guidelines For The Application, Installation and Maintenance of Solid

State Control).

Allen-Bradley Company cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.

No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment or software described in this text.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen-Bradley Company is prohibited.

Throughout this manual we make notes to alert you to possible injury to people or damage to equipment under specific circumstances.

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

Attention helps you:

- Identify a hazard

- Avoid the hazard

- recognize the consequences

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

1A.0

Section Overview

1A.1

Audience

Using This Manual

Section

This manual provides the information necessary to integrate the

Allen-Bradley 9/Series control to a suitable machine tool. It begins with a system overview followed by sections covering mechanical and electrical system design to assist the system installer with component installation.

The manual also includes electrical and mechanical specifications for all components of the controls.

This section describes how to use this manual. Major topics include:

Topic:

Audience

Terms and Conventions

Attentions and Important Information

Related publications

See page:

1A-1

1A-2

1A-3

This manual presumes that the reader understands machine tools, basic wiring and electronics, and CNC control theory.

1A-1

Section 1A

Using This Manual

1A.2

Terms and Conventions

When your see:

AMP

CNC

CPU

CPU Board

CRT

The Control

E-STOP

Flash Memory

HPG

I/O

I/O CPU

Main CPU

MDI

MTB

Motherboard

ODS

PAL

Processor Board

RAM

RIO

SIMM

Softkeys

System Installer

Workstation

To make this manual easier to read and understand, full product names and features are shortened where possible. Here are the shortened terms:

It Means:

Adjustable Machine Parameters

Computer Numerical Control

Central Processing Unit (the computing part of the (9/260 and 9/290 control) the board that holds the processor of the control. It slides into the enclosure to connect to the motherboard (9/260 and 9/290 control)

Cathode Ray Tube (the control’s monitor screen) general term that we use to refer to the 9/230, 9/260, 9/290 or 9/440 control.

Emergency Stop

Non-volatile, programmable memory that resides in Flash SIMMs on the CPU board. This memory backs up the executive program, PAL, and AMP. It retains information even during power failure

Hand Pulse Generator

Input/Output

One of two CPUs in the 9/290. It processes the machine logic interface and I/O control information.

One of two CPUs in the 9/290 and the only CPU in the 9/230 and 9/260. It processes internal CNC functions, including system scans and block decode.

Manual Data Input

Machine Tool Builder’s control panel the board that is installed onto the back panel of the enclosure on the 9/260 and 9/290.

Most system connections are on this board.

Offline Development System

Programmable Application Logic the board that is installed onto the back panel of the enclosure on the 9/230. Most system connections are made on this board.

Random Access Memory

Allen Bradley Remote I/O communications.

Single, In-line Memory Module. Flash SIMMs are on the lower half of the CPU module. If you have a 9/290, it has Shadow RAM SIMMs installed on the top half of the module as well as Flash SIMMs.

The row of keys directly below the Operator Panel screen

The company or contractor responsible for installing this control on the machine

The IBM or compatible personal computer that the ODS software is installed on

1A-2

Section 1A

Using This Manual

1A.3

Attention and Important

Information

1A.4

Related Publications

We indicate vital information in these ways:

ATTENTION: indicates circumstances or practices that can lead to damage to the control or other equipment.

Information that is especially important is indicated by the following:

Important: indicates information that is necessary for successful application of the control.

The following documents are also available:

Pub. No.

MCD-5.1

Document Name

9/Series CNC Offline Development System User’s Manual

8520-4.3

9/Series CNC 9/230, 9/260, and 9/290 PAL Reference Manual

8520-5.1.1

9/Series CNC Lathe Operation and Programming Manual

8520-5.1.3

9/Series CNC Mill Operation and Programming Manual

8520-5.1.4

9/Series CNC Grinder Operation and Programming Manual

8520-6.4

8520-6.5

9/Series CNC 9/230, 9/260, and 9/290 AMP Reference Manual

9/Series CNC Transfer Line Quick Start Guide (Shipped with T-Line-9 only)

END OF SECTION

1A-3

Section 1A

Using This Manual

1A-4

System Overview

Section

1B.0

Section Overview

1B.1

System Configuration

This section provides an overview of the 9/230, 9/260, and 9/290 controls.

Typical system configurations and the external appearance of each component of the control are provided in this section. Detailed information on each component is provided in specific sections in this manual.

For Information on:

System Configuration

System Configuration for 9/230 System

9/230 Component Enclosure

9/260 and 9/290 Component Enclosure

Operator Interface

Drives Interface

I/O Interface

Communication Interface

Offline Development System

Adjustable Machine Parameters (AMP)

Programmable Application Logic (PAL)

Fiber Optic I/O Ring

See page:

1B-1

1B-2

1B-6

1B-7

1B-8

1B-11

1B-12

1B-15

1B-16

Figure 1B.2 to Figure 1B.3 show three typical configurations for the 9/230,

9/260, and 9/290 controls. Use these figures for an overview of the inter-component connections you make during integration of the control.

1B-1

Section 1B

System Overview

Enclosure

RS -- 232 or

RS -- 422

Remote

I/O

Power source

Figure 1B.1

Typical System Configuration for 9/230

To on/off swithch on MTB Panel

Main

Power

Supply

9/230 ac power video

+ 5V dc

Mono/Color

Operator

Panel

+ 12V dc

MTB

Panel

MTB Panel

I/O Module

E -- stop reset

E -- stop string

Hand

Pulse

Generator

1746 I/O

High

Density

I/O Module ac/dc power

Digital or

Analog I/O dc power

66 inputs

36 outputs to servo amplifiers from encoders indicates fiber optic cable

19416

1B-2

Section 1B

System Overview

Figure 1B.2

Typical System Configuration for the 9/260

Power source

To on/off switch on

MTB Panel

Enclosure ac power video

Main

Power

Supply

+5 Vdc

Mono/Color

Operator

Panel

+12 Vdc

MTB

Panel indicates fiber optic cable

RS-232 MTB Panel

I/O Module

E-Stop reset

RS-232

RS-422

9/260

E-Stop string

Hand

Pulse

Generator

Remote

I/O

Servo

Module

Optional

Feedback

Module

1746 I/O

High

Density

I/O Module

Fast I/O to servo amplifiers from encoders ac/dc power

Digital or

Analog I/O dc power

66 inputs

36 outputs

11170-I from encoders

The optional feedback module is compatible only with digital servo modules. It cannot be used with analog modules.

1B-3

Section 1B

System Overview

Figure 1B.3

Typical System Configurationfor the 9/290

Power source indicates fiber optic cable

Enclosure

To on/off switch on

MTB Panel ac power video

Servo

Module

RS-232

RS-232 or

RS-422

Digital

Servo

Module

Remote

I/O

Main

Power

Supply

Servo

9/290

Module

+5 Vdc

Optional

Feedback

Module

1771 I/O

Adapter to servo amplifiers from encoders to servo amplifiers from encoders from encoders to servo amplifiers

Fast

I/O

1 The optional feedback module is compatible only with digital servo modules. It cannot be used with analog modules.

1746 I/O

Adapter

Mono/color

Operator

Panel

+12 Vdc

MTB Panel

I/O

Module

E-Stop reset

MTB Panel

E-Stop string

Hand

Pulse

Generator

Hand

Pulse

Generator

Digital

I/O

High

Density

I/O Module

Analog

I/O ac/dc power

20 in

12 out dc power

66 in

36 out ac power

1 analog in

1 analog out ac/dc power

Digital or

Analog I/O

11088-I

1B-4

Section 1B

System Overview

Classification Module Name

Basic Modules Processor

Expansion

Modules

CPU Module and

Motherboard

Main Power Supply

Digital Servo

Analog Servo

I/O Ring Input/

Output

Modules

Digital I/O

I/O Ring

Operator/MTB

Panels

High Density I/O

MTB Panel I/O

Analog I/O

Hand Pulse Generator

1746 I/O Ring Adapter

1771 I/O Ring Adapter

Monochrome Operator Panel

Color Operator Panel

Portable Operator Panel

Table 1B.A lists the component options used to configure the control.

Table 1B.A

Component Options

Quantity

Notes

9/230 only

9/260 and 9/290 only

1 maximum 3 servo modules per system;

not used on the 9/230 and

9/440

(any combination of analog and/or digital servo modules)

not used on the 9/230 and

9/440

Refer to page 10A-1 20 inputs, 12 outputs

Refer to page 9A-1

66 inputs, 36 outputs

44 inputs, 18 outputs

1 input, 1 output

Max. 3

A-B 8500-1746I module

A-B 8500-XIOC module

Data Highway Communication

MMS/Ethernet Communication

Requires Portable Operator

Panel Interface Assembly

44 inputs, 18 outputs Rotary or Push-Button MTB Panel

Monochrome Pendant Option

Color Pendant Option

Optional Feedback 3 max.

9/260 and 9/290 Digital only

Refer to 9/Series Data Highway Plus Communication

Module User Manual, publication 8520-5.1.6.

Refer to 9/Series MMS/Ethernet Communication Module

User Manual, publication 8520-5.1.5.

Not used on the 9/230

1B-5

Section 1B

System Overview

1B.2

9/230 Component Enclosure

The enclosures of the 9/230, shown in Figure 1B.4, supports the system and the power supply. For dimensions refer to page 2B-1. For specific information about the enclosure, refer to page 3A-1.

Figure 1B.4

9/230 Component Enclosures

Processor Board

Power Supply

Back

Plate

Power Supply

Processor Board

9/230 Analog

Power Supply Cut Away to Show Connectors

Front View

Side View with Cover Removed and Power Supply Cut Away

9/230 Digital

The 9/230 analog control pictured above can also be purchased as a single axis control. Pictured here is the 9/230 three axis control. Refer to page

3A-1 for more details. The single axis version is identical to the three axis version with the exception of the single axis version having only one closed loop axis connector. The single axis version is also always equipped with a remote I/O port which can be purchased as an option on the 3 axis system.

1B-6

Section 1B

System Overview

1B.3

9/260 and 9/290 Component

Enclosure

The 9/260 and 9/290 use the same component enclosure. The enclosure, shown in Figure 1B.5, supports the system and CPU boards, the servo modules, and the power supply. For dimensions refer to page 2B-1. For information about the motherboard, CPU board and power supply (PS1), refer to page 4A-1.

Figure 1B.5

9/260-9/290 Component Enclosure

Component Enclosure

8520-PS1

Power

Supply

Remote I/O Port

(available on 9/290 only)

Motherboard

CPU Board

Analog Servo Module

19102

1B-7

Section 1B

System Overview

1B.4

Operator Interface

1B.5

Operator Interface

Components

The Operator Interface consists of the Operator Panel, the MTB Panel, and the HPG. These components provide the operator with a direct interface to the control. For dimensions refer to page 2B-1. For specific information on these components refer to page 9A-1.

The Operator Interface components are shown in Figure 1B.6 through

Figure 1B.11. For dimensions refer to page 2B-1. For specific information on these components, refer to page 9A-1.

Figure 1B.6

Operator Panels

9/SERIES

Monochrome Operator Panel

Portable Operator Panel

: CALC

[

SHIFT

]

(

EOB

)

DEL

LINE

CAN

TRANSMIT

RES

CNTRL

Color Operator Panel

(CRT and Flat Panel)

1B-8

Section 1B

System Overview

Figure 1B.7

Portable Operator Panel Interface Assembly

Figure 1B.8

Push-Button MTB Panel

MODE SELECT

AUTO MDI MAN

CYCLE

START

SINGLE

BLOCK

CYCLE

STOP

JOG SELECT

INCR CONT

HAND HOME

AXIS

+4 --X

+Y TRVRS --Y

SPEED/MULTIPLY

LOW

MEDL

X10

MED

X100

MEDH

X1000

HIGH

X10000

FUNCTION

F1 F2

F3 F4

+Z --4 --Z

F5 F6

SPINDLE SPEED

OVERRIDE

SPINDLE

CCW CW

50 120

OFF

FEEDRATE

OVERRIDE

100

RAPID FEEDRATE

OVERRIDE

F1 25

ESTOP

RESET

150

50 100

OFF

19930

Figure 1B.9

Hand Pulse Generator

Front

Side

11174-I

1B-9

Section 1B

System Overview

Figure 1B.10

Monochrome Pendant Option

Figure 1B.11

Color Pendant Option

Rear cover

HPG Cover

19931

Rear Cover

HPG Cover

19932

1B-10

Section 1B

System Overview

1B.6

Drives Interface

CN1

CN11

CN12

CN13

CN8

CN2

CN3

CN4

CN5

CN6

CN7

CN9

CN10

Digital Servo Module

Figure 1B.12 shows the 3-axis Servo Module and Figure 1B.13 shows the

4-axis Servo Module. The 9/230 has a servo module built into it and does not use these modules. For specific information the 3-axis Servo Module, refer to page 4B-1. For specific information on the 4-axis Servo Module, refer to page 4C-1.

Figure 1B.12

3-axis Servo Module

LT3

LT2

LT1

\FL

FBF

RUN

RUN\FLTL

FBFLT1

FBFLT2

FBFLT3

TB1

CN1

TB2

Analog Servo Module

1B-11

Section 1B

System Overview

Digital Servo Module

(8520-ENC4)

Figure 1B.13

4-axis Servo Module

Analog/1394 Servo Module

(8520-SM4)

(CN1)

Side View

1B.7

I/O Interface

TB2

TB1

(CN1)

TB2

TB1

Front View

Side View

Front View

The I/O Interface modules are shown below. For dimensions refer to page

2B-1. For specific information on these modules refer to page 10A-1.

Figure 1B.14

MTB Panel I/O Module

+12V DC

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

I/O ring fault indicator

CN52

1B-12

Section 1B

System Overview

Figure 1B.15

Digital and Analog I/O

11180-I

Figure 1B.16

High Density I/O - 8500-HDM1

DIP switch

CN61M

CN62M

Optical connector OP23 (OUT)

BT33

CN63F

Optical connector OP24 (IN)

1B-13

Section 1B

System Overview

Figure 1B.17

1771 I/O Ring Adapter - 8500

-XIOC

ACTIVE

ADAPTER

FAULT

I/O RING

FAULT

I/O RING

ADAPTER

ALLEN-BRADLEY

RECEIVER

TRANSMITTER

REMOTE

RESET

11086-I

1B-14

Figure 1B.18

1746 I/O Ring Adapter - 8500-1746I

Section 1B

System Overview

1B.8

Communication Interface

Page 8-1 covers the peripherals that can be interfaced to the control. These peripherals are used to input or output data to the control. This data can be in the form of part programs, AMP, PAL and others. The data is input to the control through Port A or Port B, for Series 9/260 and 9/290, or only

Port B for 9/230.

1B.9

Offline Development System

(ODS)

The Offline Development System (ODS) is a menu driven software package that resides on your personal computer. You can use ODS to: create and edit part program files download AMP and PAL files to the control create, edit and document AMP and PAL files upload, copy, restore, rename, or delete files

1B.10

Adjustable Machine

Parameters (AMP)

The system installer uses AMP and PAL to integrate the control to the machine. Through AMP, the system installer can: define a number of basic parameters such as system resolution, axis types, that affect the overall operation of the control.

define a number of individual axis parameters such as soft travel limits, position tolerances, feedback constants.

Refer to the 9/Series 9/230, 9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more information.

1B-15

Section 1B

System Overview

1B.11

Programmable Application

Logic (PAL)

1B.12

Fiber Optic I/O Ring

The system installer uses AMP and PAL to integrate the control to the machine. The system installer uses PAL to form a ladder logic program that is continuously executed by the control to control devices such as tool turrets, limit switches, coolant systems, and lamps.

PAL also controls the I/O process between the control and the machine tool. Through PAL, system variables, which are assigned to each input or output terminal of an I/O device, are monitored. PAL uses these variables to provide system control.

Refer to the 9/Series CNC 9/230, 9/260, and 9/290 PAL Reference Manual, publication 8520-4.3, for more information.

9/Series I/O devices are linked together by a fiber optic I/O ring. This I/O ring provides serial communication with the control.

Inputs to the control are first converted to fiber optic signals at the I/O device. These signals are transmitted through the fiber optic I/O ring to the control. There they are converted back to electrical signals that can be monitored and acted on by the PAL program.

Outputs from the control originate from the continuously executing PAL program which is stored in the control’s memory. They are converted to fiber optic signals at the control and transmitted through the fiber optic I/O ring to the appropriate I/O device. There they are converted back to electrical signals which cause the desired action.

END OF SECTION

1B-16

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software. Rockwell is one of the world’s leading technology companies.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.1 -- February 1996 PN160474

8520-6.2.2 -- August 1998

9/Series Hardware

TAB 2

System Layout and Dimensions

Front

119 (4.69)

80 Æ

(3.15”)

60 Æ

(2.36”)

48max.

(1.89)

46 max.

(1.81)

Side

(1.97)

( j2.36)

4 Æ x 15 long, three places, on

72 Æ bolt circle

(in)

(1.10)

Bottom

I/O ring fault indicator

Address switches

+5 Vdc terminal

Common terminal

Fiber optic connectors

PN--176437

Section

Planning Your System Layout

2A.0

Section Overview

2A.1

Determining Cable Lengths

When planning the system layout of your control, take into consideration the restrictions and specifications covered in this section.

Mechanical system design specifications necessary for cabinet design and construction are listed in the following sections:

Table 2A.A

To Plan your System Layout

For Information on:

Determining Cable Lengths

Meeting Environmental Conditions

Designing the Cabinet for Its Environment

Reducing Noise

Installing the Components

See Page

2A-1

2A-3

2A-8

When you install the components, refer to page 7A-1 for electrical cable lengths, and page 7B-1 for fiber optic cable lengths.

ATTENTION: The system installer should consult local and state regulations for additional installation requirements.

2A.2

Meeting Environmental

Conditions

You must install the components inside a cabinet that satisfies the environmental conditions listed in Table 2A.A. All components must meet these conditions for you to successfully operate the control.

2A-1

Section 2A

Planning Your System Layout

Table 2A.A

Environmental Conditions

Condition Range or Limit

Operating temperature

Storage or Transport Temperature

CPU Board and Servo Amplifiers:

° C to 55 ° C (32 ° F to 131 ° F) except 9/440

C to 50

C (32

F to 122

F) 9/440 only

Operator Panels (standard and removable):

C to 55

C (32

F to 131

C to 45

C (32

F to 113

F) external ambient

Operator Panels (flat):

C to 50

C (32

F to 122

C to 40

C (32

F to 104

F) external ambient

Operator Panels (pendant):

C to 55

C (32

F to 131

C to 40

C (32

F to 104

F) external ambient

8500 Digital Servo Motors:

C to 40

C (32

F to 104

CPU Board, Servo Motors, and Servo Amplifiers

-30

C to 70

C (-40

F to 158

Operator Panel:

-30

C to 65

C (-40

F to 131

Maximum Temperature Change Rate

1.1

C/min. (1.80

F/min.)

Altitude Above temperature based on operation at 1000m (3500 ft)

Atmosphere Components placed in a protected enclosure with filtered air. Avoid placing components in areas where there is high concentration of dust, cutting oil, or organic solvents.

Relative Humidity

Vibrations (operating)

CPU Board and Operator Panel

5-95% (no condensation)

8500 Digital Servo Motors

20-80% (no condensation)

Max. 1.0 G (operator panel)

Max. 2.5 G (all 9/Series controls except 9/440)

Max. 1.0 G (9/440 CNC)

Max. 2.5 G (E-150 Series I/O)

ATTENTION: Environmental conditions exceeding those shown above may cause component failure and/or unpredictable control operation.

2A-2

Section 2A

Planning Your System Layout

2A.3

Designing the Cabinet for your System’s Environment

When designing the cabinet, consider the environment in which the control operate. The degree of cabinet sealing and whether or not external air must be filtered before entering the cabinet will depend on the expected environmental conditions.

Industrial environments frequently require the cabinet be airtight. If it is not airtight, outside air may bring contaminants into the cabinet. Dust will accumulate in high voltage areas on the operator panel. Coolant mist adhering to this dust may cause an insulation failure.

ATTENTION: If the environmental conditions require an airtight cabinet, the cooling system cannot bring outside air into the cabinet. In this case, an air conditioner or heat exchanger may be required.

To make the cabinet airtight, place gaskets between the component mounting faces, service ports, doors, covers, and the cabinet.

Figure 2A.1 is an installation example that shows gasket placement between the operator panel and the cabinet.

Figure 2A.1

Gasket Placement Example

19437

2A-3

Section 2A

Planning Your System Layout

2A.4

Maintaining Cabinet

Temperature

The components of the control, like all electronic devices, dissipate power in the form of heat. The components and all modules in the control cabinet must be continuously cooled to prevent overheating.

ATTENTION: If the internal temperature of the control cabinet exceeds 55 ° C (131 ° F), irreparable damage may result to the control and its components within the enclosure and injury to personnel.

Since solid state electronic equipment is more reliable at lower operating temperatures, we recommend that the internal control cabinet temperature be kept as cool as possible, without going below 0 ° C (32 ° F).

Using Fans

Install fans inside the cabinet to keep the modules cool by circulating air inside the enclosure as shown in Figure 2A.2. Do not blow the air directly on the modules as this may cause accumulation of foreign matter on or inside the module.

As fan driven air circulates inside the control enclosure, it absorbs some of the heat dissipated by the control components. If this air circulation does not guarantee sufficient thermal exchange through the cabinet walls, then the air must be cooled before it comes in contact with the components again.

Using Air Conditioners or Heat Exchangers

The approximate change in internal air temperature due to a heat exchanger or air conditioner is a function of dissipated power, vertical surface area, and air conditioner or heat exchanger rating. In calculating the change in internal air temperature, be sure to use only the exposed vertical surface areas of the enclosure; do not include the top or bottom of the enclosure in the calculation.

Important: To help assure adequate internal air flow, do not mount any obstructions within 0.6 meters of the intake and exhaust ports of fans, heat exchangers or air conditioners.

2A-4

Section 2A

Planning Your System Layout

Figure 2A.2

Filtered Air Flow In A Fan Cooled Cabinet

Exhaust air

Cabinet temperature between 0°C and 55°C

Servo

Amplifier

Filter

Cooling air

Regardless of air conditioner or heat exchanger rating, be sure its blowers and all other fans provide sufficient internal air flow.

Calculating the Temperature within the Cabinet

If you have a cabinet that contains an Operator Panel, allow for an increase in ambient temperature of up to +5

C (10

F). If you have a cabinet that contains modules other than the Operator Panel, allow for an increase of up to +10

C (20

F).

Temperature information needed when designing a cabinet is listed with the specifications for each module.

Design the cabinet so that temperature rise inside the cabinet, caused by heat generation of the modules and other units mounted inside, will not exceed allowable maximums.

Table 2A.B shows the heat generation wattages of each component or module.

2A-5

Section 2A

Planning Your System Layout

Table 2A.B

Component and Module Heat Generation Wattages

Component or Module

9/230 and Main Power Supply

9/260 or 9/290 and Main Power Supply

9/440 CNC/1394 Drive 5kw System Module

(@100%)

9/440 CNC/1394 Drive 10kw System Module

(@100%)

9/440 Axis Modules/1394 Drive

(each module @100%)

AM03

9/440 CNC Power On/Off Control Module

Portable Operator Panel Interface Assembly

Monochrome Operator Panel

Color TFT Operator Panel (flat panel)

Color CRT Operator Panel

MTB Panel

HPG

3-axis Digital Servo Module

3-axis Analog Servo Module

4-axis Digital Servo Module (8520-ENC4)

4-axis Analog/1394 Servo Module (8520-SM4)

1746I Ring Adaptor (module only)

1771-HTE Termination Panel

MTB Panel I/O Module

Remote I/O Module (8520--RIOM)

* 18 Watts in cabinet, 328 Watts out through cabinet heat sink

Heat Generation Wattage (W)

130

225

AM04

175

1.2

13.5

125

AM07

4.2

0.9

AM75

346*

The temperature rise inside a metallic cabinet incorporating only an internal convection cooling fan can be roughly calculated with the following formula:

T = W/6S

- T = Temperature rise in cabinet (

- W = Heat generation (Watts) by units and modules

- S = Heat radiation surface area (sq. meter) of cabinet

(total cabinet surface area minus any area in contact with the floor or building wall)

The above equation assumes a closed cabinet with heat dissipated only through cabinet radiation.

2A-6

Section 2A

Planning Your System Layout

Example of Calculating Cabinet Temperature

A design example of a cabinet is given below assuming a component-type frame incorporating the following:

Main Power Supply (PS1)

Main Power Supply (PS2A)

CPU Board

3-axis Digital Servo module

225 watts @ 50

130 watts @ 50

33.5 watts

13.5 watts

The total heat generation (W) for this example would be 47W.

Determine a minimum T value for the equation in the previous section: a.

Estimate the maximum air temperature at the location where the cabinet will be installed.

Subtract this estimate from the maximum internal cabinet temperature for your application (if you use 55 ° C, there is no margin for error).

The difference is the allowable temperature rise in the cabinet (T).

For example, assume a maximum air temperature of 35

C and a desired maximum internal cabinet temperature of 45 value of T would be 45 - 35 = 10

° C, The

Using the W and T values just derived, calculate the minimum heat radiation surface area, S.

T = W/6S

S = W/6T

= 47/(6 x 10)

= 0.783 sq. meter (8.4 sq. feet)

This result indicates that a cabinet with a minimum of 0.783 m

(8.4 ft

) of heat radiation surface is required.

Important: Any cabinet surface in contact with the floor or building wall is not considered a heat radiation surface in this calculation.

If the resulting cabinet size is prohibitively large, or if the T value calculated was 10 or more, then the use of a heat exchanger or air conditioner must be considered. Such designs require more detailed analysis, beyond that considered within scope of this manual.

Important: The temperature rise value used in this calculation is a constant. Actual temperature rise will vary depending on the amount of air flow inside the cabinet.

2A-7

Section 2A

Planning Your System Layout

2A.5

Reducing Noise

2A.6

Installing the Components

For information on noise prevention measures refer to page 7C-1. We mention them here because these factors should be taken into consideration during the beginning stages of cabinet design. These noise prevention measures are covered in that section:

Signal Grounding

Mechanical Shielding

Shielded Cables and Twisted-pair Cables

Separation of Cable Routes

Noise Suppressors

Install the components in the cabinet with at least 100 mm (4 inches) of clearance between the cabinet side wall and each component to allow air flow inside the cabinet. Install the components in the cabinet with 50 mm

(2 inches) of clearance between them.

The system installer should also consider any local regulations regarding component placement within a cabinet.

ATTENTION: Do not install modules above heat generating devices (transformers, resistors, etc.)

Figure 2A.3 shows the minimum component spacing.

2A-8

Section 2A

Planning Your System Layout

Figure 2A.3

Minimum Component Spacing to Allow Air Flow in the Cabinet

100 (3.94)

(in)

100

(3.94)

Enclosure

100

(3.94)

50 (1.97) 50 (1.97)

100 (3.94)

100

(3.94)

50 (1.97) 50 (1.97)

100

(3.94)

9/440 CNC and digital amplifiers see page 2A-11

100 (3.94)

Follow the minimum component spacing requirements when designing the electrical system layout. You can reduce noise by placing the modules at least 50 mm apart. If this is not possible, install an electrically conductive metallic shield plate between the units. Place all devices at least 100 mm from the cabinet walls. For additional information on electrical system design requirements refer to 4D-1.

ATTENTION: Do not install the control close to equipment, such as an arc welder, power transformer, or large motor, that generates high level noise.

2A-9

Section 2A

Planning Your System Layout

Installing Servo Modules

Digital and analog servo modules include processors that make them very sensitive to electrical noise. These modules must be placed more than 100 mm (4 in) away from devices and cables to which any AC voltages or DC voltages greater than 50 Vdc are applied.

Installing Operator Panels

You must place the Operator Panel more than 300 mm (12 inches) away from devices (transformers, main AC, electromagnetic contactors, etc.) that generate magnetic fields to protect the CRT display from any possible adverse effects.

However, a strong magnetic field generated by multiple devices can have an adverse effect on the CRT display even if the operator panel is placed more than 300 mm away from these devices. If this occurs, shield the operator panel from the devices using an electromagnetic and electrostatic shield plate.

Installing Servo Amplifiers

If you are installing analog servo amplifiers, refer to documentation that came with your amplifiers for specific installation instructions.

If you are using digital servo amplifiers, place them vertically so that cooling air can flow upward and remove heat efficiently. Figure 2A.4 and

Figure 2A.5 show the digital servo amplifier installation and spacing restrictions.

If you are installing digital or analog servo amplifiers in the same cabinet as the control chassis (excluding the 9/440), then separate the amplifiers and the control chassis with a grounded, metallic plate to shield the control from electrical noise. You can use a cabinet with a center divider, where the power transformers and servo amplifiers are installed on one side, and the control, operator panel, and I/O modules installed on the other side.

2A-10

Section 2A

Planning Your System Layout

Figure 2A.4

1394 and 9/440 CNC Servo Amplifier Spacing Restrictions

50.8 (2.00) Clearance for Airflow and Installation

100 (3.94) minimum

Servo

Amplifier

200 (7.87) minimum

(in)

10.0 (0.4) Min. Along Side

Allow 25.4 (1.00) Clearance at Cover Tab for Opening & Closing

10.0 (0.4) Min. along side

Allow 50.8 (2.00) clearance for depth of terminator connector.

Poor Instalation

Wire Entry Area

(min 152.4 (6.00)

Figure 2A.5

8520 Digital Servo Amplifier Spacing Restrictions

Dimensions are in millimeters and (inches)

Poor

Installation

100 (3.94) minimum

Proper

Installation

200 (7.87) minimum

Poor

Installation

Servo Amplifier

END OF SECTION

2A-11

Section 2A

Planning Your System Layout

2A-12

2B.0

Processor Dimensions

(in.)

37.3

(1.47)

138.9

(5.47)

354.0

(13.94 )

215.1

(8.47 )

316.7

(12.47)

TB1

Mounting Dimensions

Section

9/230 Component Enclosure

This section covers the dimensions and weight of the component for the

9/230. The dimensions outside of the brackets are given in millimeters and inside the brackets in inches. For additional information on this component refer to page 3A-1.

Figure 2B.1

9/230 Analog Component Enclosure Dimensions

143

(5.60)

482.6

(19.0)

465.1

(18.31 )

INPUT

115/230V

8A/5.5A

47 - 63 Hz

8.8

(.34 5)

6.5

(.26)

TB2 TB3

J3 J2 J1

The 9/230 enclosure weighs 6.2 kg (13.7 lb).

19415

2B-1

Section 2B

Mounting Dimensions

(in.)

Figure 2B.2

9/230 Digital Component Enclosure Dimensions

12.5

(.5)

125

(5)

(3.48)

16.27

(.64)

400.0

(16)

375.0

(14.8)

226.16

(9.05)

125

(5)

Front View

The 9/230 enclosure weighs 6.75 kg (15 lb).

Top View

2B-2

Section 2B

Mounting Dimensions

354.0

(13.94)

215.1

(8.47)

138.9

(5.47)

316.7

(12.47)

198.0

(7.80)

112.0

(4.41)

37.3

(1.47)

9/260 and 9/290 Component Enclosures

This section covers the dimensions and weight of the component for the

9/260 and the 9/290. The dimensions outside of the brackets are given in millimeters and inside the brackets in inches. For additional information on this component refer to page 4A-1.

Figure 2B.3

9/260 and 9/290 Component Enclosure Dimensions mm

(in.)

13.5

(.53)

6.5

(.26)

19101

72.0

(2.84)

324.3

(12.77)

465.1

(18.31)

482.6

(19.0)

The 9/260 and 9/290 component enclosure weighs 9.25 kg (20.41 lb).

2B-3

Section 2B

Mounting Dimensions

101.6

(4.00)

76.2

(3.00)

101.6

(4.00)

Figure 2B.4

Blank Cut-Out Dimensions for the 9/260 or 9/290 Component Enclosure

465.1

(18.31)

(in.)

(0.24)

8 places

11186-I

2B-4

Section 2B

Mounting Dimensions

9/440 CNC and 1394 Drive

This section covers the dimensions and weight of the component for the

9/440. The dimensions outside of the brackets are given in millimeters and inside the brackets in inches. For additional information on this component refer to page 5A-1 or page 11A-1.

Figure 2B.5

Mounting Options for 9/440 or 1394 Drive

Through Enclosure Wall

Customer--supplied enclosure

Inside Enclosure Using U Bracket

Note: This configuration does not require a gasket between the AM50 or

AM75 and the enclosure

Customer--supplied enclosure

2B-5

Section 2B

Mounting Dimensions

Figure 2B.6

9/440 CNC and 1394 Drive Mounting Template

Dimensions are in millimeters and (inches)

(1.97)

(0.00)

62.5

(2.46)

(1.97)

100

(3.94)

137.5

(5.41)

125

(4.92)

150

(5.91)

175

(6.89)

212.5

(8.37)

200

(7.87)

225

(8.86)

250

(9.84)

287.5

(11.32)

275

(10.83)

System outline

385

(15.16)

System module mounting holes

A B C

D E

Heat sink cutout for the

AM50/75 module

Heat sink cutout for the

AM50/75 module

Heat sink cutout for the

AM50/75 module

Heat sink cutout for the

AM50/75 module

19.5

(0.768)

348

(13.70)

33.5 TYP

(1.32)

67 TYP

(2.64)

8 TYP

(0.32)

M6 tapped hole or

1/4--20 UNC -- 2B

Mounting

Options

Number of

Axes

1 up to 3

2 up to 2

Type of Axis

1394--AM50 or AM75 Axis, 75 mm (2.95 in.) wide

1394--AM03, AM04 or AM07 Axis, 50 mm (1.97 in.) wide

1394--AM50 or AM75 Axis, 75 mm (2.95 in.) wide

1394--AM03, AM04 or AM07 Axis, 50 mm (1.97 in.) wide yes

Cutout

Needed?

no yes no

3 up to 1

1394--AM50 or AM75 Axis, 75 mm (2.95 in.) wide

1394--AM03, AM04 or AM07 Axis, 50 mm (1.97 in.) wide yes no

D 4 1394--AM50 or AM75 Axis, 75 mm (2.95 in.) wide yes

When mounting axis module combinations, the AM50 and AM75 must be mounted closest to the system module and ahead of any 1394--AM03, AM04, and AM07 axis modules.

2B-6

Section 2B

Mounting Dimensions

28.5

(1.12)

Figure 2B.7

9/440 CNC and 1394 Drive System Module Dimensions

150.0 (5.91)

91.0 (3.58)

50.0

(1.97)

25.4

(1.0)

8.0 (0.32)

Dimensions are in millimeters and (inches)

Depth = 279.4 (11.0)

400.0

(15.75)

343.0

(13.50)

ESC SEL

JOG

Mounting Hole Detail

8.0 (0.31)

10.1 (0.40)

385.0 (fastener location)*

(15.16)

15.9 (0.63)

8.0 (0.31)

12.0 (0.47)

All Slots Accept M6, 1/4--20 Mtg. Screws

*Note Dimension shown is for mounting hardware location and does not reflect the location of the lower slot radius.

50.0

(1.97)

2B-7

Section 2B

Mounting Dimensions

400.0

350.0

Figure 2B.8

9/440 CNC and 1394 Drive Dimensions for AM03, AM04, and AM07 Axis Modules

Dimensions are in millimeters and (inches)

8.0 (0.32)

Mounting Hole Detail

8.0 (0.31)

10.1 (0.40)

15.9 (0.63)

8.0 (0.31)

12.0 (0.47)

All slots accept M6, 1/4--20 mtg. screws

280

(11.02)

350

(13.78)

2B-8

400.0

350.0

Section 2B

Mounting Dimensions

Figure 2B.9

9/440 CNC and 1394 Drive Dimensions for AM50 and AM75 Axis Modules

8.0 (0.32)

Dimensions are in millimeters and (inches)

Mounting Hole Detail

8.0 (0.31)

10.1 (0.40)

15.9 (0.63)

8.0 (0.31)

12.0 (0.47)

All slots accept M6, 1/4--20 mtg. screws

When using the gasket provided with the axis module, torque the M6 to 7.9 N--m and the 1/4--20 to 75 in--lbs.

Remove the paper backing and attach the gasket here

(hole side on top)

*Note: Heat sink width only.

2B-9

Section 2B

Mounting Dimensions

20.17 cm

(7.94 in.)

Figure 2B.10

9/440 CNC Power Control Module Dimensions

Left-side View

.157 cm

(0.062 in.)

.80 cm

(.310 in.)

.65 cm

(.256 in.)

Front View

R .60 cm

(.236 in.)

3.03 cm

(1.194 in.)

2.14 cm

(.844 in.)

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

19.37 cm

(7.625 in.)

16.38 cm

(6.45 in.)

AC IN

AUX AC

ON SW

COMMON

OFF SW

12.70 cm

(5.00 in.)

1.30 cm

(.512 in.)

5.08 cm

(1.999 in.)

6.38 cm

(2.51 in.)

3x R .33 cm

(R .13 in.)

2B.1

Common System

Component Dimensions

Detailed information on the common system component is provided in the following sections.

Form Information On:

Operator Panel (monochrome and color)

MTB Panel

Pendant Option

Hand Pulse Generator

Servo Modules

Encoder Termination Panel

Servo Drives

MTB Panel I/O Module

Digital I/O Module

High Density I/O Module

See Page

2B-11

2B-14

2B-15

2B-17

2B-18

2B-19

2B-20

2B-21

2B-10

Section 2B

Mounting Dimensions

Operator Panel

For detailed information on operator panels refer to page 9A-1.

Figure 2B.11

Monochrome Operator Panel Dimensions mm

(in.)

(0.47)

(0.20) 400

(15.75)

26.2

(1.03)

200

(7.87)

190

(7.47)

(0.20)

130

(5.12)

4.8mm Æ (0.19), eight places

260

(10.24) 390

(15.36)

The monochrome operator panel weighs 6.5 kg (19.8 lb).

19447

2B-11

Section 2B

Mounting Dimensions

Figure 2B.12

Blank Cut-Out Dimensions for the Monochrome Operator Panel

4.8 (0.19)

, eight places

130

(5.12)

130

(5.12)

130

(5.12)

4.5 (0.18)

382

(15.04)

181

(7.12)

(in.)

190

(7.48)

(0.16)

11187-I

Figure 2B.13

Blank Cut-Out Dimensions for the Color Operator Panels

(both CRT and TFT flat panel)

130

(5.12)

4.8 (0.19) Æ twelve places

130

(5.12)

130

(5.12)

7(0.28)

376

(14.8)

5 (0.20)

120

(4.72)

(in.)

130

(5.12)

360

(14.17)

120

(4.72)

11188-I

2B-12

Depth CRT Color Operator Panel

Figure 2B.14

Color Operator Panel Dimensions

Section 2B

Mounting Dimensions

(in.)

2.6

(0.10)

377

(14.58)

Depth TFT Color Operator Panel (flat panel)

2.6

(0.10)

(3.35)

7.5

(0.30)

385

(15.16)

250

(9.84)

120

(4.72)

130

(5.12)

260

(10.24)

370

(14.56)

390

(15.36)

5.0

(0.20)

4.8mm Æ (0.19), twelve places

The color CRT operator panel weighs 20.0 kg (44.0 lb).

The color TFT operator panel (flat panel) weighs 6.1 kg (13.5 lb).

2B-13

Section 2B

Mounting Dimensions

(0.08)

(0.20)

150

(5.91)

140

(5.51)

(0.20)

MTB Panel

For detailed information on this component refer to page 9A-1.

Figure 2B.15

MTB Panel Dimensions

372

(14.65)

88.9

(3.5)

(1.46)

13.5

(0.53)

124

(4.88)

130

(5.12)

130

(5.12)

400

(15.75)

130

(5.12)

The MTB panel weighs 2.09 kg (4.62 lb).

130

(5.12)

4.8 (0.19) Æ eight places

Figure 2B.16

Blank Cut-Out Dimensions for the MTB Panel

130

(5.12)

130

(5.12)

7 (0.28)

376

(14.8)

126

(4.95)

(in.)

12.5

(0.49)

19933

140

(5.51)

7 (0.28)

11189-I

2B-14

Section 2B

Mounting Dimensions

Pendant Option

Figure 2B.17 and Figure 2B.18 show the dimensions for the pendant option that contains the monochrome or color operator panel and the MTB panel. For detailed information on the pendant components refer to page

9A-1.

Figure 2B.17

Monochrome Pendant Dimensions

417.58

(16.44

)

304.8

( 12.0

)

(in.)

Rear cover

406.4

(16.0

)

HPG cover

19448

The monochrome pendant weighs 21.3 kg (46.1 lb).

Figure 2B.18

Color Pendant Dimensions

417.58

(16.44

)

459.74

(18.10

)

(in.)

Rear cover

590.55

(23.25 )

HPG cover

The color pendant weighs 41.1 kg (90.5 lb).

19449

2B-15

Section 2B

Mounting Dimensions

Removable Operator Panel Interface Assembly

The removable operator panel interface assembly is used in conjunction with the 9/Series removable operator panel. For detailed information on this component refer to page 9A-1.

Figure 2B.19

Removable Operator Panel Interface Assembly

153

(6.02)

167 ±0.5

(6.57)

212 ±0.5

(8.35)

194.52

(7.66)

Æ 6.35 4 Places

(.25)

Cable Radius

& Cable Hoods

196.80

(7.75)

108.00

(4.25)

2B-16

Section 2B

Mounting Dimensions

Hand Pulse Generator

For detailed information on this component refer to page 9A-1.

Figure 2B.20

Hand Pulse Generator Dimensions

Front

119 (4.69)

80 Æ

(3.15”)

60 Æ

(2.36”)

48max.

(1.89)

46 max.

(1.81)

Side

(1.97)

( j2.36)

4 Æ x 15 long, three places, on

72 Æ bolt circle

(in.)

(1.10)

Bottom

I/O ring fault indicator

Address switches

+5 V dc terminal

Common terminal

Fiber optic connectors

The hand pulse generator weighs .58 kg (1.28 lb).

Figure 2B.21

Hand Pulse Generator Dimensions

mounting panel gasket

4.8 (0.19) holes 120 degrees apart

72 +.2

, three places bolt circle

(2.83 +0.01)

(in.)

11082-I

62 +.8 (2.44 +.03) clearance bore

11190-I

2B-17

Section 2B

Mounting Dimensions

Servo Modules

Mount the 3-axis or 4-axis servo module by gently sliding them into the guides that run along the bottom of the 9/260 or 9/290 component enclosure. Figure 2B.3 and Figure 2B.4 show the dimensions for installing the component enclosure. To connect the 3-axis servo module, refer to page 4B-1. To connect the 4-axis servo module, refer to page 4C-1.

Encoder Termination Panel

The 1771-HTE encoder termination panel simplifies the integration of an analog amplifier system. The termination panels are shipped with all the connectors and associated circuitry installed. Mount the termination panels to a DIN type #46277-1 rail, as shown in the figure below. You can attach the rail either vertically or horizontally to the enclosure wall.

Figure 2B.22

1771-HTE Encoder Termination Panel Dimensions mm

(in.)

DRIVE

AXIS

DRIVE

RET

SHLD

ENCODER

CH A. HI

CH A. LO

AB SHLD

CH B. HI

CH B. LO

Z SHLD

CH Z. HI

CH Z. LO

ENC POWER

+5V

RET

+15V

EX PWR OUT

SHLD

EXT

POWER

EX PWR IN

EX RET IN

FDBK IO

RET

SHLD

91670401

1771HTE ENCODER TERMINATION PANEL

(3.0)

158

(6.25)

The encoder termination panel weighs .17 kg (.37 lb)

(1.88)

2B-18

Section 2B

Mounting Dimensions

Servo Amplifiers

The 9/230, 9/260 and 9/290 are compatible with a variety of analog servo amplifiers. For the dimensions of your analog servo amplifier, refer to its documentation. For detailed information on compatible analog servo amplifiers refer to page 12-1.

Figure 2B.23 shows the mounting dimensions for the 8520 digital servo amplifier. For detailed information on the 8520 digital servo amplifier refer to page 13A-1. For detailed information on the 1394 digital servo amplifiers refer to page 11A-1.

Figure 2B.23

8520 Digital Servo Amplifier Dimensions

(in.)

6 (0.24) Æ

6.5 (0.26)

11 (0.43)

Y H

8520 Amplifier

1AX-D

2AX-D

3AX-D

W mm (in.)

158 (6.22)

241 (9.49)

H mm (in.)

450 (17.72)

D mm (in.)

205 (8.07)

X mm (in.)

100 (3.94)

200 (7.87)

Y mm (in.)

430 (16.93)

C mm (in.)

6.5 (0.26)

10 (0.39)

11090-I

2B-19

Section 2B

Mounting Dimensions

(.197)

108

(4.25)

117.9

(4.64)

MTB Panel I/O Module

For detailed information on this component refer to page 10A-8.

Figure 2B.24

MTB Panel I/O Module Dimensions mm

(in.)

28.4

(1.12)

106.6

(4.2)

85.7

(3.37)

302

(11.88)

53.2

(2.09)

46.4

(1.83)

77.7

(3.06)

Æ 4 (.157)

9 places

19935

Digital I/O Module

For detailed information on this component refer to page 10A-18.

Important: The digital I/O module uses the cabinet’s back panel as a heat sink for dissipating excess heat during operation. It is important that the unit be mounted on a smooth, metal, back panel to provide good thermal conductivity.

2B-20

Section 2B

Mounting Dimensions

(in.)

Figure 2B.25

Digital I/O Dimensions

249

(9.80)

260

(10.24)

5.5 (0.22) Æ , four places

11 (0.43)

106

(4.17)

139

(5.47)

150

(5.91)

(2.76)

(2.36)

11 (0.43)

(in.)

Optical connector

OP21

(OUT)

Optical connector

OP22

(IN)

The digital I/O module weighs 1.77 kg (3.9 lb)

11083-I

High Density I/O Module

For more information on connection and configuration of high density I/O modules refer to page 10A-33.

Figure 2B.26

High Density I/O Module Dimensions for 8500-HDM1

155

(6.102)

180.98

170.18

(6.7)

(7.125)

Not including cables

5 (0.20) Æ , four places

360.4

(14.189)

375.4

(14.78)

342.7

(13.49)

The high density I/O module weighs 1.63 kg (3.61 lb)

32.6 (1.28)

60.45 max

(2.38)

2B-21

Section 2B

Mounting Dimensions

Left-side View

0.1cm

(0.04in)

17.1 cm

(6.73 in.)

14.0 cm

(5.51 in.)

1746 I/O

Three standard 1746 I/O assemblies with a variety of commonly used I/O modules already installed are available for the 9/Series CNC. These assemblies come with the I/O cards you need, and a 1746I module to interface to the 9/Series I/O ring. For more details on 1746 I/O refer to page 10A-49. If you did not purchase one of these preconfigured assemblies refer to page 10B-1 for details. The three standard 1746 I/O configurations all use the 4--card 1746 chassis. The dimensions for the

4--slot chassis (1746-A4) are shown below.

1746-A4 I/O Mounting Dimensions

Front View

1.1 cm Dia.

(0.433 in.)

7.0 cm

(2.76 in.)

Ì Ë Ê

0.55 cm Dia.

(0.217 in.)

15.8 cm

(6.22 in.)

14.0 cm

(5.51 in.)

17.1 cm

(6.73 in.)

14.5 cm

(5.71 in.)

0.55 cm Dia.

(0.217 in.)

26.1 cm

(10.28 in.)

23.5cm

(9.25 in.)

21.5 cm

(8.46 in.)

4.5 cm

(1.77 in.)

Ê Dimensionsforpowersupplycatalognumber1746--P1

Ë Dimensions for power supply catalog number 1746--P2 & 1746--P3

Ì Dimensionsforpowersupplycatalognumber1746--P4

1.4 cm

(0.55 in.)

END OF SECTION

2B-22

Publication 8520-6.2.2 -- August 1998

I--2

Index

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.2 -- August 1998

PN176437

9/Series Hardware

TAB 3

9/230 CNC Systems

9/230 Analog

8520-6.2.3 -- February 1997

9/230 Digital

PN--176025

3A.0

Section Overview

Section

Primary 9/230 Components

This section discusses:

9/230 1 axis and 3 axis processor boards main power supply (PS2A)

9/230 mounting

This section covers standard 9/230 CNCs as well as 9/230 CNCs purchased as part of the T-Line-9 transfer line control. A portion of this section is devoted to each of the following:

For Details on the Processor Board and Power Supply

Processor Board

Connections on the Processor Board

Reading LEDs

Battery Backup

Main Power Supply (PS2A)

For Details on the Analog Servo Interface

Servo Axis Connectors on the Analog Processor Module

Connecting Axes to the Analog Servo Interface

Analog Servo Operation and Specifications

Analog Servo Connectors and Pin Assignments

Analog Servo Amplifiers

Analog Servo Motors

For Details on the 9/230 Digital Servo Interface

Servo Axis Connectors on the 9/230 Digital Processor Module

Connecting Axes to the Digital Servo Interface

Digital Servo Operation and Specifications

Digital Servo Connectors and Pin Assignments

Digital Servo Amplifiers

Digital Servo Motors

For Details on Testing and Connecting Feedback Devices

Using Test Points

Encoder Termination Panel

Feedback Devices

Wiring an Incremental Feedback Device

Wiring a Touch Probe to the Processor Module

See Page:

3A-24

3A-26

3A-27

3A-30

3A-31

See Page:

3A-32

3A-17

3A-18

3A-21

3A-33

See Page:

3A-2

3A-3

3A-5

3A-6

3A-7

See Page:

3A-8

3A-9

3A-12

3A-13

3A-16

3A-1

Section 3A

Primary 9/230 Components

3A.1

The Processor Board

The processor board is attached to the mounting plate. Refer to

Figure 3A.1 and Figure 3A.2 for the processor board identification.

Figure 3A.1

Front View of the 9/230 Analog Processor

Flash Memory SIMMs

Power Supply Connector

Lithium Battery Connector

Remote I/O Port

I/O Ring Output

Connector (red)

I/O Ring Input

Connector (black)

Processor

Board

E-STOP Terminal

INPUT

11 5/230 V

8A /5.5A

47 --6 3Hz

Port B (RS232/422)

Spare Fuse

Video Connector

Lithium Battery Pack

LEDs cable tie down holes earth ground screws

TB2

Analog Out

Port

J3 J2 J1

Servo Connectors

(only J1 is available on 1 axis 9/230)

Power Supply Connector

DS2 DS4

Figure 3A.2

Side View of the 9/230 Digital with Power Supply Cut Away

Main Power Supply

Flash Memory SIMMs

Back Plate

Main

Power

Supply

19422

Lithium Battery Connector

“Run”LED

Spare Fuse

E-STOP Terminal

Touch Probe Connector

Analog Out Port

Video

Connector

Port B

(RS232

/422)

J1 J2 J3

Servo Connectors

I/O Ring Output

Connector (red)

Power Supply Cut Away to Show

Servo and Fiber Optic Connectors

I/O Ring Input

Connector (black)

3A-2

Section 3A

Primary 9/230 Components

3A.1.1

Connections on the

Processor Board

Port B

Table 3A.A lists the connections on the 9/230 processor board and where to locate the cable diagrams within this manual. Refer to page 7A-1 for detailed cable drawings.

Table 3A.A

Locating Wiring Diagrams for the 9/230 Processors

Attach this connector:

Lithium Battery (P1)

I/O Ring Output (Red)

I/O Ring Input (Black)

E-Stop (TB1)

Port B (J7)

Video (J8)

TP (TB2)

Analog Out (TB3)

Analog Servo Connector

(J1, J2, or J3)

Digital Servo Connector

(J1, J2, or J3)

Power Supply (P12)

To:

Lithium Battery Pack

First Device on I/O Ring

Last Device on I/O Ring

E-stop String

Peripheral Devices

Operator Interface

(Color or Monochrome)

Touch Probe

Spindle

Termination Panel

Servo System

Power Supply

Use this Cable

C13,

C10

C05, C06

C07

C09

C46

C42

C36

C18, C20

C04

11257-I

Port B

Serial port B is used to transmit data to and from peripheral devices. It can be wired for RS-232 communications or RS-422 communications.

Softkey selections on the controls operator panel now selection at the specific device protocol to be used.

The MTB panel may have the optional serial interface connector mounted on it. This connector provides an external interface port for RS-232 or

RS-422 interface from a peripheral to the control. It connects to port B with cable C07. Refer to the “Cable List” section on page 7A-1 for additional information on cable C07. For more information on the signals of each pin, refer to page 8-1.

Figure 3A.3

Port B-J7 (has pin sockets) and Pin Assignments

Pin Assignment

1 Chassis GND

Send Data A

Receive Data A

Request to Send A

Clear to Send A

Data Set RDY A

Signal GND

Data Term RDY A

Pin

Assignment

Send Data B

10 Receive Data B

11 Request to Send B

Clear to Send B

Data Set RDY B

Data Term RDY B

Not Used

3A-3

Section 3A

Primary 9/230 Components

11257-I

Video Monitor Connector

The video monitor connector is used to interface the video monitor with the control. Figure 3A.4 shows this connector and lists the pin assignments of this connector.

Figure 3A.4

Video Monitor Connector J8 and (has pin sockets) Pin Assignments

Pin No.

Signal Name Pin No.

Signal Name

GND (SHIELD)

RED (H)

GREEN (H)

BLUE (H)

CLOCK (H)

H-SYNC (H)

V-SYNC (H)

RED (L)

GREEN (L)

BLUE (L)

CLOCK (L)

H-SYNC (L)

V-SYNC (L)

Touch Probe Connector (TB2)

The control module receives touch probe feedback through the connector labeled TP (TB2). Figure 3A.5 shows the location of the TP connector.

Table 3A.B lists the terminal assignments of this connector.

Figure 3A.5

Touch Probe, 4 Plug-type Terminal Block Connections.

3A-4

4 3 2 1

3A.1.2

Reading LEDs

Section 3A

Primary 9/230 Components

Table 3A.B

Connector TB2, TP, Terminal Assignments

Terminal

No.

Signal Description Signal Destination

+5V

PRB_FIRE

Probe Power

Probe Fired Signal 1

Touch Probe

Servo Module

3 TP_GRD Touch Probe Common Touch Probe

4 Shield Probe Shield connect at module only

The True level (voltage transition the probe fires) is either “HIGH”or “LOW”as defined by the AMP parameter PROBE TRANSITION.

information.

Refer to the 9/Series CNC 9/230,

9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more

Important: The touch probe connector supports only +5V probing device applications.

The 9/230 can have two LEDs (DS4 is present only if you have purchased the 9/230 remote I/O option). Figure 3A.1 shows the location of these

LEDs on the main board. Use them to determine the following:

Table 3A.C

LED Sequence at Power Up for the 9/230

LED

DS2

WDOG OK

DS4

NA COMM

Status

OFF

Description

System is running.

Watchdog timeout has occurred, or system did not power-up properly

Active Link to PLC. This is the normal state when the

RIO channel is on and active.

FLASHING The remote I/O channel is on and active but the PLC is currently in program mode.

OFF Remote I/O channel is offline. The port is not being used, not configured, or not attached to a remote I/O scanner device.

3A-5

Section 3A

Primary 9/230 Components

3A.1.3

Battery Backup

Pin Number

Polarity

The memory for data such as part programs, tool offset/compensation data, and work coordinate offset data is stored on the processor board. In the case of a power failure, there is a super capacitor on the processor board that backs up this data for up to 5 days (at 40

C) on systems without extended program storage. This super capacitor recharges within 1 hour of power turn on if completely discharged. If you want to extend this backup time, install the lithium battery pack (8520-LIBAT) that supports the data for:

9/230 Control and Description:

standard with extended program storage

Time (at 40°C Discharge):

3 years

1 year

The lithium battery pack also supports 8520 absolute encoder power. This battery pack is connected to the lithium battery connector (P1) on the processor board as shown in Figure 3A.6. Batteries and battery cable are included with the battery replacement kit.

Figure 3A.6

Lithium Battery

Pin Number

Polarity

The lithium battery contains heavy metals and must be collected separately from other waste.

3A-6

3A.1.4

Main Power Supply

(PS2A)

Section 3A

Primary 9/230 Components

You receive the main power supply with your control. The main power supply powers the system processor board, customer 24V devices, encoders and the operator panel power supply. Figure 3A.7 shows the main power supply.

Figure 3A.7

8520-PS2A Main Power Supply

To processor module connector P12

8520-PS2A

Power

OFF

Power

COM

OFF

24 Vdc

RTRN

INPUT

115/230V

8A/5.5A

47 - 63 Hz

From AC

Power Source

Switched AC

Power to Operator’s

Panel Power Source

19417

3A-7

Section 3A

Primary 9/230 Components

3A.2

Servo Axis Connectors on the 9/230 Analog

Output Specifications

The 8520-PS2A main power supply output specifications are shown in

Table 3A.D. For input specifications and fuse specifications refer to page 13A-22. The power supply shuts down if the 2A limit on the customer 24V supply is exceeded. This causes the control to shut off. You must provide protection for this circuit if you do not want this auto-shut down feature to activate.

Table 3A.D

8520-PS2A Main Power Supply Output Specifications

Item Specifications

Rated Outputs

+5.30V dc (10A) @ 50

(8A) @ 60

+15V dc (.75A) @ 50

(.2A) @ 60

° C

-15V dc (-.75A) @ 50

(.2A) @ 60

° C

+24V dc (2.0A) @ 50

(2.0A) @ 60

Line Monitor

Hold Up Time 6 msec

----

Remark

Total of 130 Watts @ 50

96.4 Watts @ 60 convection cooling, or 130

Watts @ 60 of 25 CFM

C with

C with minimum

Detects Loss of AC Power

@ 130 Watts

The 9/230 analog control can be purchased as either a three axis controller or as a single axis controller. Both the single and three axis configurations have an additional open loop analog spindle output terminal.

A separate analog servo amplifier amplifies the signal from the 9/230 processor to deliver the power necessary to drive the servo motors. Refer to appendix D for analog drive options.

Position and velocity data are read from a feedback device that is mounted on the slide, ballscrew, or servo motor. This feedback device generates differential signals that are then fed to the processor. If the spindle motor incorporates an encoder (closed loop) it will supply spindle position feedback to the processor module. If you require a closed loop spindle you must connect the spindle drive to the last available axis connector (no closed loop spindle port is available on the single axis 9/230).

Most analog servo drive amplifiers require some form of velocity feedback from the servo motor. This feedback is usually generated by a tachometer or resolver attached to the motor shaft. Refer to your servo drive amplifier literature for details.

3A-8

Section 3A

Primary 9/230 Components

3A.2.1

Connecting Axes to Analog

Servo Interface

Axes are connected to the D-shell connectors marked J1, J2, and J3 (single axis 9/230 processors only have a J1 connector). Axes must be connected consecutively with no empty connections between axes. For example, an axis may not be connected to connector J3 unless both J1 and J2 are used.

If a spindle with feedback is configured the spindle must be connected to the first available D-Shell connector after the last connector used by a linear or rotary axis. If you have a closed loop axis on a single axis 9/230 control you can not connect a spindle with position feedback.

ATTENTION: Do not insert the plug-type ANALOG OUT terminal block (TB3) into an encoder termination panel DRIVE terminal block or vice versa. Although these plugs will fit together, pin assignments are different. Switching these connections without rewiring the plug-type terminal block may cause damage to equipment.

Figure 3A.8 and Figure 3A.9 show typical analog servo drive configurations for a mill and a lathe. For specific details on configuring axes, axis positioning loops, and axis port selection, refer to the 9/Series

CNC 9/230, 9/260, and 9/290 AMP Reference Manual, publication

8520-6.4.

3A-9

Section 3A

Primary 9/230 Components

Cabinet or Enclosure

9/230

Figure 3A.8

Typical Analog Servo Drive Configuration for a Mill

Spindle

Drive

Feedback device

Spindle

Motor

Velocity Feedback

(Axis 3)

Term Panel

(Axis 2)

Term Panel

(Axis 1)

Term Panel

Drive Signal

(Axis 3)

Servo

Amplifier

(Axis 3)

Drive Signal

(Axis 2)

Servo

Amplifier

(Axis 2)

Drive Signal

(Axis 1)

Servo

Amplifier

(Axis 1)

Feedback device

Position feedback

Encoder power

Velocity

Feedback

Servomotor

(Axis 1)

Velocity

Feedback

Servomotor

(Axis 2)

Velocity

Feedback

Servomotor

(Axis 3)

19424

3A-10

Section 3A

Primary 9/230 Components

Cabinet or Enclosure

9/230

Figure 3A.9

Typical Analog Servo Drive Configuration for a Lathe

Spindle

Drive

Feedback devices

Spindle

Motor

Processor Board

Velocity Feedback

Drive Signal

(Spindle)

(Axis 3)

Term Panel

(Axis 2)

Term Panel

(Axis 1)

Term Panel

Position feedback

Encoder power

Drive Signal

(Axis 1)

Velocity

Feedback

Position feedback

Encoder power

Velocity

Feedback

Drive Signal

(Axis 2)

Servo

Amplifier

(Axis 1)

Servomotor

(Axis 1)

Servomotor

(Axis 2)

Servo

Amplifier

(Axis 2)

19425

For additional information on each of the major components refer to the section that covers that component.

3A-11

Section 3A

Primary 9/230 Components

3A.2.2

Analog Servo Operation and

Specifications

The Analog Servo control is a function at the 9/230 Analog processor board. The control calculates positioning and velocity data and processes the data to generate the necessary analog drive signals. These signals are sent to the analog servo amplifiers, which power the servo motors of the machine. The 9/230 Analog may control up to three closed loop axes and one open loop axis (typically used for a spindle).

The control receives position data from the axis feedback devices. It combines this position feedback data with the interpolated commands from the control to generate the command signals that are outputs to the servo amplifiers.

The function of the control on the processor module is designed to make the servomotors run with optimum performance. The maximum feedrates are limited by the mechanical abilities of the machine. System gain and the maximum allowable following error also limit the feedrates. These limits are entered as AMP parameters. Refer to the 9/Series CNC 9/230,

9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more information.

Table 3A.E lists the analog servo output specifications. This table is provided as an aid to determine the compatibility of different analog servo amplifiers. This section contains a list of compatible analog servos. Input specifications are discussed in sections covering the individual input devices. Refer to Table 3A.I for encoder feedback input specifications.

Table 3A.E

Analog Servo Interface Output Specifications

Item Specification Remark

Output Voltage Range

10V

Output Offset Voltage

500 m

V Max.

Resolution 1.22mV

(13 bits) 1

Sampling Frequency 500 Hz

Output Current

Load Range

Conversion Time

5mA Max.

2K ohms to infinity

8.25

m s

Differential

Non-Linearity

Gain Error

Load Capacitance

1 LSB Max.

0.01

F Max.

This resolution is obtained through software. It is equal to a

13-bit numeric value with an additional sign bit (14 bits total).

Monotonic over the entire temperature range. LSB means least significant bit.

3A-12

Section 3A

Primary 9/230 Components

3A.2.3

Analog Servo Connectors and Pin Assignments

Table 3A.F lists the connectors that are used to integrate the analog servo connections with other modules of the control. If you have purchased the single axis 9/230 control, only one servo connector (J1), an open loop spindle connector (TB3), and the touch probe connector (TB2) is available.

Table 3A.F

Typical Processor Module Connection

Connector On

J3 (D shell)

J2 (D shell)

J1 (D shell)

T.P. (TB2)

ANALOG OUT (TB3)

Remote I/O (P2)

Connected To

Module

Term. Panel

Connector

AXIS

Term. Panel

AXIS

---Touch Probe

Spindle Drive

PLC Scanner

Cable

Number

C35

C46

C42

C17

Remark

AXIS

----

Spindle

Page 8-19 has details on RIO

(purchased as an option)

-- Not available on single axis 9/230 controls

J1, J2, and J3 D-Shell AXIS Connectors

The 9/230 sends drive signals to the servo amplifier through connectors labeled J1, J2, and J3. Figure 3A.10 shows an end view of connector J1,

J2, and J3 and lists the pin assignments of these connectors.

3A-13

Section 3A

Primary 9/230 Components

9 1

26 .

11300-I

Figure 3A.10

Connectors J1, J2, and J3 - 26 Pin Female, D-Shell Connector

Pin No.

Signal

Not Used

CHA_HI

CHB_HI

CHZ_HI

+5V_ENC

SEN

DRIVE

Description

Feedback device Channel A

Feedback device Channel B

Feedback device Channel Z

+5V Encoder Power Supply

Not Used

CHA_LO

CHB_LO

Feedback device Channel A

Feedback device Channel B

Feedback device Channel Z CHZ_LO

Not Used

GND

SEN. RET

DRIVE.RET

Encoder Power Return

10V analog drive command return

Not Used

SHLD_CHA Shield for phase A

SHLD_CHB Shield for phase B

Signal Destination

Servo Module

Feedback Device

+5V Encoder Power Supply Feedback Device

Switched +5V Encoder Power Supply (not used) Feedback Device

10V analog drive command

Servo Amplifier

Servo Module

Feedback Device

Servo Amplifier connect at module only connect at module only

SHLD_CHZ Shield for phase Z

SHLD_+5V Shield for +5V

SHLD_SEN Shield for switched +5V

SHLD_DRV Shield for drive command connect at module only connect at module only connect at module only connect at module only

ANALOG OUT Auxiliary Output Connector

An auxiliary analog output is provided through the connector labeled

ANALOG OUT (TB3). This connector is typically used to command an analog spindle drive system with no position feedback. TB3 is not capable of receiving encoder feedback information. Figure 3A.11 shows the location of ANALOG OUT connector. Table 3A.G lists terminal assignments of this connector.

3A-14

Section 3A

Primary 9/230 Components

Important: TB3 (labeled ANALOG OUT) should only be used for drive applications that do not require a feedback device. If a feedback is required, the output signal to the drive and its corresponding encoder feedback should be wired through one of the axis connectors J3, J2, or J1.

A drive application with feedback would typically not use the connector

TB3.

Figure 3A.11

Analog Out Connector, 3 Plug-type Terminal Block Connections

1 2 3

Table 3A.G

Analog Out Connector Terminal Assignments

Description Terminal

No.

Signal

Analog Out +

Analog Out -

Shield

10V Analog with no feedback

Signal Destination

(typically spindle drive)

Signal Return and chassis ground (typically spindle drive) connect at control only

3A-15

Section 3A

Primary 9/230 Components

3A.3

Analog Servo Amplifiers

3A.4

Analog Servo Motors

The 9/Series CNC supports Allen-Bradley Series 1386, 1387, 1388, 1389,

1391, and 1392 analog servo drive systems. If you are using a 1387 drive, it must be equipped with 115V ac and the dynamic-braking option. Refer to appendix D for details on wiring one of these AB drives to your control.

Table 3A.H lists references to help you select a suitable drive system.

Table 3A.H

Compatible A-B Drives

A-B Drive

1386

1387

1388

1389

1391

1392

Publication No.

1386-5.0

1387-5.0

1388-5.1

1389-5.1

1391-5.0

1392-5.1

Title

DC PWM Servo Drive (Multi-Axis)

DC Spindle Drive (Analog) Product Data

DC PWM Servo Drive (Single Axis) Product Data Series B

AC Servo Amplifier (Multi-Axis) Product Data

AC Servo Amplifier (Single Axis) Product Data

High Performance AC Drive (460V and 230V) Product Data

The processor module provides a + 10V analog velocity command output for up to four drive amplifiers. This analog voltage is generated from a

12-bit value plus an additional sign bit (13 bits total) and interfaces to drive amplifiers with a 2K-20K ohm range.

Servo Motors are used to drive the axes of the machine because of their ability to respond accurately to small positioning commands. Typically they have two feedback devices mounted on them, one that provides position data to the processor module, and one that provides velocity data to the servo amplifier.

Any servo motor that meets the needs of your machine tool and is compatible with the servo amplifier that you will be using, can be used with the control.

Allen-Bradley has a wide selection of servo motors that can be used with the Allen-Bradley servo amplifiers. These motors can also be used with other servo amplifiers that are compatible with the servo interface. For more information on Allen-Bradley servomotors, contact your

Allen-Bradley sales representative.

Motor installation and maintenance will depend on the type of motor used and the hardware to which it is mounted. For more specific information, refer to the documentation prepared by your drive and motor manufacturers.

3A-16

Section 3A

Primary 9/230 Components

3A.5

Encoder Termination Panel

The encoder termination panels are options with the analog system that provide an easy and convenient means for you to connect and troubleshoot your servo system. We strongly recommend the use of termination panels as part of the system.

Termination panels feature:

D-shell connectors for cables from the motion controller (A-B cable number 8520-TPC)

Plug-type connectors for wiring to user devices

DIN Rail Mountable

All user connections with the exception of the ANALOG OUT (TB3) and

TP (TB2) connections are routed through the termination panels. User side voltages of +5V dc and +15V dc for encoder power (chosen by wiring to the appropriate connector pin) are available on-board. External power supplies for the encoders may also be routed through the termination panel

(refer to the feedback section).

Figure 3A.12 shows an encoder termination panel.

Figure 3A.12

Encoder Termination Panel

DRIVE

AXIS

DRIVE

RET

SHLD

ENCODER

CH A. HI

CH A. LO

AB SHLD

CH B. HI

CH B. LO

Z SHLD

CH Z. HI

CH Z. LO

ENC POWER

+5V

RET

+15V

EX PWR OUT

SHLD

EXT

POWER

EX PWR IN

EX RET IN

FDBK IO

RET

SHLD

91670401

1771HTE ENCODER TERMINATION PANEL

11305-I

3A-17

Section 3A

Primary 9/230 Components

3A.6

9/230 Compatible

Feedback Devices

This section discusses encoder feedback devices that are compatible for both analog and digital servo systems. Feedback devices on all the CNCs must return a 5V compatible output signal to the control.

For analog systems this feedback device can be used to provide: velocity feedback (used only if your system does not provide tachometer velocity feedback to the drive) In this case, the analog servo amplifier must be configured to run in “torque mode” with no tachometer.

Tachless servo configurations work best if an encoder type feedback device is used and mechanically coupled directly to the servomotor shaft.

position feedback (can be the same device as used to close the velocity loop if the velocity loop is closed by the CNC, or an additional feedback device, as discussed in this section, can be used for the position loop) spindle feedback

For digital systems this feedback device can be used to provide: position feedback (digital systems require the motor mounted feedback device, provided on our standard digital servo motors, be used for velocity loop feedback. This motor mounted feedback device can also be used to close the position loop or an additional feedback device, as discussed in this section, can be used for the position loop.) You can not replace or bypass the motor mounted feedback device. The motor mounted feedback device must be used for velocity feedback and to attain proper motor commutation on digital servo systems.

spindle feedback

Only the 8520 digital drive system supports absolute feedback.

3A-18

Section 3A

Primary 9/230 Components

The 9/230 supports:

Feedback Device

Allen-Bradley 845H series differential encoders

Sony Magnascale model GF-45E

Heidenhain Model 704

Futaba Pulscale model FM45NY

Additional hardware

----

Board-type detector model MD10-FR

External interpolation and digitizing model EXE602 D/5-F

PCB interface Module model CZ0180 with cable PCB020EA

Other feedback devices can be compatible if they comply with the specifications listed in Table 3A.I. Refer to the 9/Series CNC AMP

Reference Manual, publication 8520-6.4, for more information.

This manual is written under the assumption that your system is using the

Allen-Bradley 845H series differential encoder. If you are using some other feedback device such as a linear scale, an application note is available through Allen-Bradley CNC Commercial Engineering

Department at area code (216) 646-3963.

The following table lists feedback specifications for a differential encoder however, this information can be interpreted to select an appropriate linear scale.

3A-19

Section 3A

Primary 9/230 Components

Item

Maximum Encoder Channel

Frequency (ECF)

Maximum Axis Speed

Input Signal

Current Drawn from Encoder by

Servo Module

Marker Channel

Encoder Cable Length

Table 3A.I

Encoder Specifications

Specification

Use the following equation to determine the maximum channel frequency

Maximum Encoder Channel Frequency =

Where:

Clock

360

90-Eq x 1.15

Clock -- is the Control’s Feedback Clock Frequency:

5 x 10

-- for 9/230, 9/440, and three axis servo cards.

2.3 x 10

-- for 9/260 or 9/290 systems using a four axis servo card

= Quadrature Error in Degrees

1.15 = Our minimum recommended safety factor

As long as the actual feedback channel frequency does not exceed the maximum channel frequency calculated above, the servo module should process the feedback data without a quadrature fault.

Use the following equation to determine the maximum axis speed. Note that this equation does not take into consideration any mechanical deficiencies in the encoder or motor. It is only concerned with the

9/Series capability of receiving feedback. Refer to the manufactures specs for encoder and motor hardware RPM limitations.

(ECF x 60)

----------------

(E) (N) (P)

= Maximum Axis Speed

Where:

Max Axis Speed = Maximum Axis Speed based on encoder feedback (inches or millimeters per minute)

ECF = Maximum encoder channel frequency the control may receive in units of cycles/sec.

E = the number of encoder lines between markers for your encoder

N = the ratio of encoder turns to ballscrew turns

P = the ballscrew pitch (turns per inch or turns per millimeter. For rotary axes, substitute the appropriate gear ration for N and P in the equation above to solve for a max RPM in revolutions per minute.

If the maximum axis speed resulting from this equation is less than you would like, you may need to sacrifice some axis resolution by selecting an encoder with fewer lines between markers.

Encoder feedback must be differential format with 5V compatible output signals, single-ended open-collector outputs are not supported, i.e., channels A, B, and Z must have source and sink current capability, 8830 line driver outputs or equivalent.

7mA maximum; 44mA peak

Narrow marker (gated) or Wide marker (ungated) type markers are supported

Refer to 9/Series Integration and Maintenance Manual for details on cabling

3A-20

Section 3A

Primary 9/230 Components

3A.6.1

Wiring an Incremental

Feedback Device

Figure 3A.13 shows an incremental feedback device equivalent circuit for feedback channel A.

Figure 3A.13

Incremental Feedback Device Equivalent Circuit

+5V

768

221 W

0.01u f

+5V

768

Processor Module

Cable

8500-TPC

Ch A HI

Ch A LO

Termination Panel

Differential

Line Driver

Customer

Encoder

11306-I

Wiring Position Feedback

Feedback devices used with the control must be configurable such that the marker Z is true at the same time that channels A & B are true. If you are using an Allen-Bradley 845H encoder this requirement will already be met if you wire them as shown in the cable diagrams on page 7A-1.

If you are using an encoder type feedback device other than the

Allen-Bradley 845H encoder, then use the following wiring procedure:

Obtain the encoder output timing diagram from the vendor’s data sheets. A typical one is provided in Figure 3A.14 as an example.

On the timing diagram, look at the marker Z and its complement, marker Z. Whichever one is low for most of the encoder revolution and pulses high should be wired to “CH Z.HI” of the encoder termination panel. Wire the remaining marker to “CH Z.LO” of the encoder termination panel.

Look at channel B and its complement, channel B. Whichever one is high for at least part of the marker interval should be wired to

“CH B.HI” of the encoder termination panel. It is possible that both channels meet this requirement depending on the encoder manufacturer, in which case, use either one. Wire the remaining channel to “CH B.LO” of the encoder termination panel.

Look at channel A and its complement channel A and repeat as in step 3 using “CH A.HI” and “CH A.LO” of the encoder termination panel.

3A-21

Section 3A

Primary 9/230 Components

If the previous procedure is not performed correctly, inconsistent homing of the axis may occur. If your encoder phasing cannot provide an interval at which the marker and both channels are simultaneously true, the encoder should be considered incompatible with the control.

Figure 3A.14

Example of a Typical Vendor Encoder Timing Diagram

NOTE:

Below w irin g is an e xa m p le o n ly o f a typ ica l ve n d ors e n co de r. S e e you r e n co de r

1 cycle

STEP 3

C h an ne l A is h igh at le a st pa rt o f m a rker t

”C H A . H I” of te rm ina tio n p a ne l.

Channel A

STEP 1

H ig h m a rker in terva l. C onne ct to

”C H Z. H I” of te rm inatio n pane l.

Optional

A’

STEP 2

B is h ig h fo r a t le a st p a rt o f m a rk e r in te rv a l. C o n n e c t to

”C H B . H I” o f te rm in a tio n p a n e l.

B’

Z’

CCW rotation viewing shaft

W ire CH B, CH A , and CH Z to CH B LO ,

CH A LO and CH Z LO , respectively, on the term ination panel.

11307-I

Important: Since positive and negative axis directions can be assigned without regard to encoder rotation directions, it is possible for the feedback direction to be ”backwards”. This is easily corrected before attempting to command axis motion through the AMP parameter Sign of Position

Feedback. Refer to the 9/Series CNC 9/230, 9/260, and 9/290 AMP

Reference Manual, publication 8520-6.4, for more information.

3A-22

Section 3A

Primary 9/230 Components

Optional

Customer Supplied

Power Supply

Wiring Power for your Feedback Device (Analog Systems Only)

The control supports feedback devices with 5v compatible output signals.

The voltage that these feedback devices require may vary. The processor module is equipped to supply 5V dc power to feedback devices. These voltages may be accessed directly from the encoder termination panel

If your feedback device requires an external power supply, it may be easily incorporated through the EXT. POWER connector on the termination panel. Power is then output through the ENC POWER connector terminal labeled EX PWR OUT. The following figure shows the termination panel connection for EXT. POWER. Refer to page 7A-1 for details on wiring to

ENC POWER.

Figure 3A.15

Wiring Optional Customer Supplied Power Supply for Feedback Devices

External Power

Ground

Shield

EXT.

POWER

EXT PWR IN

EXT RET IN

11308-I

3A-23

Section 3A

Primary 9/230 Components

3A.7

Servo Axis Connectors on the 9/230 Digital CNC

3A.7.1

Connecting Axes to Digital

Servo Interface

There are two different digital 9/230 systems. One is used to support the

8520-xx series of digital amplifiers (its catalog number is 8520-DSP). The other supports 1394-xx series of digital servo amplifiers (its catalog number is 8520-CSP). Both 9/230 digital systems support a maximum of three axes, each having a servo motor and feedback device, and an open loop spindle motor.

The servo amplifier amplifies the signal from the 9/230 processor in order to deliver the power necessary to drive the servo motors.

Position and velocity data are read from a feedback device that is mounted on the servo motor. If the spindle motor incorporates an encoder it must supply spindle position feedback to the processor module.

Axes are connected to the D-shell connectors that are at the bottom edge of the processor board. Axes must be connected consecutively with no empty connections between axes. If a spindle with feedback is configured the spindle must be connected to the first available D-Shell connector after the last connector used by a linear or rotary axis.

Figure 3A.16 and Figure 3A.17 show typical digital servo drive configurations for a 8520 system and a 1394 system respectively. For specific details on configuring axes, axis positioning loops, and axis port selection, refer to the 9/Series CNC AMP Reference Manual, publication

8520-6.4.

3A-24

Section 3A

Primary 9/230 Components

Spindle motor

Velocity feedback

Spindle motor

Velocity feedback

Figure 3A.16

Typical 8520 Digital Servo Drive Configuration

9/230 CNC

8520 Drive Version

(8520-DSP)

Configured for three axes and one spindle without position feedback

Spindle drive

DAC output

J3 J2 J1

Velocity/Position Feedback

Servomotor

(Axis 1)

Encoder

8520 Digital

Servo

Amplifier

(3 Axis amplifier)

Servomotor

(Axis 2)

Encoder

Servomotor

(Axis 3)

Encoder

Figure 3A.17

Typical 1394 Digital Servo Drive Configuration

9/230 CNC

1394 Drive Version

(8520-CSP)

Configured for three axes and one spindle without position feedback

Spindle drive

DAC output

J3 J2 J1

1394 Digital

CNC System Module

Axis

Module

Axis

Module

Axis

Module

Resolver Resolver Resolver

Velocity/Position Feedback

For additional information on each of the major components refer to the section that covers that component.

3A-25

Section 3A

Primary 9/230 Components

3A.7.2

Digital Servo Operation and

Specifications

The Digital Servo control is a function at the 9/230 Digital processor board. The control calculates positioning and velocity data and processes the data to generate the necessary digital drive signals. These signals are sent to the digital amplifiers which power the servo motors of the machine.

The 9/230 Digital may control up to three closed loop axes and one open loop axis (typically used for a spindle).

The control receives position data from the axis feedback devices. On a

1394, system position data is converted to an A quad B signal in the 1394 drives system module. The control combines this position feedback data with the interpolated commands from the control to generate the command signals that are outputs to the servo amplifiers.

The 9/230 control is designed to make the servomotors run with optimum performance. The maximum feedrates are limited by the mechanical abilities of the machine. System gain and the maximum allowable following error also limit the feedrates. These limits are entered as AMP parameters. Refer to the 9/Series CNC AMP Reference Manual, publication 8520-6.4, for more information.

Table 3A.J lists the digital servo output specifications. Refer to Table 3A.I

for 8520 encoder feedback input specifications or appendix H for 1394 systems. Be aware that encoders or resolvers are mounted directly to the digital motor shaft before they are shipped and should not be removed.

Use only if you intend to use a second feedback device for an axis.

Table 3A.J

Digital Servo Interface Output Specifications

PWM Output

(8520 digital only)

Comutated Output

(1394 digital only)

DAC Output

Item

PWM Frequency

PWM Signal Type

Comutated Signal

IA and IB

Output Voltage Range

Resolution

Sampling Frequency

Output Current

Load Capacitance

Specification

Approx. 2.0 KHz

RS-422-A

Approx. 1000 Hz

10V

2.44mV

1000 Hz

5mA Max.

0.01

F Max.

Remark

(

12 bits)

( ± 12 bits)

3A-26

Section 3A

Primary 9/230 Components

3A.7.3

9/230 Digital Connectors and Pin Assignments

15 1

The 9/230 CNC sends drive signals to the servo amplifier and receives feedback through these connectors. Figure 3A.18 and Figure 3A.19 show an end view of a digital servo connector and lists its pin assignments for the 8520 and 1394 digital 9/230 CNC’s respectively.

Figure 3A.18

Pinout for the Servo Connectors on the 9/230 8520 Digital

44 .

Pin Signal Description Connect Pin Signal Description Connect

2 CHU_HI

4 CHW_HI Channel W Sense_HI

5 /PWM_A_LO Current Cmd for Phase A_LO Servo Amplifier

6 /PWM_B_LO Current Cmd for Phase B_LO

7 /PWM_C_LO Current Cmd for Phase C_LO

10 CHB_HI

11 CHA_HI

12 I

FDBK Phase B

(lb)

13 ENABLE

14 I

FDBK Phase A

(la)

15 GND

17 +15V_ENC

19 GND

20 +5V_ENC

Shield

CHV_HI

STATUS

CHZ_LO

Chassis Ground

Channel U Sense_HI

Channel V Sense_HI

Amplifier Status_HI

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Current sensing from feedback Phase _B

Motor Amplifier Enable_HI

Current sensing from feedback Phase _A

Encoder Return

+15V Encoder Power Supply

Encoder Return

+5V Encoder Power Supply

Not Used

Feedback Device

30 Shield

Feedback Device 31

32 CHU_LO

Servo Amplifier

Feedback Device

34 CHW_LO

38 /STATUS

40 CHB_LO

EXT_BAT

+5V_ENC

GND

CHV_LO

PWM_A_HI

PWM_B_HI

PWM_C_HI

CHZ_HI

CHA_LO

FDBK Phase B

(/lb)

43 /ENABLE

44 /I

FDBK Phase A

(/la)

Battery +/-- for absolute encoder

+5V Encoder Power Supply

Encoder Return

Chassis Ground

Channel U Sense_LO

Channel V Sense_LO

Channel W Sense_LO

Current Cmd for Phase A_HI

Current Cmd for Phase B_HI

Current Cmd for Phase C_HI

Amplifier Status_LO

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Current sensing from feedback Phase _B

Motor Amplifier Enable_LO

Current sensing from feedback Phase _A

Feedback Device

Not Used

Feedback Device

Servo Amplifier

Feedback Device

Servo Amplifier

Feedback Device

3A-27

Section 3A

Primary 9/230 Components

44 .

Figure 3A.19

Pinout for the Servo Connectors on the 9/230 1394 Digital

Pin Signal

16 GND

19 GND

20 +5V_ENC

24 +5V_ENC

28 GND

29 GND

30 Shield

31 GND

32 CHU_LO

33 CHV_LO

34 CHW_LO

35 V

38 /STATUS

39 CHZ_HI

40 CHB_LO

41 CHA_LO

43 Return

1 Shield

2 CHU_HI

3 CHV_HI

4 CHW_HI

5 V

8 STATUS

9 CHZ_LO

10 CHB_HI

11 CHA_HI

13 ENABLE

15 GND

Description

Chassis Ground

Channel U Sense_HI

Channel V Sense_HI

Channel W Sense_HI

Command Voltage

Amplifier Status_HI

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Motor Amplifier Enable_HI

Signal Common

Ground 24V input return

Signal Common

+5V Encoder Power Supply

Encoder Return

Signal Common

Chassis Ground

Motor Amplifier Enable_LO

Channel U Sense_LO

Channel V Sense_LO

Channel W Sense_LO

Command Voltage

Amplifier Status_LO

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Drive Return

Signal Destination

N/A

Servo Module

CNC Interface Board

Servo Module

CNC Interface Board

Feedback Device

CNC Interface Board

CNC Interface Board n/a

CNC Interface Board

Servo Module

CNC Interface Board

Servo Module

3A-28

Section 3A

Primary 9/230 Components

ANALOG OUT Auxiliary Output Connector

An auxiliary analog output is provided through the connector labeled

ANALOG OUT. This connector is typically used to command a spindle drive system with no position feedback. This connector is not capable of receiving encoder feedback information. Figure 3A.20 shows the location of ANALOG OUT connector. Table 3A.K lists terminal assignments of this connector.

Important: For spindle applications, you need to wire the drive to the analog out connector, and the feedback to a servo connector (J1, J2, or J3).

Figure 3A.20

Analog Out Connector, 3 Plug-type Terminal Block Connections

Table 3A.K

Analog Out Connector Terminal Assignments

Description Terminal

No.

Signal

Analog Out +

Analog Out -

Shield

± 10V Analog with no feedback

Signal Destination

(typically spindle drive)

Signal Return and chassis ground (typically spindle drive) connect at control only

3A-29

Section 3A

Primary 9/230 Components

3A.7.4

Digital Servo Amplifiers

Two versions of the 9/230 digital are available which interface to the 8520 digital amplifier or the 1394 digital amplifier. Do not attempt to interface an 8520 digital 9/230 to a 1394 drive or a 1394 digital 9/230 to an 8520 digital drive. These two systems are mutually exclusive.

Both the 1394 and 8520 digital servo amplifiers receive an “Axis enable” signal and returns a “Drive OK” signal from/to the 9/230 digital CNC provided certain system and motor tests are successful.

Important: The digital servo amplifier should be separated or isolated from the processor module because of the electrical noise it generates.

Refer to page 7A-1 for unit mounting spacing and other noise prevention techniques that will have to be followed when installing 8520 digital amplifiers. Refer to your 1394 Amplifier documentation for details on installing 1394 drive systems.

Figure 3A.21 shows the interface between the digital servo interface and the servo amplifier.

Figure 3A.21

Digital Servo Amplifier Interface

9/230 Digital

Drive Signal

Axis enable

Status

Feedback (1394 only)

Servo

Amplifier

CNA1 or

CNC1

(Axis 1)

CNA2 or

CNC2

(Axis 2)

CNA3 or

CNC3

(Axis 3)

ANALOG OUT

Velocity signal (analog)

Spindle amplifier

11089-I

Important: The configuration of the digital servo module output ports with the digital servo amplifier connectors will vary depending on the

AMP configuration of the system. Refer to the 9/Series CNC AMP

Reference Manual, publication 8520-6.4, for more information.

3A-30

3A.7.5

Digital Servo Motors

Section 3A

Primary 9/230 Components

The digital servo motors are used to drive the axes of the digital servo drive system. The digital servo motors have a feedback device mounted on them that provides position and velocity data to the servo module. This motor mounted feedback device must never be removed from the digital motor. Even a slight change in the feedback devices orientation relative to the motor shaft will cause improper motor commutation. This motor mounted feedback device provides the control with velocity and motor commutation information. It is also typically used for position feedback.

A second feedback device can be mounted directly on the axis (such as a linear slide) to provide greater precision for positioning feedback. On these systems with multiple feedback devices, the motor mounted feedback must still be used for motor commutation and velocity feedback.

The digital servo motors that the 8520 9/230 Digital CNC supports are listed in the appendix titled Digital Motor Dimensions. This appendix lists all compatible 8520 series motors in two sections. The first section lists motors that include holding brakes, and the second section list motors without holding brakes.

The 1394 9/230 Digital CNC supports 1326 digital servo motors. For more information on this Allen-Bradley family of motors, refer to the 1326AB

Torque Plus Series Servomotors Product Data, publication 1326A-2.9.

3A-31

Section 3A

Primary 9/230 Components

3A.8

Using Test Points

Test Point Analog DAC reference

TP11 Analog Ground

Test Point Encoder Feedback Reference Voltage

TP10 Digital Ground

Test Point Encoder Feedback Signals

TP25

TP24

TP23

TP22

TP21

TP20

TP19

TP18

TP17

TP16

TP15

TP14

TP13

A Channel connector J1

B Channel connector J1

Z Channel connector J1

Analog out J1

A Channel connector J2

B Channel connector J2

Z Channel connector J2

Analog out J2

A Channel connector J3

B Channel connector J3

Z Channel connector J3

Analog out J3

Analog Out TB3

Test points are small metallic pins on the processor module circuit board.

Hardware troubleshooting and testing for proper wiring can begin by testing for proper voltage or signals at these pins. Test points are labeled with the letters TP followed by a number. Use Figure 3A.22 to find the location and function of each test point on the 9/230 Analog CNC. Use

Figure 3A.23 to find the location and function of each test point on the

9/230 Digital CNC.

Figure 3A.22

Test Points on the 9/230 Analog

TP10

TP13

TP11

TP15

TP17

TP14 TP16

TP19 TP21

TP18 TP20

TP23 TP25

TP22 TP24

3A-32

Section 3A

Primary 9/230 Components

Figure 3A.23

Test Points on the 9/230 Digital

Test Point Analog Out Signal (Spindle)

TP34

TP33

DAC Spindle Output

Analog Output

Test Point Encoder Feedback Signals

TP22

TP23

TP24

TP11

TP10

TP21

TP15

TP14

TP13

A Channel connector J1

B Channel connector J1

Z Channel connector J1

A Channel connector J2

B Channel connector J2

Z Channel connector J2

A Channel connector J3

B Channel connector J3

Z Channel connector J3

Test Point Other Signals

TP5

TP12

Digital Ground

Reset Pin (Connect to Analog GND to Reset)

TP 33

TP 34

TP 5

TP 12

TP 21

TP 22

TP 23

TP 24

TP 13

TP 14

TP 15

TP 11

TP 10

TP 7

3A.9

Wiring a Touch Probe to the

Processor Module

Connect a touch probe to the connector labeled TP on the processor module (TB2). Connector terminal identification is provided in

Figure 3A.24. Touch probe cable information can be found on page 7A-1 of this manual.

The time delay between the processor module receiving the touch probe trigger and latching the current axis position is negligible. However, you should be aware of any external delays that may introduce position

“staleness” in the probing operation, especially at high probing speeds.

It is a good idea to establish an offset for the distance between the actual location, as sensed by the probe at a very low speed, and the location sensed by the probe at the intended probing speed. The offset can then be added or subtracted to any future values obtained through probing. This helps make sure that if there are any external delays in the trigger signal, the position staleness shows up as a constant position offset error and is removed from the measurement (assuming the external delay is repeatable).

The motion controller touch probe interface is intended for use with units that offer 5V dc compatible solid state relay outputs. Other configurations can be supported as long as the user operates within the published electrical specifications.

3A-33

Section 3A

Primary 9/230 Components

The touch probe circuitry resident on the processor module only responds to the trigger probe edge changes. Polarity transition (high to low or low to high) is selectable through the AMP parameter Probe Transition.

Specify the probe transition in AMP as rising edge or falling edge. Once the active edge occurs, position data is captured , and additional occurrences of the trigger signal have no effect until the probe is reenabled under program control.

Refer to the 9/Series CNC 9/230, 9/260, and 9/290 AMP Reference

Manual, publication 8520-6.4, for more information.

ATTENTION: It is preferred, from a safety standpoint, that the touch probe relay be closed at rest and open when the touch probe stylus deflects. Then, if a wire breaks or shorts to ground, it will appear to the system as a probe fired and the probing cycle in process will stop commanding motion towards the part.

The user should make every effort towards the fail-safe operation of the touch probe. Not all vendor’s touch probe control units conform to this safety consideration.

Figure 3A.24 shows the internal processor module circuitry that interfaces to the touch probe connector. It is shown here to assist you in determining whether your touch probe hardware is compatible.

3A-34

Section 3A

Primary 9/230 Components

Figure 3A.24

Internal Circuitry Supporting the Touch Probe

75ALS197

TB2

5V dc common

+ 5V dc

1000ohm

464ohm

4 3 2 1

19534

The following table indicates probing threshold voltages. Maximum Input

Threshold (critical if the control has been configured to fire on the falling edge of the probe signal) indicates the voltage that the probe signal must fall below to be considered as “fired”. Minimum Input Threshold (critical if the control has been configured to fire on the rising edge of the probe signal) indicates the voltage that the probe signal must rise above to be considered as fired

Probe Thresholds

Minimum Input Threshold (probe circuit)

Maximum Input Threshold (probe circuit)

Voltage at Threshold

2.875 (min)

2.125V dc (max)

To avoid misfires use the threshold values from the above table to determine the necessary signal voltage for steady state operation (probe not fired). For probes configured to fire on the falling edge the steady state voltage must remain above 2.875 volts. For probes configured to fire on the rising edge the steady state voltage must remain below 2.125 volts.

3A-35

Section 3A

Primary 9/230 Components

3A.10

Adaptive Depth Probing

Wiring a Probe for Rising Edge Configurations

Typical wiring of a simple contactor type touch probe configured to fire on the rising edge of the probe signal, requires the addition of a 1000 ohm pull down resistor. Figure 3A.25 shows a typical wiring diagram compatible with most probe designs configured to trigger on the rising edge of the probes signal.

Figure 3A.25

Typical Wiring of a Touch Probe Configured for Rising Edge Trigger

4 3 2 1

TB2

1000 ohm pull down resistor

(customer supplied)

Probe Contact

Wiring a Probe for Falling Edge Configuration

Figure 3A.26 shows a typical wiring diagram compatible with most probe designs configured to trigger on the falling edge of the probe signal.

Figure 3A.26

Typical Wiring of a Touch Probe Configured for Falling Edge Trigger

4 3 2 1

TB2

Probe Contact

Use the Adaptive Depth probe feature to enable an adaptive depth probe that monitors tool depth relative to the actual part surface. This feature allows: a more flexible part mounting system (small changes to part size or part mounting do not require reprogramming of the machine or station) greater accuracy with a less accurate machine drive system (tool position is relative to the part surface rather than the machine home) a retroactive change in axis positioning resolution (feedback for axis positioning switches between the normal axis encoder and the adaptive depth probe once the probe is triggered).

3A-36

Section 3A

Primary 9/230 Components

Important: Since the adaptive depth probing feature requires one feedback port to pass probe position data to the control and one feedback port for normal axis positioning feedback, the adaptive depth feature is not compatible with the single axis 9/230 processor which only has one feedback port.

The adaptive depth probe is wired like any A quad B rotary encoder. It is connected to one of the controls feedback ports. Refer to page 7A-1 for details on cabling requirements for a feedback device. Table 3A.I lists specifications for an encoder. These same specifications apply to your adaptive depth probe.

If you are using the adaptive depth probe to close the position loop

(selected in AMP) the maximum axis speed calculations from Table 3A.I

also apply. Refer to your AMP reference manual for details on other configuration required to operate using an adaptive depth probe.

In AMP the adaptive depth probe is assigned an axis name. Using the axis monitor page for that axis (see page 15A-35) you can view the current following error on the adaptive depth probe and the adaptive depth probe position relative to zero. The probe is zeroed automatically at power up or through PAL.

END OF SECTION

3A-37

Section 3A

Primary 9/230 Components

3A-38

Power Distribution

Section

3B.0

Section Overview

Once you have planned your system layout, you can begin connecting power and components to your system. In this section we discuss: how ac power is distributed through the system connecting the main power supply and operator interface power supply main and operator panel power supply input power specifications protective grounding

The external ac power connections to the control and operator panel are covered in this section. For information on external ac power source connections to servo amplifiers, servo motors, and I/O modules, refer to the sections that cover these components. For details on external ac power source connections to an analog servo amplifier or analog servo motor, refer to the documentation provided by the manufacturer.

Figure 3B.1 shows the power distribution from the supply to the control and its components.

Figure 3B.1

Power Distribution from the Supply to the Control and its Components

Indicates fiber optic cable

9/230 CNC

Customer supplied

24V dc

115/230V ac 115/230V ac

E-Stop

Digital I/O

E151/E152/E153

Digital I/O

E154

Analog I/O

24V dc

Customer supplied1

Low current

( < 1.0 amp) pilot relay

CN07

1746

I/O ring adapter

HPG

I/O Ring

MTB

I/O

High density

I/O

Cable C04

On button

COM

Main power supply

8A Fuse ac input

115/230V ac

Auxiliary ac

115/230V ac

5V dc 12V dc

Operator panel power supply

Customer supplied

24V dc

12V dc

Off button

OFF

Color monitor

To power circuitry

5V dc connectors to servo modules (encoder power)

(9/260 and 9/290 only)

May not be necessary on PS2 24V is part of the power supply.

May be mounted on operator panel or portable operator panel interface assembly.

Monochrome monitor

11194-I

3B-1

Section 3B

Power Distribution

3B.1

Connecting the PS2 Main

Power Supply

This section discusses the connections of the main power supply and the operator panel power supply.

Connecting the Main Power Supply to AC Power Source

ATTENTION: To guard against electrical shock hazards, never make connections or disconnections at the ac distribution network unless the main ac disconnect switch is open and locked.

Important: In addition to supplying power to the operator panel power supply, the main power supply also supplies power to the motherboard and the CPU board. As shown in Figure 3B.2, the power cables for these modules originate from the side of the main power supply.

Refer to Figure 3B.2 while performing these steps:

Locate AC-IN, L1, L2, and PE on terminal block BT04.

Connect the ac power source cable (C02) from the external ac power source to AC-IN, L1, L2, and PE on BT04.

Connect the chassis ground terminal to the cabinet’s grounding bus bar.

Important: The chassis ground terminal connects to the control chassis and designated cable shields. Power supply common is AC coupled to chassis ground. It is the users responsibility to determine if a direct connection to cabinet ground bus is required.

3B-2

Section 3B

Power Distribution

Figure 3B.2

Main Power Supply Connection for the 9/230

To processor module supply connector P12

Power

OFF

Power

COM

OFF

24V dc

RTRN

INPUT

115/230V

8A/5.5A

47 - 63 Hz

AUX

BT04

From AC

Power Source

Switched AC

Power to Operator’s

Panel Power Source

19417

3B-3

Section 3B

Power Distribution

3B.2

Main and Operator Panel

Power Supply Input Power

Specifications

The input power specifications of the main power supply, the operator panel power supply, and the portable operator panel interface module power supply are shown in Table 4D.A and Table 4D.B. For output power specifications of the main power supply for the 9/260 and 9/290, refer to page 4A-10. For output power specifications of the operator panel power supply, refer to page 9A-7.

Table 3B.A

Main Input Power Specifications

Item

Input Rated Input

Input Range

Power Consumption

8520-PS1

8520-PS2A

Specifications

115V/230V ac -- 50/60Hz

90-265V ac -- 47-63Hz

225 Watts @ 50 ° C

130 Watts @ 50

Fuse 8A/250V

Remark

168 Watts @ 60 ° with min. 25 CFM

96.4 Watts @ 60 with 25 CFM

C or 225 Watts

C or 130 Watts

Protects power supply module and sub-power supply and the color CRT

Connection Terminal Block

3B-4

Section 3B

Power Distribution

Connecting the Main Power Supply to the Monochrome

Operator Panel Power Supply

You connect the operator panel power supply directly to the main power supply. Refer to Figure 3B.2 and Figure 3B.3 when performing these steps:

Use the ac power supply cable (C03) to connect terminals AUX-AC

L1 and L2 of terminal block BT04 on the main power supply to terminals L1 and L2 of terminal block BT02 on the operator panel power supply.

Connect the chassis ground terminal on the operator panel power supply to the cabinet’s grounding bus bar.

Important: The chassis ground terminal connects to the operator panel chassis and designated cable shields. Power supply common is AC coupled to chassis ground. It is the user’s responsibility to determine if a direct connection to cabinet ground bus is required.

Figure 3B.3

Power Supply Connector on Monochrome Operator Panel

HPG

GND

HPG

GND

HPG

GND

12V

MTB

GND

BT02

A C

5 V

G N D

5 V

G N D

5 V

G N D

1 2 V

G N D

T o H P G

T o M T B p a n e l

I/O m o d u le

19450

3B-5

Section 3B

Power Distribution

Connecting the Main Power Supply to the Portable

Operator Panel Interface Assembly Power Supply

You connect the Portable Operator Panel Interface Assembly power supply directly to the main power supply. Refer to Figure 3B.2 and Figure 3B.4

when performing these steps:

Use the ac power supply cable (C03) to connect terminals AUX-AC

L1 and L2 of terminal block BT04 on the main power supply to terminals L1 and L2 of terminal block BT02 on the power supply for the portable operator panel interface module.

Connect the chassis ground terminal on the portable operator panel interface assembly power supply to the cabinet’s grounding bus bar.

Figure 3B.4

Power Supply Connector on Portable Operator Panel Interface Assembly

GND

12V

GND

TO MTB panel

TO HPG

3B-6

Section 3B

Power Distribution

Connecting Main Power Supply to the Color Operator Panel

You connect the operator panel power supply directly to the main power supply. The operator panel power supply receives power from the color

CRT power supply through an internal jumper from the AC (H and L) terminals.

Figure 3B.5

Color Operator Panel Power Supply Connection

HPG

GND

HPG

GND

HPG

GND

12V

MTB

GND

BT02

A C

5 V

G N D

5 V

G N D

5 V

G N D

1 2 V

G N D

T o H P G

T o M T B p a n e l

I/O m o d u le

19450

Connect terminals AUX-AC H and L of terminal block BT04 on the main power supply to the color CRT power supply terminals AC H and

AC L, which are located on the rear of the color operator panel, using the power supply cable C03.

3B-7

Section 3B

Power Distribution

Connecting the Power Supply to the MTB Panel ON/OFF Switch

Terminal block BT04 terminals ON-SW, COM, and the OFF-SW are connected to terminal block BT-20 terminals ON, COM, and OFF on the

MTB panel using the ON/OFF signal cable C01. Figure 3B.6 shows terminal block BT-20 on the MTB panel.

Figure 3B.6

MTB Panel ON/OFF Switch Connection

To Main Power

Supply (BT04)

To Motherboard/

Processor Board

(TB1)

PWR

COM

PWR

OFF

ESTOP

COM

RESET

BT20

+12V

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

CN52

I/O ring fault indicator

MTB Panel

Table 3B.B

Operator Panel or Portable Operator Panel Interface Assembly

Power Supply Input Power Specifications

Item

Input Rated Input

Input Range

Power Consumption

Fuse

Connection

Specifications

115/230V ac --- 50/60Hz

90-265V ac --- 47-63Hz

55 Watts

2A/250V

Terminal Block

3B-8

3B.3

Protective Grounding

Section 3B

Power Distribution

All components and modules must be correctly grounded to protect against electrical shock hazards. Proper grounding also helps to reduce the effect of electrical noise by isolating induced noise voltages to individual ground wires and shunting them to ground.

There are two types of grounds used in electrical system design, chassis and earth. Chassis ground is defined as the internal ground of a cabinet.

Earth ground is defined as the central ground for all electrical equipment and ac power within any factory.

For the chassis ground use a conductor such as the control cabinet or the cabinet’s grounding bus bar. To provide good conductivity when the cabinet is used as the conductor, remove rust and any coating from the area of the cabinet that will be a contact point for the ground cables. Each component installed in the cabinet will have a separate grounding cable connected to the conductor.

Each electrical cabinet requires two separate connections from the cabinet to the earth ground: from the chassis ground -- each component installed in a cabinet is connected to the cabinet’s chassis ground. The cabinet chassis ground is connected to the earth ground by a single grounding cable.

from the cabinet -- each cabinet is connected separately to the earth ground.

ATTENTION: To guard against damage to the machine, do not interconnect chassis ground wires between the components.

This would place ground wires in series and cause their noise voltages to be additive. The resulting increased noise energy can interfere with proper control and machine functions.

A general system grounding diagram, which shows both chassis ground and earth ground, is shown in Figure 5A.21.

3B-9

Section 3B

Power Distribution

3B-10

Earth GND (typically AWG 8)*

Chassis GND (typically AWG 10)*

Chassis GND (typically AWG 12)*

Signal GND

GND through mounting

Shield

Protected Earth (PE)

(typically AWG 8)*

Refer to local standards and codes for wire sizing.

Machine Tool

Analog

I/O input output

Digital

I/O (dc)

Servo

Motor

Servo

Motor

Encoders/Resolvers

Spindle

Motor

Operator Cabinet

Operator Panel

(see below)

Chassis

GRND Stud

MTB Panel

I/O Module

Chassis

GRND Stud

HPG

Component Enclosure

9/230 CNC

Drives Cabinet

Servo

Amplifier

Spindle

Drive

Digital

I/O (dc)

High Density

I/O

Main power supply

Single point

GND

Line Filter/

Transformer

Color Operator Panel

Color

CRT

Keyboard

Interface

Chassis

GRND Stud

RS--422 or

RS--232

Terminal

Monochrome Operator Panel

Monochrome

CRT

Keyboard

Interface

Chassis

GRND Stud

Portable Operator Panel Interface Assembly

Operator Panel

Interface Module

Keyboard

Interface

Chassis

GRND

Stud

Operator Panel power supply

END OF SECTION

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.3 -- February 1997 PN176025

9/Series Hardware

TAB 4

9/260 and 9/290 CNC Systems

8520-6.2.4 -- August 1998 PN--176438

4A.0

Section Overview

Section

Primary 9/260 and 9/290 Components

This section discusses the primary components of the 9/260 and 9/290 enclosure:

Motherboard (9/260 and 9/290)

CPU Board (9/260 and 9/290)

Main Power Supply (PS1)

These modules are installed into the component enclosure. The component enclosure also supports the digital or analog servo module(s), the remote

I/O port (9/290) and main power supply on the 9/260 and 9/290. The 9/260 and 9/290 component enclosure is shown in Figure 4A.1.

Figure 4A.1

Component Enclosure

Component Enclosure

8520-PS1

Power

Supply

Remote I/O Port

(available on 9/290 only)

Motherboard

CPU Board

Analog Servo Module

19102

4A-1

Section 4A

Primary 9/260 and 9/290 Components

Scanner

Remote I/O Port

Main

Power

Supply

The motherboard is attached to the back wall of the enclosure. The CPU board slides into the enclosure and connects to the motherboard.

Figure 4A.3 shows motherboard is featured.

The servo module(s) slide into the right-most module guides on the enclosure. The right-most component in the rack is the power supply.

Figure 4A.2

9/260 & 9/290 CNC’s System Overview

External

E-Stop ac power source

MTB

Panel

Port B

(RS-232/

RS-422)

Port A (RS-232)

Operator Panel or

ROPI assembly

MTB

I/O

9/260 or 9/290

Fast I/O

Battery

Servo

Module

(third)

9/290 0nly

Servo

Module

(first)

1746 I/O

HPG

High

Density

I/O

Digital

I/O

Analog

I/O

Optical signal cable

Terminal type connection

Servo

Module

(second)

115/230V ac

24V dc

Machine

24V dc

Machine

115/230V ac

24V dc

Machine

115/

230V ac

4A-2

Section 4A

Primary 9/260 and 9/290 Components

4A.1

The Motherboard

On the 9/260 and the 9/290 the motherboard works with the CPU board to process all software functions of the control. Figure 4A.3 shows the CPU board connected to the motherboard within the enclosure.

Figure 4A.3

Front View of the Motherboard within the Enclosure

Connectors for Optional Modules

Connector for Remote I/O Port (9/290 only)

Power Supply Connector

Lithium Battery Connector

Fast I/O Connector

I/O Ring Output Connector (Red)

Motherboard LEDs

I/O Ring Input Connector (Black)

E-stop Fuse and Spare

Pluggable E-Stop Connector

Port B

(Port A is on the CPU Board)

Servo

Board

Connectors

(available on

9/290 only)

Video Connector CPU Board

Power Supply

4A-3

Section 4A

Primary 9/260 and 9/290 Components

4A.2

Connections on the

Motherboard

Table 4A.A lists the connections on the 9/260 and 9/290 motherboard and where to locate the cable diagrams within this manual. Refer to page 7A-1 for cable details.

Table 4A.A

Locating Motherboard Wiring Diagrams for the 9/260 and 9/290

Attach this connector:

Lithium Battery (P1)

Fast I/O (P3)

I/O Ring Output (Red)

I/O Ring Input (Black)

E-Stop (TB1)

Port B (J7)

Video (J8)

Remote I/O (P2)

)

CPU Board (J2, J9)

Servo Connector (P4)

Servo Connector (P6)

Servo Connector (P5)

Power Supply (J1)

To:

Lithium Battery Pack

Fast Inputs

First Device on I/O Ring

Last Device on I/O Ring

E-stop String

Peripheral Devices

Operator Interface

(Color or Monochrome)

PLC Scanner

Motherboard

Servo Module #1

Servo Module #2

Servo Module #3

Power Supply

Use this Cable

C13, C24

C11

C10

C05, C06

C07

C09

C17

No cable necessary

C12

C04

Port B

Use serial port B transmits data to and from peripheral devices. It is configured for RS-232 communications. You can configure, it for use as a

RS-422 port by using the softkeys on the operator panel.

The MTB panel may have the optional serial interface connector mounted on it. This connector provides an external interface port for RS-232 or

RS-422 interface from a peripheral to the control. It communicates with ports A or B with cable C07. Refer to the “Cable List” section on page

7A-1 for additional information on cable C07. For more information on the signals of each pin, refer to page 8-1.

4A-4

Section 4A

Primary 9/260 and 9/290 Components

Figure 4A.4

Port B-J7 (has pin sockets) and Pin Assignments

Port B

11257-I

Pin Assignment Pin Assignment

Chassis GND

Send Data A

9 Send Data B

10 Receive Data B

Receive Data A 11 Request to Send B

Request to Send A 12 Clear to Send B

Clear to Send A

Data Set RDY A

Signal GND

Data Term RDY a

13 Data Set RDY B

14 Data Term RDY B

15 Not Used

Fast I/O Connector (P3)

The fast I/O connector provides an interface port for fast input and output to and from the control. Use the Fast I/O feature for direct inputs and outputs to PAL, affecting features such as block skip and probing. Use cable C11 to interface this connector with external I/O devices. For information on using a termination panel to wire your fast I/O, refer to page 10A-63, I/O Interface. Refer to the Cable List section on page 7A-26 for additional information on cable C11. Figure 4A.5 shows this connector and lists the pin assignments.

Figure 4A.5

Fast I/O Connector-P3 (has pins) and Pin Assignments

Pin No.

Signal Name Pin No.

Signal Name

FAST_I1

COM

FAST_I2

COM

FAST_I3

COM

FAST_I4

COM

FAST_O1

COM

FAST_O2

COM

FAST_O3

COM

FAST_O4

COM

4A-5

Section 4A

Primary 9/260 and 9/290 Components

4A.3

CPU Board for 9/260 and

9/290

Video Monitor Connector

The video monitor connector is used to interface the video monitor with the control. Figure 4A.6 shows this connector and lists the pin assignments.

Figure 4A.6

Video Monitor Connector-J8 (has pin sockets) and Pin Assignments

11257-I

Pin No.

Signal Name Pin No.

Signal Name

GND (SHIELD)

RED (L1)

GREEN (L1)

BLUE (L1)

CLOCK (L1)

H-SYNC (L1)

V-SYNC (L1)

RED (L2)

GREEN (L2)

BLUE (L2)

CLOCK (2L)

H-SYNC (L2)

V-SYNC (L2)

The CPU board works with the motherboard to process all software functions of the 9/260 and 9/290 control. You can remove the CPU board from the enclosure by gently sliding it out. When you replace the board be sure to line the board with the guide tracks on the top and bottom panels of the enclosure. Figure 4A.7 shows the CPU board layout.

4A-6

Section 4A

Primary 9/260 and 9/290 Components

Figure 4A.7

CPU Board

High--Speed Shadow RAM

Green

LED

RS--232

Port

Connector to

Motherboard

Used only for extended program storage

Front

Plate

Connector to

Motherboard

EPPS Jumper

Super Capacitor

Front View

Side View

Flash Memory on SIMMS

RS-232 Port (Port A)

Serial port A is used to transmit data to and from peripheral devices. It is configured for RS-232 communications only. Figure 4A.8 shows this connector and lists the pin assignments of Port A. For more information on the signals of each pin, refer to page 8-1.

Figure 4A.8

Port A (has pin sockets) and Pin Assignments

Port A

Pin

8-15

Assignment

Chassis GND

Send Data

Receive Data

Request to Send

Clear to send

No connection

Signal GND

Not Used

4A-7

Section 4A

Primary 9/260 and 9/290 Components

4A.4

Reading LEDs

The green and red LEDs on the motherboard and the CPU board for 9/260 and 9/290 indicate the overall status of your system during power and operation. Use Table 4A.B to read these LEDs when you power up the system.

Table 4A.B

LED Sequence at Power Up for the 9/260 and 9/290

Motherboard LEDs

Red

OFF

Green

OFF

CPU Board

LED

Green

OFF

Status

CNC off- No power

OFF

Power is on. Control begins diagnostics. If control does not quickly change states, this indicates an error during diagnostics. If cycling power does not clear the error, then contact A-B System Support Services.

CNC is on and running diagnostics. If control does not quickly change states, this indicates an error during diagnostics. If cycling power does not clear the error, then contact A-B System Support Services.

Diagnostics completed. Check CRT for error messages.

If control does not quickly change states this indicates an error. If cycling power does not clear the error, then contact A-B System Support Services.

ON System is running.

System Error LED Pattern

If this LED pattern appears while the control is running, contact

Allen-Bradley Support Services:

Motherboard LEDs

Red

OFF

Green

CPU Board LED (for 9/260 and 9/290)

Green

OFF

Status

Watchdog timeout has occurred.

4A-8

Section 4A

Primary 9/260 and 9/290 Components

4A.5

Battery Backup for the 9/260 and 9/290

Pin Number Polarity

Cable

Motherboard

Enclosure

The memory for data such as part programs, tool offset/compensation data, interference zones, and work coordinate offset data is stored in on the CPU board. In the case of a power failure, there is a super capacitor on the

CPU board that backs up this data for up to 5 days (at 40°C) on systems without extended program storage. This super capacitor recharges within 1 hour of power turn on if completely discharged. If you want to extend this backup time, or if you have extended program storage (2 Megabytes) you install a lithium battery pack (8520-LIBAT) that supports the data for:

9/260 and 9/290 Control and Description:

standard with extended program storage

Time (at 40°C Discharge)

3 years

1 years

This battery pack is connected to the lithium battery connector (P1) on the motherboard as shown in Figure 4A.9. Batteries and the battery cable are included with the battery replacement kit.

Figure 4A.9

Lithium Battery Connector (P1)

The lithium battery contains heavy metals and must be collected separately from other waste.

Lithium Battery Pack

Power Supply

4A-9

Section 4A

Primary 9/260 and 9/290 Components

4A.6

Main Power Supply

You receive the main power supply with your control. The main power supply powers the motherboard, the CPU board, the servo module(s), and the operator panel power supply. Figure 4A.10 shows the main power supply.

Figure 4A.10

Main Power Supply

ALLEN-BRADLEY

AC POWER

250V

5V DC Encoder Power --

Use this table to connect to the servo or optional feedback modules on the 9/260 or 9/290

Module in 9/260 or 9/290 Connector

3-axis Digital Servo

3-axis Analog Servo

4-axis Digital Servo

4-axis Analog/1394 Servo

Optional Feedback

CN13

CN25M

To motherboard power supply connector J1

AC IN

AUX

ON SW

COM

OFF SW

BT04

From ac power source

Switched ac power to operator panel power supply

Power-on switch

Power-off switch

4A-10

Section 4A

Primary 9/260 and 9/290 Components

Output Specifications

The main power supply output specifications are shown in Table 4A.C.

For input specifications and fuse specifications refer to page 4D-5.

Table 4A.C

Main Power Supply Output Specifications

Item Specifications

Rated Outputs

+5.1V dc (25A) @ 50

(18A) @ 60

+15V dc (4A) @ 50

(3A) @ 60

° C

-15V dc (2A) @ 50

(1A) @ 60

° C

+5.35V dc (4A) @ 50

(3A) @ 60

Line Monitor

Hold Up Time 6 msec

----

Remark

Total of 225 Watts @ 50

168 Watts @ 60

C with convection cooling, or

225 Watts @ 60 ° C with minimum of 25 CFM

Detects Loss of AC Power

@ 225 Watts

END OF SECTION

4A-11

Section 4A

Primary 9/260 and 9/290 Components

4A-12

4B.0

Section Overview

Section

Connecting the 3-axis Servo Module

This section covers the integration of the 8520 digital and analog servo module and its components. A section of this section is devoted to each of the following drive components:

For Information: See Page:

8520 Digital Servo Module

Optional Feedback Module

Wiring a Touch Probe

Analog Servo Module

4B-6

4B-16

4B-25

4B-29

Analog Servo Module Connectors and Pin Assignments 4B-33

Analog Servo Module Specifications 4B-37

Connecting Axes to Analog Servo Module

Analog Servo Module LED Indicators

4B-38

Analog Servo Module Test Points

Encoder Termination Panel

Feedback Devices

Wiring a Touch Probe to the Analog Servo Module

4B-39

4B-41

4B-42

4B-48

4B-1

Section 4B

Connecting the 3-axis Servo Module

Battery

Touch Probe

Spindle drive

230V ac

3 Æ

8520 digital Servo

Drive Connection

8520 Digital

Servo Module

Figure 4B.1

9/260 and 9/290 Connections from the 3-Axis Servo Module to 8520 Digital Drives

8520 Digital Servo Drive Connection with Optional Feedback Module

Non-motor Mounted

Feedback Devices

9/260 or 9/290

Control

Optional Feedback

Module

Battery

Touch Probe

8520 Digital

Servo Module

Spindle drive

Servo Amp

230V ac

3 Æ

Servo Amp

Motor

Encoder

Motor

Encoder

Motor

Encoder

Motor

Encoder

Motor

Battery

Touch Probe

Spindle drive

8520 Digital

Servo Module

Servo Amp

Optical signal cable

Terminal type connection

230V ac

Motor

Encoder

Motor

Encoder

Motor

11204-I

4B-2

Section 4B

Connecting the 3-axis Servo Module

Optical signal cable

Terminal type connection

Term Panel Term Panel

Figure 4B.2

9/260 and 9/290 Connections from the 3-axis Servo Module to Analog Drives

9/260 or 9/290

Control

Analog

Servo Module

ANALOG OUT BAT/TP

Analog

Servo Module

(for 9/290 only)

Analog

Servo Module

Term Panel

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Motor

Encoder

Motor

Encoder

Motor

Encoder

11205-I

4B.1

How the 8520 Digital Servo

Card Works

There are two typical 8520 digital servo drive configurations for the control. The typical mill configuration has 3-axes, each having a servo motor and feed back device, and a analog open loop spindle motor. The typical lathe configuration has 2-axes, each having a servo motor and feedback device, and a analog open loop spindle motor with position feedback.

The 8520 digital Servo module functions as a high--speed servo processor.

It is installed in the component enclosure.

4B-3

Section 4B

Connecting the 3-axis Servo Module

The 8520 digital Servo Amplifier translates low-level PWM signals from the 8520 digital servo module to the power levels necessary to drive the servo motors.

Current feedback data is read from the current sensors in the 8520 digital servo amplifier and returned to the 8520 digital servo module. This data is processed by the servo module to maintain velocity and position control, according to module, AMP, and part program constraints.

Important: In order to use the solid tapping feature that is available on the

9/260 and 9/290 CNC, you must use the Allen-Bradley 8510 AC spindle drive system.

Cabinet or enclosure

9/260 or 9/290

8520 digital

Servo Module

(configured for three axes and one open loop spindle)

Position and velocity data are read from a feedback device that is mounted on the servo motor. This feedback device generates differential signals that are then fed to the 8520 digital servo module. If the spindle motor uses an encoder, it will supply spindle position feedback to the 8520 digital servo module.

Figure 4C.1 and Figure 4C.2 show typical 8520 digital servo drive configurations for a mill and a lathe. Refer to the 9/Series CNC 9/230,

9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for specific details on configuring axes, axis positioning loops, and axis port selection.

Figure 4B.3

Typical 8520 Digital Servo Drive Configuration for a Mill

Feedback device

Servomotor

(Axis 1)

Servo drive signal (Axis 1)

Current feedback (Axis 1)

Servo drive signal (Axis 2)

Current feedback (Axis 2)

Servo drive signal (Axis 3)

Current feedback (Axis 3)

Servo

Amplifier

(3 Axis amplifier)

Servomotor

(Axis 2)

Servomotor

(Axis 3)

Feedback device

Analog signal

Spindle drive

Spindle motor

Velocity feedback

Position feedback

11274-I

4B-4

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.4

Typical 8520 digital Servo Drive Configuration for a Lathe

Cabinet or enclosure

9/260 or 9/290

8520 digital

Servo Module

(configured for two axes and one open loop spindle with position feedback)

Servo drive signal (axis 1)

Current feedback (axis 1)

Servo drive signal (axis 2)

Current feedback (axis 2)

ServoAmplifier

(2 axis amplifier)

Servomotor

(Axis 1)

Servomotor

(Axis 2)

Feedback device(s)

Analog signal

Spindle drive

Spindle motor

Feedback device

Position feedback

Velocity feedback

11275-I

For additional information on each of the major components, refer to the section that covers that component.

4B-5

Section 4B

Connecting the 3-axis Servo Module

4B.2

8520 Digital Servo Module

(8520-ENC3)

The 8520 Digital Servo Module is mounted in the component enclosure. It functions as a high-speed servo processor. The control sends positioning and velocity data to the servo module where it is processed to generate the necessary pulse width modulated (PWM) command signals. These signals are sent to the digital servo amplifier, which power the servo motors of the control. The digital servo module also provides an analog velocity command signal for a servo (typically the spindle) that is not using a digital servo amplifier.

Figure 4B.5

Servo Module

CN1

CN11

CN10

CN12

CN4

CN5

CN6

CN7

CN9

CN13

CN8

CN2

CN3

11276-I

The digital servo module receives two forms of feedback: position data from the feedback devices on the axes current feedback from the servo amplifier

It combines this position and current feedback data with the interpolated commands from the control to generate the PWM command signals that it outputs to the servo amplifiers.

4B-6

Section 4B

Connecting the 3-axis Servo Module

4B.2.1

Servo Module Connectors and Pin Assignments

The functions of the digital servo module are designed to make the axes run with optimum performance. Generally, the maximum feedrates are limited by the mechanical abilities of the machine. System gain and the maximum allowable following error will also limit the feedrates. These limits are entered as AMP parameters. Refer to the 9/Series CNC 9/230,

9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more information.

Table 4C.A lists the connectors that are used to integrate the digital servo module with other modules of the control.

Table 4B.A

Digital Servo Module Connectors

Connector on Servo Module Connected to: Cable Number Remark

Component Connector

CN1

CN2

CN3

CN4

CN5

CN6

CN7

Motherboard

Servo Amplifier

Feedback Device

P4, P5 or P6

CNA1

CNA2

CNA3

C12

C19

C17

Axis 1

Axis 2

Axis 3

CN8

CN9

CN10

CN11

CN12

Spindle

Touch Probe

Battery Pack

Optional Feedback Module

C21

C22

C23

CN13 +5V Encoder Power Cable from Main Power Supply

Important:

When 1 servo module is used, it must be connected to P4 of the motherboard. When 2 servo modules are used, the first servo module must be connected to P4 and the second to connector P6.

9/290 only, when three modules are used, connect the first to P4, the second to P6 and the third to P5.

If a spindle incorporates an encoder to supply position feedback to the servo module, the spindle encoder must be interfaced with the last open connector of these 3 connectors. Refer to the

9/260-9/290 AMP Reference Manual, publication 8520-6.4, for more information.

CN1 Servo Module Interface Connector

The servo module is interfaced with the motherboard through connector

CN1. The control transmits and receives various signals to and from the servo module through this connector.

4B-7

Section 4B

Connecting the 3-axis Servo Module

1 2 3 4 5 6 7

8 9 10 11 12 13

14 15 16 17 18 19 20

CN2, CN3, and CN4 Servo Drive Signal Connectors

The digital servo module sends servo drive signals and receives current feedback from the servo amplifier through connectors CN2, CN3, and

CN4. Figure 4C.7 shows an end view of connectors CN2, CN3, and CN4 and lists the pin assignments of the these connectors.

Figure 4B.6

End View of Connectors and Pin Assignments of CN2, CN3, CN4, 20 pin male, Honda MR-20RMD2

11277-I

Pin

No.

Signal Description True

Level

Signal Destination

ENABLE Motor Amplifier Enable

/ENABLE “ON”State ---- Enable (Active)

Shield

Chassis ground for shielded cable

Shield Chassis ground for shielded cable

STATUS Amplifier status flag

HIGH

LOW

Servo Amplifier

HIGH Servo Module

/STATUS “ON”state - normal operation

PWM_A Current command for Phase_A

9 /PWM_A Diff. signal

10 PWM_B Current command for Phase_B

LOW Servo Module

HIGH Servo Amplifier

LOW Servo Amplifier

HIGH Servo Amplifier

11 /PWM_B Diff. signal

12 PWM_C Current command for Phase_C

15 /Ia

16 Shield

Diff. Signal

Chassis ground for shielded cable

LOW Servo Amplifier

HIGH Servo Amplifier

13 /PWM_C Diff. signal

14 Ia Current sensing value for Phase_A

LOW

HIGH

Servo Amplifier

Servo Module

LOW Servo Module

17 Shield

18 Shield

19 Ib

20 /Ib

Chassis ground for shielded cable

Current sensing value for Phase_B HIGH Servo Module

Diff. Signal LOW Servo Module

4B-8

Section 4B

Connecting the 3-axis Servo Module

14 15 16 17 18 19 20

8 9 10 11 12 13

1 2 3 4 5 6 7

11278-I

CN5, CN6, and CN7 for Absolute and Incremental Encoder Connectors

The digital servo module receives feedback from the feedback devices

(absolute or incremental encoders) of the servo motors or spindle through connectors CN5, CN6, and CN7. Figure 4B.7 shows an end view of connectors CN5, CN6, and CN7 and lists the pin assignments of this connector when it is used with absolute encoders.

Figure 4B.7

Absolute Encoder Connections and Pin Assignments of Connectors

CN5, CN6, CN7, 20 pin female, Honda MR-20RFD2

Pin. No Signal Description

8-11 N.C.

12 Reset

N.C.

GND

Encoder Power Return

ENC_5V Switched +5V Encoder Power

Supply

ENC_5V +5V Encoder Power

ENC_15V +15V Encoder Power

BAT_+ Battery Power Supply

Used for Reset Operation Only

/PZ

/PA

Phase_Z, 1 pulse per rev

Diff. Signal

Phase_A, 2-phase pulse

Diff. Signal

Phase_B, 2-phase pulse

/PB

Shield

Diff. Signal

Chassis Ground

True

Level

Signal Destination

Feedback Device

High

Low

High

Low

High

Low

Feedback Device

Servo Module

ATTENTION: Reversing the polarity of the absolute encoder battery power supply can destroy some elements of the absolute encoder.

4B-9

Section 4B

Connecting the 3-axis Servo Module

Table 4B.B lists the pin assignments of this connector when it used with incremental encoders.

Pin No.

Table 4B.B

CN5, CN6, and CN7 Incremental Encoder Pin Assignments

Signal Description

GND

ENC_5V

Encoder Power Return

Switched +5V Encoder Power Supply

+5V Encoder Power

ENC_15V Spindle Encoder +15V Power Supply

ENC_15V +15V Encoder Power

N.C.

/PU

/PV

/PW

/PZ

/PA

/PB

Shield

Pole Sensor output Phase_U, 0

Diff. Signal

Phase_Z, 1 pulse per rev.

Diff. Signal

Phase_A, 2-phase pulse

Diff. Signal

Phase_B, 2-phase pulse

Diff. Signal

Chassis Ground

Pole Sensor output Phase_V, 120

Pole Sensor output Phase_W, 240

Diff. Signal

High

Low

High

Low

High

Low

High

Low

High

Low

High

Low

True Level Signal Destination

Feedback Device

Servo Module

Feedback Device

The encoder marker signal is sent to the control on the Phase_Z pins

(#14 and #15).

Important: If a spindle incorporates an encoder to supply position feedback to the digital servo module, the spindle encoder must be interfaced with the last open connector of these 3 connectors. Refer to the

AMP reference manual for additional information on digital servo board configuration.

Pins 8 through 13 of connectors CN5, CN6, and CN7 are used for motor phasing only. When using connectors CN5, CN6, or CN7 for spindle feedback, pins 7 through 13 are not connected (N.C.).

4B-10

Section 4B

Connecting the 3-axis Servo Module

11279-I

1 2 3

4 5

6 7 8

CN8 DAC Output Connector

The digital servo module sends analog signals to the spindle motor drive through connector CN8. Figure 4B.8 shows an end view of connector CN8 and lists the pin assignments.

Figure 4B.8

Connector CN8, 8 pin female, Honda MR-8RFD2 and the Pin

Assignments

Pin No Signal Description True

Level

Signal

Destination

1-3 N.C.

4 SPDL_O

10V Analog (Spindle AMP

Drive Signal)

Analog Signal Return

Spindle Drive

5 SPDL_G

6-8 Shield

Spindle Drive

Important: Note that the DAC output connector (CN8) can also be used to output selected servo information using a feature called DAC monitor.

This feature is controlled by Patch AMP. Refer to the 9/Series CNC 9/230,

9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more information.

CN9 Touch Probe Connector

The digital servo module receives touch probe feedback through connector

CN9. Figure 4B.9 shows an end view of connector CN9 and lists the pin assignments.

11280-I

Figure 4B.9

Connector CN9, 8 pin male, Honda MR-8RMD2 and Pin assignments

Pin No.

Signal Description True Level Signal Destination

+5V dc Probe Power

TP_IN Touch signal input

TP_G

4-5 N.C.

Touch signal ground

Touch Probe

LOW (HIGH) Servo Module

Touch Probe

6-8 Shield

The True level is either “HIGH”or “LOW”as defined by AMP parameter PROBE TRANSITION.

Refer to the 9/Series CNC 9/230, 9/260, and 9/290 AMP Reference Manual, publication

8520-6.4, for more information.

4B-11

Section 4B

Connecting the 3-axis Servo Module

CN10 Absolute Encoder Battery Connector

The digital servo module receives battery power from the battery pack through connector CN10. This battery power supplies battery backup to the absolute encoder position register. You can connect up to four lithium battery backs to one enclosure: one to support the SuperCap memory backup and three others to support a maximum of three digital servo modules. Figure 4B.10 shows the lithium battery packs installed in the component enclosure. Figure 4B.11 shows the connector on the module and lists the pin assignments.

Figure 4B.10

Lithium Battery Packs Installed in the Component Enclosure

Connections to digital servo modules with absolute encoders

Lithium Battery Packs

ATTENTION: Reversing the polarity of the absolute encoder battery power supply can destroy some elements of the absolute encoder.

4B-12

Section 4B

Connecting the 3-axis Servo Module

1 2

11281-I

Figure 4B.11

Connector CN10 Pin Assignments

Pin No.

Signal

BAT_+

BAT_-

Description

Battery Voltage Supply

Battery Ground

Signal Destination

Absolute Encoder

CN11 Optional Feedback Module Interface Connector

The servo module is interfaced with the optional feedback module through connectors CN11 and CN12. Control signals from the servo module and position feedback information from the non-motor mounted feedback devices pass through this connector. Connector CN11 connects directly to connector CN21M on the optional feedback module. A cable is not required for this connection.

CN12 Optional Feedback Module Interface Connector

The servo module is interfaced with the optional feedback module through connectors CN11 and CN12. Encoder feedback signals from the digital servo module pass through this connector. Connector CN12 connects directly to connector CN22M on the optional feedback module. A cable is not required for this connection.

CN13 5V dc Encoder Power Connector

The digital servo module receives +5 V dc power directly from the main power supply through connector CN13. This +5V dc power is used only for powering the encoders. If the 5V dc encoder power is not used (i.e.

you are not using AB standard motors, you are using 15V dc encoders, or some other power source is used), this connection is not needed.

Figure 4B.12 shows an end view of connector CN13 and lists the pin assignments of this connector. For details on this connection refer to the section in page 4D-4 that discusses connections to the Main Power Supply.

Important: This connector must be used to provide power for the encoders if using the standard digital servo motors.

4B-13

Section 4B

Connecting the 3-axis Servo Module

4B.2.2

Digital Servo Module

Specifications

11282-I

Figure 4B.12

Connector CN13 Pin Assignments

Pin No.

Signal

+5V dc

Description

+5V dc Encoder Power Supply

2 N.C.

______

Signal Destination

Absolute or Incremental

Encoder

_____

Table 4B.C lists the digital servo module input specifications.

Table 4B.C

Digital Servo Module Input Specifications

Item Specification

Input Power Range for Encoders +5V (+10%, -1%)

+15V

(±

7%)

546KHz Maximum Input Frequency of

Encoder Feedback

Desired Voltage Range of

Encoder Battery Backup

3.5V to 4.5V

Remark

From Main Power Supply

_______

______

Table 4B.D lists the digital servo module output specifications.

Table 4B.D

Digital Servo Module Output Specifications

PWM Output

DAC Output

Item

PWM Frequency

PWM Signal Type

Output Voltage Range

Resolution

Sampling Frequency

Output Current

Load Capacitance

Specification

Approx. 2.5 KHz

RS-422-A

10V

2.44mV

500 Hz

5mA Max.

0.01

m F Max.

Remark

( ± 12 bits)

4B-14

Section 4B

Connecting the 3-axis Servo Module

4B.2.3

Servo Module Battery

Replacement

Important: Battery backup is required for absolute encoders only.

Incremental encoders do not require battery backup.

The servo module provides battery backup for the absolute encoder position register. This register retains position data during power loss.

The battery backup power originates from the batteries plugged into the servo board at connector CN10.

Even if battery backup fails, or the encoder cable is temporarily disconnected, the encoder will still maintain position data for up to 24 hours. This also allows for battery replacement without loss of data.

The battery backup is tested at power up, and at four hour intervals while system power is on. If battery voltage drops to 2.8V during the battery test, the control automatically displays the warning message “REPLACE

ABSOLUTE FEEDBACK BATTERY” on the operator panel.

Important: Once the “REPLACE ABSOLUTE FEEDBACK BATTERY” message is displayed, it is essential that the batteries be replaced to avoid loss of absolute position data.

To replace the servo module battery, turn all system power OFF and disconnect the old batteries from CN10 on the servo module. Battery replacement instructions are included with the battery replacement kit.

Before installing new batteries, use a voltage meter to make sure that new battery voltage is higher than 3.5V dc.

Figure 4B.13

Digital Servo Module Battery Connector CN10

CN10

Servo Module

CN12

CN8

CN2

CN3

CN4

CN5

CN6

CN7

CN9

The lithium battery contains heavy metals and must be collected separately from other waste.

4B-15

Section 4B

Connecting the 3-axis Servo Module

4B.3

Optional Feedback Module

The optional feedback module provides extra feedback ports for the digital servo module. Use these ports to provide axis position feedback to the digital servo module from a non-motor mounted second feedback device.

When using an optional feedback module, the incremental or absolute encoder mounted on the digital servo motor provides current and velocity loop feedback while a non-motor mounted feedback device provides axis position feedback.

Figure 4B.14

Optional Feedback Module

CN21M

CN23M

CN14F

VR1

VR2

CN15F

VR3

JP1

CN24M

CN25M

CN22M

CN16F

11861-I

Figure 4B.15 shows the optional feedback module mounted to and interfaced with the digital servo module through connectors CN21M and

CN22M. Typically the optional feedback module receives +5V dc power from the main power supply through connector CN25M. This +5V dc power is then transferred from connector CN24M on the optional feedback module to connector CN13 on the digital servo module using the cable supplied with the optional feedback module.

4B-16

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.15

Optional Feedback Module Interfaced with Digital Servo Module

CN21M

CN14F

CN23M

CN15F

JP1

CN24M

CN25M

CN16F

CN22M

Digital Servo Module

CN13

Optional Feedback

Module

Cable C43

(supplied with

Optional Feedback Module)

4B.3.1

Optional Feedback Module

Power Requirements

+5V dc Power Supply Cable From Main Power Supply or External Power Source

11862-I

Table 4B.E lists the power requirements of the optional feedback module and the non-motor mounted feedback devices.

Table 4B.E

Optional Feedback Module Power Requirements

Item

Voltage +5V dc

+15V dc

Current +5V dc

+15V dc

Power Consumption

Optional Feedback Module Feedback Devices

5.1V dc

3.2%

15V dc ± 4.34%

340mA max.

6mA max.

1.9W max.

5.347V dc

3.1%

15V dc ± 4.34%

0.25A max./device

0.2A max./device

4B-17

Section 4B

Connecting the 3-axis Servo Module

4B.3.2

Optional Feedback Module

Connectors and Pin

Assignments

Table 4B.F lists the connectors used to connect the optional feedback module to the servo module, non-motor mounted feedback devices, and power sources.

Table 4B.F

Optional Feedback Module Connectors

Connector on Optional

Feedback Module

CN14F

CN15F

CN16F

CN21M

CN22M

CN23M

CN24M

CN25M

Connected to:

Module Connector

Non-motor Mounted Feedback Device

Digital Servo Module CN11

Digital Servo Module

+15V dc External Power Source

CN12

Digital Servo Module

+5V dc Power Source

CN13

Cable

Number

C44

C43

CN14F, CN15F, and CN16F Optional Feedback Device Connectors

The optional feedback module is interfaced with non-motor mounted feedback devices through connectors CN14F, CN15F, and CN16F. These connectors provide +5V dc or +15V dc power to the non-motor mounted feedback devices and receive axis position feedback. Figure 4B.16 shows an end view of connectors CN14F, CN15F, and CN16F and lists the pin assignments of these connectors.

4B-18

Section 4B

Connecting the 3-axis Servo Module

11 12 13 14 15 16

7 8 9 10

1 2 3 4 5 6

11863-I

Figure 4B.16

Connectors and Pin Assignments for the CN14F, CN15F, CN16F, 16 pin female, Honda MR-16MRFD2

Pin No.

Signal

Description

PB Phase B, phase pulse

PB Diff. Signal

ENC_15V +15V dc power for feedback device

Shield Chassis ground for shielded cable

Shield

Chassis ground for shielded cable

Phase C, phase pulse

Diff. Signal

Phase A, phase pulse

GND

Diff. Signal

Feedback device power return

ENC_5V +5V dc power for feedback device

True Level

HIGH

LOW

HIGH

LOW

HIGH

LOW

Signal Destination

Optional Feedback Module

Feedback Device

Optional Feedback Module

Feedback Device

CN21M Optional Feedback Module Interface Connector

The optional feedback module is interfaced with the the servo module through connectors CN21M and CN22M. Control signals from the servo module and position feedback information from the non-motor mounted feedback devices pass through this connector. Connector CN21M connects directly to connector CN11 on the servo module. A cable is not required for this connection.

CN22M Optional Feedback Module Interface Connector

The optional feedback module is interfaced with the the servo module through connectors CN21M and CN22M. Encoder feedback signals from the digital servo module pass through this connector. Connector CN22M connects directly to connector CN12 on the servo module. A cable is not required for this connection.

4B-19

Section 4B

Connecting the 3-axis Servo Module

3 4

1 2

11864-I

CN23M External +15V dc Power Supply Connector

Use connector CN23M on the optional feedback module to connect an external +15V dc power supply to the optional feedback module.

Typically the optional feedback module receives +15V dc power from the main power supply through connector CN21M. This +15V dc power supply powers the non-motor mounted feedback devices of the optional feedback module.

When the sum of the power requirements of the non-motor mounted feedback devices exceed the internal +15V dc output of the main power supply, use an external power source to supply the +15V dc power.

Figure 4B.17 shows an end view of connector CN23M and lists the pin assignments.

Important: Jumper JP1 shown in Figure 4B.20 must be jumpered for external +15V dc power if an external +15V dc power supply is used.

Figure 4B.17

Connector and Pin Assignments for the CN23M, 4 pin male, Molex 5566-4A

Pin No.

Signal

EXT_15V

GND

Ground

Description

External +15V dc for feedback devices

Signal Destination

Feedback Device

System Common

CN24M Servo Module +5V dc Power Supply Connector

Use connector CN24M on the optional feedback module to provide +5V dc power to the digital servo module. Typically the optional feedback module receives +5V dc power from the main power supply through connector

CN25M. This +5V dc power is transferred from connector CN24M on the optional feedback module to connector CN13 on the digital servo module using cable C43 that is supplied with the optional feedback module.

Figure 4B.18 shows an end view of connector CN24M and lists the pin assignments of this connector.

4B-20

Section 4B

Connecting the 3-axis Servo Module

1 2

11282-I

Figure 4B.18

Connector and Pin Assignments of the CN24M, 2 pin male, Molex

5566-2A

Pin No.

Signal

ENC_5V

GND

Description

+5V dc power for digital servo module

Ground

Signal Destination

Digital Servo Module

System Common

CN25M +5V dc Power Supply Connector

Use connector CN25M on the optional feedback module to connect a +5V dc power supply to the optional feedback module. Typically the optional feedback module receives +5V dc power from the main power supply through connector CN25M. This +5V dc power supply powers the encoders of the digital servo module and the non-motor mounted feedback devices of the optional feedback module.

When the sum of the power requirements of the servo module and the optional feedback module exceed the +5V dc output of the main power supply, use an external power source to supply the +5V dc power.

Figure 4B.19 shows an end view of connector CN25M and lists the pin assignments.

Figure 4B.19

Connector and Pin Assignments for the CN25M, 2 pin male, Molex 5566-2A

Pin No.

Signal

ENC_5V

GND

Description

+5V dc for optional feedback device

Ground

Signal Destination

Optional Feedback Device

System Common

4B.3.3

Optional Feedback Module

Jumper (JP1)

Use jumper JP1 on the optional feedback module to select whether the

+15V dc power supply for the non-motor mounted feedback devices is : supplied from the main power supply supplied from an external power source removed from the feedback connectors

Non-motor mounted feedback devices receive +15V dc power through pins

3 and 4 of connectors CN14F, CN15F, and CN16F on the optional feedback module. Figure 4B.20 shows the jumper selections of jumper

JP1.

4B-21

Section 4B

Connecting the 3-axis Servo Module

4B.3.4

Optional Feedback Module

Variable Resistors (Pots)

Figure 4B.20

Optional Feedback Module Jumper JP1 Jumper Selections

5 6

Internal +15V dc from Main

Power Supply

External +15V dc from external power source

11865-I

All other jumper selections remove the +15V dc power from the pins of connectors CN14F, CN15F, and CN16F on the optional feedback module.

There are three variable resistors (pots) located on the optional feedback module. Use these pots to adjust the +5V dc output to the non-motor mounted feedback devices. Figure 4B.21 shows the optional feedback module pots,corresponding connectors and lists the pots and their corresponding connectors and pin numbers on the optional feedback module.

Figure 4B.21

Optional Feedback Module Pots and Corresponding Connectors

CN21M

CN23M

JP1

CN24M

CN25M

CN22M

VR1

CN14F

VR2

VR3

CN15F

CN16F

11866-I

Pot

VR1

VR2

VR3

Optional feedback Module

Corresponding Connector and Pins

CN14F, Pins 14, 15, and 16

CN15F, Pins 14, 15, and 16

CN16F, Pins 14, 15, and 16

Adjust the pots so that the +5V dc voltage of pins 14, 15, and 16 at the feedback device end of the feedback cable is within the operating voltage range of the non-motor mounted feedback device. The pot adjustment depends on the: length of the cable running from the optional feedback module to the non-motor mounted feedback devices

+5V dc operating voltage range of the non-motor mounted feedback devices

If adjusting the pots does not adjust the +5V dc output so that it falls within the operating voltage range of the non-motor mounted feedback device, an external +5V dc power supply is required or the feedback device cable must be shortened.

4B-22

Section 4B

Connecting the 3-axis Servo Module

CN21M

CN23M

JP1

CN24M

CN25M

Rotary

Switch

CN22M

4B.3.5

Optional Feedback Module

Test Points

Test points are small metallic pins on the optional feedback module.

Hardware troubleshooting and testing for proper wiring can begin by testing for proper voltage or signals at these pins.

Test points are labeled with the letters TP followed by a number.

Figure 4B.22 shows the location of each test point and lists the test data of each test point.

Figure 4B.22

Optional Feedback Module Test Point Locations and Test Point Values

TP9, TP13

TP14

TP3, TP6, TP12

TP15

TP10

TP11

TP2, TP5, TP8

TP1, TP4, TP7

11867-I

Test Point

TP9

TP14

TP15

TP11

TP10

TP13

Test Point

TP5

TP2

TP8

TP4

TP7

TP1

Optional Feedback Module Voltage

+5V dc Power for Feedback Devices

+15V dc Power for Feedback Devices

GND

Servo Module Encoder Feedback Signals

A Channel

B Channel

Z Channel

U Channel

V Channel

W Channel

Test Point

TP12

TP6

TP3

Optional Feedback Device Feedback Signals

A Channel

B Channel

Z Channel

The test points of the optional feedback module can monitor the feedback signals from one feedback port on the servo module and/or one feedback port on the optional feedback module at one time. A rotary switch on the optional feedback module allows the selection of which ports the test points are monitoring. Table 4B.G lists the rotary switch positions and the corresponding ports the test points monitor at each switch position.

4B-23

Section 4B

Connecting the 3-axis Servo Module

Table 4B.G

Optional Feedback Module Rotary Switch Positions

Rotary Switch

Position

Corresponding Ports

No Feedback Signals

Port CN5 on the servo module

Port CN6 on the servo module

Port CN7 on the servo module

Port CN14F on the optional feedback module

Ports CN5 on the servo module and CN14F on the optional feedback module

Ports CN6 on the servo module and CN14F on the optional feedback module

Ports CN7 on the servo module and CN14F on the optional feedback module

Port CN15F on the optional feedback module

Ports CN5 on the servo module and CN15F on the optional feedback module

Ports CN6 on the servo module and CN15F on the optional feedback module

Ports CN7 on the servo module and CN15F on the optional feedback module

Port CN16F on the optional feedback module

Ports CN5 on the servo module and CN16F on the optional feedback module

Ports CN6 on the servo module and CN16F on the optional feedback module

Ports CN7 on the servo module and CN16F on the optional feedback module

4B-24

Section 4B

Connecting the 3-axis Servo Module

4B.4

Wiring a Touch Probe to the

Digital Servo Module

A touch probe can be interfaced with the digital servo module through connector CN9. Refer to Figure 4B.5 for the location of connector CN9 on the digital servo module. Touch probe cable information can be found on page 7A-38.

The time delay between the servo module receiving the touch probe trigger and latching the current axis position is considered negligible. However, you should take into account any external delays that can introduce position “staleness” in the probing operation, especially at high probing speeds.

It is a good idea to establish an offset for the distance between the actual location, as sensed by the touch probe at a very low speed, and the location sensed by the touch probe at the intended probing speed. The offset can then be added or subtracted to any future values obtained through probing.

This helps insure that if there are any external delays in the trigger signal, the position staleness shows up as a constant position offset error and is removed from the measurement (assuming the external delay is repeatable).

The motion controller touch probe interface is intended for use with units that offer 5V dc compatible solid state relay outputs (see Figure 4B.23).

Other configurations can be supported as long as the user operates within the published electrical specifications.

The touch probe circuitry resident on the servo module only responds to the trigger probe edge changes. Polarity transition (high to low or low to high) is programmable through the AMP parameter Probe Transition

Specify the probe transition in AMP as rising edge or falling edge. Once the active edge occurs, position data is captured by the module, and additional occurrences of the trigger signal have no effect until the probe is reenabled under program control.

Refer to the 9/Series CNC 9/230, 9/260 and 9/290 AMP Reference

Manual, publication 8520-6.4, for more information.

The user should make every effort to insure fail-safe operation of the touch probe. Not all vendors of touch probe control units conform to this safety consideration.

4B-25

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.23 shows the internal servo module circuitry that interfaces to the touch probe connector. It is shown here to assist you in determining whether your touch probe hardware is compatible.

Figure 4B.23

Internal Circuitry Supporting the Touch Probe

+5 V dc

Servo Module

1000 ohm

470 ohm

26LS32

CN9M

5V common

11296-I

The following table indicates probing threshold voltages. Maximum Input

(critical if the control has been configured to fire on the rising edge of the probe signal) indicates the voltage that the probe signal must rise above to be considered as fired.

Probe Thresholds

Minimum Input Threshold (probe circuit)

Maximum Input Threshold (probe circuit)

Voltage at Threshold

3.06V dc (min)

2.18V dc (max)

To guard against misfires use the threshold values from the above table to determine the necessary signal voltage for steady state operation (probe not fired). For probes configured to fire on the falling edge the steady state voltage must remain above 3.06 volts. For probes configured to fire on the rising edge the steady state voltage must remain below 2.18 volts.

Wiring a Probe for Rising Edge Configurations

Typical wiring of a simple contactor type touch probe configured to fire on the rising edge of the probe signal, requires the addition of a 1000 ohm pull down resistor. Figure 4B.24 shows a typical wiring diagram compatible with most probe designs configured to trigger on the rising edge of the probes signal.

4B-26

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.24

Typical Wiring of a Touch Probe Configured for Rising Edge Trigger

Servo Module

1000 ohm

470 ohm

+5 V dc

26LS32

5V common

Probe Contact

CN9M

1000 ohm pull down resistor

(customer supplied)

Wiring a Probe for Falling Edge Configuration

Figure 4B.25 shows a typical wiring diagram compatible with most probe designs configured to trigger on the falling edge of the probe signal.

Figure 4B.25

Typical Wiring of a Touch Probe Configured for Falling Edge Trigger

Servo Module

1000 ohm

470 ohm

+5 V dc

26LS32

5V common

CN9M

Probe Contact

4B-27

Section 4B

Connecting the 3-axis Servo Module

Wiring a Probe to Multiple Servo Modules

Systems with more than one servo module should have their touch probe connections tied together in parallel. This allows the position to be latched on all servo modules at the same time with the same input. Only one power connection needs to be made (with pull up or down resistor). The other probe connections should be made in parallel on all servo cards.

Figure 4B.26 shows a typical wiring diagram for multiple servo cards.

+5 V dc

CN9M

470 ohm

26LS32

Servo Module 1

1000 ohm

5V common

Figure 4B.26

Multiple Servo Card Touch Probe Wiring ( Falling Edge Trigger)

Probe Contact

To Additional

Servo Modules

CN9M

Electrically tie Terminal 3 to 3 and Terminal 2 to 2 of all servo modules in the same 9/Series enclosure that use the same touch probe.

+5 V dc

470 ohm

5V common

1000 ohm

26LS32

Servo Module 2

4B.5

Adaptive Depth Probing

The adaptive depth probe feature is not available on the three axis digital servo card.

4B-28

4B.6

How the Analog Servo

Module Works

Section 4B

Connecting the 3-axis Servo Module

There are two typical analog servo drive configurations for the control.

The typical mill configuration has three axes, each having a servo motor and feedback device, and an open loop spindle motor. The typical lathe configuration has two axes, each having a servo motor and feedback device, and an open loop spindle motor with position feedback.

The analog servo module functions as a high speed servo processor. It is installed in the component enclosure.

The analog servo amplifier amplifies the signal from the analog servo module in order to deliver the power necessary to drive the servo motors.

4B-29

Section 4B

Connecting the 3-axis Servo Module

Cabinet or enclosure

9/260 or 9/290

Analog Servo Module

Figure 4B.27 and Figure 4B.28 show typical analog servo drive configurations for a mill and a lathe. For specific details on configuring axes, axis positioning loops, and axis port selection, refer to the 9/Series

CNC 9/230, 9/260, and 9/290 AMP Reference Manual, publication

8520-6.4.

Figure 4B.27

Typical Analog Servo Drive Configuration for a Mill

Feedback device

Spindle drive

Spindle motor

(configured for three axes and one open loop spindle)

Velocity feedback

(Axis 3)

Term Panel

Drive Signal

(Axis 3)

(Axis 2)

Term Panel

Drive Signal

(Axis 2)

Servo

Amplifier

(Axis 2)

(Axis 1)

Term Panel

Drive Signal

(Axis 1)

Servo

Amplifier

(Axis 1)

Velocity

Feedback

Servomotor

(Axis 1)

Velocity

Feedback

Feedback device

Position feedback

Encoder Power

Velocity

Feedback

Servomotor

(Axis 2)

Servomotor

(Axis 3)

Servo

Amplifier

(Axis 3)

11297-I

4B-30

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.28

Typical Analog Servo Drive Configuration for a Lathe

Cabinet or enclosure

9/260 or 9/290

Analog Servo Module

(configured for two axes and one open loop spindle with feedback)

Spindle drive

(Axis 3)

Term Panel

(Axis 2)

Term Panel

Drive Signal

(Axis 2)

Servo

Amplifier

(Axis 2)

(Axis 1)

Term Panel

Drive Signal

(Axis 1)

Servo

Amplifier

(Axis 1)

Spindle motor

Feedback

Devices

Velocity

Feedback

Drive Signal

(Spindle)

Velocity feedback

Position feedback

Encoder Power

Feedback devices

Servomotor

(Axis 1)

Position feedback

Encoder Power

Velocity

Feedback

Servomotor

(Axis 2)

11298-I

For additional information on each of the major components refer to the section that covers that component.

Important: In order to use the solid tapping feature that is available on the

9/260 and 9/290 CNC, you must use the the Allen-Bradley 8510 AC spindle drive system.

4B-31

Section 4B

Connecting the 3-axis Servo Module

4B.6.1

Analog Servo Module

The Analog Servo Module is mounted in the component enclosure. It functions as a high-speed servo processor. The control sends positioning and velocity data to the servo module, which processes the data to generate the necessary analog drive signals. These signals are sent to the analog servo amplifiers, which power the servo motors of the control. Each analog servo module may control up to three closed loop axes and one open loop axis (typically used for a spindle).

Figure 4B.29

Analog Servo Module

LT3

LT2

LT1

\FL

FBF

RUN

RUN\FLTL

FBFLT1

FBFLT2

FBFLT3

CN1

TB1

TB2

11299-I

The servo module receives position data from the axis feedback devices.

It combines this position feedback data with the interpolated commands from the control to generate the command signals that it outputs to the servo amplifiers.

The functions of the analog servo module are designed to make the servomotors run with optimum performance. The maximum feedrates are be limited by the mechanical abilities of the machine. System gain and the maximum allowable following error also limit the feedrates. These limits are entered as AMP parameters. Refer to the 9/Series CNC 9/230, 9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more information.

4B-32

4B.6.2

Analog Servo Module

Connectors and Pin

Assignments

Section 4B

Connecting the 3-axis Servo Module

Table 4B.H lists the connectors that are used to integrate the analog servo module with other modules of the control.

Table 4B.H

Typical Analog Servo Module Connection

Connector On

Servo Module

CN1

J1 (D shell)

J2 (D shell)

J3 (D shell)

BAT/T.P. (TB1)

ANALOG OUT (TB2)

(P2)

(P3)

Connected To

Module Connector

Motherboard

Term. Panel

Touch Probe

----

Not Used

Main Power Supply

(Encoder Power)

P4, P5, or P6

Cable

Number

C12

AXIS

----

C35

C41

----

N/A

C42

N/A

Wire and plug from main power supply

Remark

AXIS

Important:

When 1 servo module is used, it must be connected to P4 of the motherboard. When 2 servo modules are used, the first servo module must be connected to P4 and the second to connector P6.

When three modules are used (9/290 only), connect the first to P4, connect the second to P6, and connect the third to P5.

Analog drives attached to TB2 that incorporate an encoder to supply position feedback to the servo module must be interfaced with one of the regular AXIS ”D shell”connections (J1, J2, or J3).

The ANALOG OUT (TB2) has no feedback capabilities.

J1, J2, and J3 D-Shell AXIS Connectors

The analog servo module sends drive signals to the servo amplifier through connectors labeled J1, J2, and J3. Figure 4B.30 shows an end view of connector J1, J2, and J3 and lists the pin assignments of these connectors.

4B-33

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.30

Connectors J1, J2, and J3 - 26 Pin Female, D-Shell Connector and Pin

Assignments

11300-I

Pin No.

Signal

Not Used

SHLD_CHA

SHLD_CHB

SHLD_CHZ

SHLD_+5V

SHLD_SEN

SHLD_DRV

Not Used

CHA_HI

CHB_HI

CHZ_HI

+5V_ENC

SEN

DRIVE

Not Used

CHA_LO

CHB_LO

CHZ_LO

+15V_ENC

GND

SEN. RET

DRIVE.RET

Description

Feedback device Channel A

Feedback device Channel B

Feedback device Channel Z

+5V Encoder Power Supply

Switched +5V Encoder Power

Supply (not used)

± 10V analog drive command

Feedback device Channel A

Feedback device Channel B

Feedback device Channel Z

+15V Encoder Power Supply

Encoder Power Return

10V analog drive command return

Shield for phase A

Shield for phase B

Shield for phase Z

Shield for +5V

Shield for switched +5V

Shield for drive command

Signal

Destination

Servo Module

Feedback Device

Servo Amplifier

Servo Module

Feedback Device

Servo Amplifier connect at module only connect at module only connect at module only connect at module only connect at module only connect at module only

4B-34

LT1

\FL

LT2

LT3 FBF

FBF

RUN

RUN\FLTL

FBFLT1

FBFLT2

FBFLT3

Section 4B

Connecting the 3-axis Servo Module

ANALOG OUT (TB2) Auxiliary Output Connector.

An auxiliary analog output is provided through the connector labeled

ANALOG OUT (TB2). This connector is typically used to command an analog spindle drive system with no position feedback. TB2 is not capable of receiving encoder feedback information. Figure 4B.31 shows the location of ANALOG OUT connector and lists terminal assignments of this connector.

Important: Note that TB2 should only be used for drive applications that do not require a feedback device. If a feedback is required, the output signal to the drive and its corresponding encoder feedback should be wired through one of the axis connectors J1, J2, or J3. A drive application with feedback would typically not use the connector labeled ANALOG OUT (TB2).

However, if necessary, TB2 may be used with encoder feedback configured in

AMP to be returned to one of the axis connectors J1, J2, or J3.

Figure 4B.31

Terminal Block ANALOG OUT, 3 Plug-type Terminal Block Connections.

Terminal

No.

Signal

Analog Out

Shield

Description

10V Analog with no feedback

Signal Return shield

Signal Destination

(typically spindle drive)

(typically spindle drive) connect at module only

11301-I

4B-35

Section 4B

Connecting the 3-axis Servo Module

LT3

LT2

LT1

\FL

FBF

RUN

RUN\FLTL

FBFLT1

FBFLT2

FBFLT3

11302-I

BAT/TP (TB1) Touch Probe Connector.

The analog servo module receives touch probe feedback through the connector labeled BAT/TP (TB1). Figure 4B.32 shows the location of the

BAT/TP connector and lists the terminal assignments.

Figure 4B.32

Connector BAT/TP, 6 Plug-type Terminal Block Connections.

Terminal

No.

Signal Description Signal Destination

1 Not Used

Not Used

+5V Probe Power

PRB_FIRE Probe Fired Signal 1

Touch Probe

Servo Module

PE Touch Probe Common Touch Probe

6 Shield Probe Shield connect at module only

The True level (voltage transition the probe fires) is either “HIGH”or “LOW”as defined by the AMP parameter PROBE TRANSITION.

8520-6.4, for more information.

Refer to the 9/Series

CNC 9/230, 9/260, and 9/290 AMP Reference Manual, publication

Important: The touch probe connector supports only +5V probing device applications.

P3 5V dc Encoder Power Connector

The analog servo module receives +5V dc power directly from the main power supply through connector P3. This +5V dc power is used only for powering the encoder. If the EXT Power connection on the encoder termination panel is used or if the 15V dc encoder power is used the connection to P3 is not needed. Figure 4B.33 shows an end view of connector P3 and lists the pin assignments. For details on this connection refer to the section on the main power supply connections on page 4D-4.

4B-36

Section 4B

Connecting the 3-axis Servo Module

1 2

4B.6.3

Analog Servo Module

Specifications

11282-I

Figure 4B.33

Connector P3, 2 pin male, Molex 5566-02A

Pin No.

Signal

Not Used

+ 5V dc

Description

Encoder Power

Signal Destination

Main Power Supply

Table 4B.I lists the analog servo module output specifications. This table is provided as an aid to determining the compatibility of different analog servo amplifiers and spindle drives. Table 12.A contains a list of compatible analog servos. Input specifications are discussed in sections covering the individual input devices. Refer to Table 4C.E for encoder feedback input specifications.

Table 4B.I

Analog Servo Module Analog Output Specifications

Item Specification Remark

Output Voltage Range

10V

Analog Output Driver Single Ended Drive return connected to common.

Output Offset Voltage

500 m

V Max.

Resolution 1.22mV

(13 bits) 1

Sampling Frequency 500 Hz

Output Current

Load Range

Conversion Time

5mA Max.

2K ohms to infinity

8.25

m s

Differential

Non-Linearity

Gain Error

Load Capacitance

1 LSB Max.

0.01

F Max.

This resolution is obtained through software. It is equal to a

13-bit numeric value with an additional sign bit (14 bits total).

Monotonic over the entire temperature range. LSB means least significant bit.

4B-37

Section 4B

Connecting the 3-axis Servo Module

4B.6.4

Connecting Axes to Analog

Servo Module

4B.6.5

Analog Servo Module LED

Indicators

Axes are connected to the D-shell connectors marked J1, J2, and J3. Axes must be connected consecutively with no empty connections between axes.

For example, an axis may not be connected to the connector J3 unless both

J1 and J2 are used. If two servo modules are used, all three axes on the first servo module must be connected before an axis may be configured on the second servo module.

If a spindle with feedback is configured the spindle must be connected to the first available D-Shell connector after the last connector used by a linear or rotary axis.

ATTENTION: Do not insert the plug-type ANALOG OUT terminal block (TB2) into an encoder termination panel DRIVE terminal block or vice versa. Although these plugs will fit together, pin assignments are different. Switching these connections without rewiring the plug-type terminal block may cause damage to equipment.

For example to configure a four axis system with a spindle with feedback two servo modules are necessary. The first three axes must be connected to the three D shell connectors on the first servo board. The fourth axis must connect to the second servo board connector labeled J1. The spindle with feedback must then be connected to the D shell labeled J2 on the second servo board. For this specific application the spindle may not be attached to the first servo board or J3 of the second servo board.

The analog servo module is equipped with a set of four LEDs located on the front of the servo module. Table 4B.J lists the meaning of these LEDs.

Table 4B.J

Analog Servo Module LED Indicators

LED Color Description

RUN/FLT Green Indicates the servo processor OK when lit. Watch dog has failed or power fault has occurred when LED is not lit.

FBFLT 1 Red Indicates the servo module is not receiving feedback, or is receiving interrupted or irregular feedback from the feedback device on J1 when lit.

FBFLT 2 Red

FBFLT3 Red

Indicates the servo module is not receiving feedback, or is receiving interrupted or irregular feedback from the feedback device on J2 when lit.

Indicates the servo module is not receiving feedback, or is receiving interrupted or irregular feedback from the feedback device on J3 when lit.

4B-38

Section 4B

Connecting the 3-axis Servo Module

4B.6.6

Analog Servo Module Test

Points

Test points are small metallic pins on the analog servo module circuit board. Hardware troubleshooting and testing for proper wiring can begin by testing for proper voltage or signals at these pins.

Test points are labeled with the letters TP followed by a number.

Figure 4B.34 shows the location of each test point. Table 4B.K lists the test data of each test point.

Figure 4B.34

Analog Servo Module Test Point Locations

CN1

TP6

TP8

TP10

TP11

TP12

TB1

TP5

TP7

TP9

TP13

TP14

TP15

TP16

TP17

TP18

TP19

TP20

TP21

TB2

11304-I

4B-39

Section 4B

Connecting the 3-axis Servo Module

Table 4B.K

Analog Servo Module Test Point Values

Test Point

TP5

TP7

TP9

Analog DAC reference Voltages

+10V dc Reference

Analog Ground

-10V dc Reference

Test Point

TP6

TP8

TP10

TP11

TP12

Module Power Reference Voltages

+5 V dc

Digital Ground

+15V dc

Analog Ground

-15V dc

Test Point

TP13

TP14

TP15

TP16

TP17

TP18

TP19

TP20

TP21

Encoder Feedback Signals

Z Channel connector J1

B Channel connector J1

A Channel connector J1

Z Channel connector J2

B Channel connector J2

A Channel connector J2

Z Channel connector J3

B Channel connector J3

A Channel connector J3

4B-40

Section 4B

Connecting the 3-axis Servo Module

4B.7

Encoder Termination Panel

Termination panels feature:

D-shell connectors for cables from the motion controller (A-B cable number 8520-TPC)

Plug-type connectors for wiring to user devices

DIN Rail Mountable

All user connections with the exception of the ANALOG OUT (TB2) and

BAT/TP (TB1) connections are routed through the termination panels.

User side voltages of +5V dc and +15V dc for encoder power (chosen by wiring to the appropriate connector pin) are available on-board. External power supplies for the encoders may also be routed through the termination panel (refer to the feedback section).

Figure 4B.35 shows an encoder termination panel.

Figure 4B.35

Encoder Termination Panel

DRIVE

AXIS

DRIVE

RET

SHLD

ENCODER

CH A. HI

CH A. LO

AB SHLD

CH B. HI

CH B. LO

Z SHLD

CH Z. HI

CH Z. LO

ENC POWER

+5V

RET

+15V

EX PWR OUT

SHLD

EXT

POWER

EX PWR IN

EX RET IN

FDBK IO

RET

SHLD

91670401

1771HTE ENCODER TERMINATION PANEL

11305-I

4B-41

Section 4B

Connecting the 3-axis Servo Module

4B.8

Compatible

Feedback Devices

This section discusses encoder feedback devices that are compatible for both analog and digital servo systems. The servo module supplies these devices with either +5V or +15V power. Feedback devices on all the

CNCs must return a 5V compatible output signal to the control (1326 motor mounted resolvers have their signals converted by the system module to be compliant with this requirement).

Tachless servo configurations work best if an encoder type feedback device is used and mechanically coupled directly to the servomotor shaft.

spindle feedback

Only the 8520 digital drive system supports absolute feedback.

4B-42

Section 4B

Connecting the 3-axis Servo Module

The 3 axis 9/260 and 9/290 servo cards support:

Feedback Device

Allen-Bradley 845H series differential encoders

Sony Magnascale model GF-45E

Heidenhain Model 704

Futaba Pulscale model FM45NY

Additional hardware

----

Board-type detector model MD10-FR

External interpolation and digitizing model EXE602 D/5-F

PCB interface Module model CZ0180 with cable PCB020EA

Other feedback devices can be compatible if they comply with the specifications listed in Table 4B.L. Refer to the 9/Series CNC AMP

Reference Manual, publication 8520-6.4, for more information.

This manual is written under the assumption that your system is using the

Allen-Bradley 845H series differential encoder. If you are using some other feedback device such as a linear scale, an application note is available through Allen-Bradley CNC Commercial Engineering

Department at area code (216) 646-3963.

The following table lists feedback specifications for a differential encoder however, this information can be interpreted to select an appropriate linear scale.

4B-43

Section 4B

Connecting the 3-axis Servo Module

Item

Maximum Encoder Channel

Frequency (ECF)

Maximum Axis Speed

Input Signal

Current Drawn from Encoder by

Servo Module

Marker Channel

Encoder Cable Length

Table 4B.L

Encoder Specifications

Specification

Use the following equation to determine the maximum channel frequency

Maximum Encoder Channel Frequency =

Where:

Clock

360

90-Eq x 1.15

Clock -- is the Control’s Feedback Clock Frequency:

5 x 10

-- for 9/230, 9/440, and three axis servo cards.

2.3 x 10

-- for 9/260 or 9/290 systems using a four axis servo card

= Quadrature Error in Degrees

1.15 = Our minimum recommended safety factor

As long as the actual feedback channel frequency does not exceed the maximum channel frequency calculated above, the servo module should process the feedback data without a quadrature fault.

9/Series capability of receiving feedback. Refer to the manufactures specs for encoder and motor hardware RPM limitations.

(ECF x 60)

----------------

(E) (N) (P)

= Maximum Axis Speed

Where:

Max Axis Speed = Maximum Axis Speed based on encoder feedback (inches or millimeters per minute)

ECF = Maximum encoder channel frequency the control may receive in units of cycles/sec.

E = the number of encoder lines between markers for your encoder

N = the ratio of encoder turns to ballscrew turns

If the maximum axis speed resulting from this equation is less than you would like, you may need to sacrifice some axis resolution by selecting an encoder with fewer lines between markers.

7mA maximum; 44mA peak

Narrow marker (gated) or Wide marker (ungated) type markers are supported

Refer to 9/Series Integration and Maintenance Manual for details on cabling

4B-44

Section 4B

Connecting the 3-axis Servo Module

4B.8.1

Wiring an Incremental

Feedback Device

Figure 4B.36 shows an incremental feedback device equivalent circuit for feedback channel A.

Figure 4B.36

Incremental Feedback Device Equivalent Circuit

+5V

768

221 W

0.01u f

+5V

768

Analog Servo Module

Cable

8500-TPC

Ch A HI

Ch A LO

Termination Panel

Differential

Line Driver

Customer

Encoder

11306-I

Wiring Position Feedback

If you are using an encoder type feedback device other than the

Allen-Bradley 845H encoder, then use the following wiring procedure:

Obtain the encoder output timing diagram from the vendor’s data sheets. A typical one is provided in Figure 4B.37 as an example.

4B-45

Section 4B

Connecting the 3-axis Servo Module

4B-46

Figure 4B.37

Example of a Typical Vendor Encoder Timing Diagram

N O T E :

Be l o w w ir in g is a n e x a m p le o n ly o f a ty p ic a l v e n d o rs e n c o d e r . S e e y o u r e n c o d e r

Channel A

90°

1 cycle

STEP 3

C h a n n e l A is h ig h a t le a s t p a rt o f m a r k e r in te r v a l. C o n n e c t t o

“C H A . H I” o f te rm in a tio n p a n e l.

Optional

A’

B’

STEP 1

H ig h m a rk e r in te rv a l. C o n n e c t to

“C H Z . H I” o f te rm in a tio n p a n e l.

STEP 2

B is h ig h fo r a t le a s t p a r t o f m a r k e r in te r v a l. C o n n e c t t o

“C H B . H I” o f te r m in a tio n p a n e l.

Z’

CCW rotation viewing shaft

W ire C H B , C H A , a n d C H Z to C H B L O ,

C H A L O a n d C H Z L O , re s p e c tiv e ly , o n th e te rm in a tio n p a n e l.

11307-I

On the timing diagram, look at the marker Z and its complement, marker Z’. Whichever one is low for most of the encoder revolution and pulses high should be wired to “CH Z.HI” of the encoder termination panel. Wire the remaining marker to “CH Z.LO” of the encoder termination panel.

Look at channel B and its complement, channel B’. Whichever one is high for at least part of the marker interval should be wired to

Look at channel A and its complement channel A’and repeat as in step

3 using “CH A.HI” and “CH A.LO” of the encoder termination panel .

ATTENTION: You can find a marker even if your encoder is not phased properly. An improperly phased encoder will still home successfully.

Section 4B

Connecting the 3-axis Servo Module

Optional

Customer Supplied

Power Supply

External Power

Ground

Shield

Important: Since positive and negative axis directions can be assigned without regard to encoder rotation directions, it is possible for the feedback direction to be “backwards”. This is easily corrected before attempting to command axis motion through the AMP parameter Sign of Position

Feedback. Refer to the 9/Series CNC 9/230,9/260, and 9/290 AMP

Reference Manual, publication 8520-6.4, for more information.

Wiring Power for your Feedback Device (Analog Systems Only)

The control supports feedback devices with 5v compatible output signals.

The voltage that these feedback devices require may vary. The analog servo module is equipped to supply 5V dc or 15V dc power to feedback devices. These voltages may be accessed directly from the encoder termination panel . For more information refer to page 7A-8.

Important: Be aware that if the 5V dc encoder power is to be used the connector P3 on the servo module must be directly connected to the power supply. Refer to page 4D-4 for details on this power supply connection.

If your feedback device requires an external power supply, you can incorporate it through the EXT. POWER connector on the termination panel.

Power outputs through the ENC POWER connector terminal labeled

EX PWR OUT. The next figure shows the termination panel connection for

EXT. POWER.

Figure 4B.38

Wiring Optional Customer Supplied Power Supply for Feedback Devices

EXT.

POWER

EXT PWR IN

EXT RET IN

11308-I

4B-47

Section 4B

Connecting the 3-axis Servo Module

4B.9

Wiring a Touch Probe to the

Analog Servo Module

Connect a touch probe to the connector labeled BAT/TP on the servo module (TB1). Connector terminal identification is provided in

Figure 4B.39. Touch probe cable information can be found on page

7A-38.

The time delay between the servo module receiving the touch probe trigger and latching the current axis position is negligible. However, you should be aware of any external delays that may introduce position “staleness” in the probing operation, especially at high probing speeds.

The motion controller touch probe interface is intended for use with units that offer 5V dc compatible solid state relay outputs (see figure 9.12).

Other configurations can be supported as long as the user operates within the published electrical specifications.

The touch probe circuitry resident on the servo module only responds to the trigger probe edge changes. Polarity transition (high to low or low to high) is selectable through the AMP parameter Probe Transition. Specify the probe transition in AMP as rising edge or falling edge. Once the active edge occurs, position data is captured by the module, and additional occurrences of the trigger signal have no effect until the probe is reenabled under program control.

Refer to the 9/Series CNC 9/230,9/260, and 9/290 AMP Reference

Manual, publication 8520-6.4, for more information.

The user should make every effort towards the fail-safe operation of the touch probe. Not all vendor’s touch probe control units conform to this safety consideration.

4B-48

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.39 shows the internal servo module circuitry that interfaces to the touch probe connector. It is shown here to assist you in determining whether your touch probe hardware is compatible.

Figure 4B.39

Internal Circuitry Supporting the Touch Probe

Servo Module

26LS32

1000 ohm

5V common

Shield

GND probe

+5V Power

BAT/TP

TB1

470 ohm

+5 V dc

11309-I

The following table indicates probing threshold voltages. Maximum Input

Probe Thresholds

Minimum Input Threshold (probe circuit)

Maximum Input Threshold (probe circuit)

Voltage at Threshold

3.06 (min)

2.18V dc (max)

To avoid misfires use the threshold values from the above table to determine the necessary signal voltage for steady state operation (probe not fired). For probes configured to fire on the falling edge the steady state voltage must remain above 3.06 volts. For probes configured to fire on the rising edge the steady state voltage must remain below 2.18 volts.

Wiring a Probe for Rising Edge Configurations

Typical wiring of a simple contactor type touch probe configured to fire on the rising edge of the probe signal, requires the addition of a 1000 ohm pull down resistor. Figure 4B.40 shows a typical wiring diagram compatible with most probe designs configured to trigger on the rising edge of the probe’s signal.

4B-49

Section 4B

Connecting the 3-axis Servo Module

Figure 4B.40

Typical Wiring of a Touch Probe Configured for Rising Edge Trigger

Servo Module

26LS32

5V common

1000 ohm

470 ohm

+5 V dc

BAT/TP

TB1

Probe Contact

11309-I

Wiring a Probe for Falling Edge Configuration

Figure 4B.41 shows a typical wiring diagram compatible with most probe designs configured to trigger on the falling edge of the probe signal.

Figure 4B.41

Typical Wiring of a Touch Probe Configured for Falling Edge Trigger

Servo Module

26LS32

5V common

1000 ohm

470 ohm

+5 V dc

BAT/TP

TB1

1000 ohm pull down resistor

(customer supplied)

Probe Contact

Wiring a Probe to Multiple Servo Cards

4B-50

Section 4B

Connecting the 3-axis Servo Module

Figure 4C.22 shows a typical wiring diagram for multiple servo cards.

Servo Module 1

26LS32

5V common

1000 ohm

470 ohm

+5 V dc

BAT/TP

TB1

Figure 4B.42

Multiple Servo Card Touch Probe Wiring ( Falling Edge Trigger)

To All Additional

Servo Modules

Servo Module 2

5V common

Probe Contact

1000 ohm

470 ohm

26LS32

Electrically tie Terminal 5 to 5 and Terminal 4 to 4 of all servo modules in the same 9/Series enclosure that use the same touch probe.

BAT/TP

TB1

+5 V dc

4B.10

Adaptive Depth Probing

Important: Since the adaptive depth probing feature requires one feedback port to pass probe position data to the control and another feedback port for normal axis positioning feedback, the adaptive depth feature is not compatible with the single axis 9/230 processor which only has one feedback port.

The adaptive depth probe is wired like any A quad B rotary encoder. It is connected to one of the controls feedback ports. Table 4C.E lists specifications for an encoder. These same specifications apply to your adaptive depth probe.

If you are using the adaptive depth probe to close the position loop

(selected in AMP) the maximum axis speed calculations from Table 4C.E

also applies. Refer to your AMP reference manual for details on other configuration required to operate using an adaptive depth probe.

4B-51

Section 4B

Connecting the 3-axis Servo Module

END OF SECTION

4B-52

Section

Connecting the 4-axis Servo Module

4C.0

Section Overview

This section covers the integration of the 4-axis analog/1394 and digital servo module components. A section is devoted to each of the following drive components:

For Information:

How the Digital Servo Card Works

Digital Servo Module (8520-ENC4)

How the Analog/1394 Servo Card Works

Analog/1394 Servo Module (8520-ENC4)

Connecting Axes to the Servo Module

Servo Module Connectors and Pin Assignments

8520-ENC4 Servo Module Specifications

8520-SM4 Servo Module Specifications

Servo Module Battery Replacement

Servo Module LED Indicators

Servo Module Test Points

Encoder Termination Panel

Feedback Devices

Wiring a Touch Probe to the Servo Module

See Page:

4C-17

4C-19

4C-20

4C-21

4C-27

4C-1

4C-4

4C-5

4C-8

4C-9

4C-15

4C-16

4C.1

How the Digital Servo Card

Works

There are two typical digital servo drive configurations for the control.

The typical mill configuration has 3-axes, each having a servo motor and feed back device, and a 1-axis analog open loop spindle motor. The typical lathe configuration has 2-axes, each having a servo motor and feedback device, and a 1-axis analog open loop spindle motor with position feedback.

The servo module functions as a high speed servo processor. It is installed in the component enclosure. The digital servo amplifier translates low-level PWM signals from the servo module to the power levels necessary to drive the servo motors.

Current feedback data is read from the current sensors in the digital servo amplifier and returned to the servo module. This data is processed by the servo module to maintain velocity and position control, according to module, AMP, and part program constraints.

4C-1

Section 4C

Connecting the 4-axis Servo Module

Important: In order to use the solid tapping feature that is available on the

9/260 and 9/290 CNC, you must use the Allen-Bradley 8510 AC spindle drive system.

Cabinet or enclosure

9/260 or 9/290

Digital

Servo Module

(configured for three axes and one open loop spindle)

Position and velocity data are read from a feedback device that is mounted on the servo motor. This feedback device generates differential signals that are then fed to the servo module. If the spindle motor uses an encoder, it will supply spindle position feedback to the digital servo module.

Figure 4C.1 and Figure 4C.2 show typical servo drive configurations for a mill and a lathe. Refer to your AMP reference manual for specific details on configuring axes, axis positioning loops, and axis port selection.

Figure 4C.1

Typical Digital Servo Drive Configuration for a Mill

Feedback device

Servomotor

(Axis 1)

Servo drive signal (Axis 1)

Current feedback (Axis 1)

Servo drive signal (Axis 2)

Current feedback (Axis 2)

Servo drive signal (Axis 3)

Current feedback (Axis 3)

Servo

Amplifier

(3 Axis amplifier)

Servomotor

(Axis 2)

Servomotor

(Axis 3)

Feedback device

Analog signal

Spindle drive

Spindle motor

Velocity feedback

Position feedback

11274-I

4C-2

Section 4C

Connecting the 4-axis Servo Module

Figure 4C.2

Typical Digital Servo Drive Configuration for a Lathe

Cabinet or enclosure

9/260 or 9/290

Digital

Servo Module

(configured for two axes and one open loop spindle with position feedback)

Servo drive signal (axis 1)

Current feedback (axis 1)

Servo drive signal (axis 2)

Current feedback (axis 2)

ServoAmplifier

(2 axis amplifier)

Analog signal

Spindle drive

Spindle motor

Servomotor

(Axis 1)

Servomotor

(Axis 2)

Feedback device(s)

Feedback device

Position feedback

Velocity feedback

11275-I

For additional information on each of the major components refer to the section that covers that component.

4C-3

Section 4C

Connecting the 4-axis Servo Module

4C.2

Digital Servo Module

(8520-ENC4)

The servo module is mounted in the component enclosure. It functions as a high-speed servo processor. The control sends positioning and velocity data to the servo module where it is processed to generate the necessary pulse width modulated (PWM) command signals. These signals are sent to the digital servo amplifier, which power the servo motors of the control.

The servo module also provides an analog velocity command signal for a servo (typically the spindle) that is not using a digital servo amplifier.

Figure 4C.3

8520-ENC4 Servo Module

(CN1)

TB2

TB1

The servo module receives two forms of feedback: position data from the feedback devices on the axes current feedback from the servo amplifier

It combines this position and current feedback data with the interpolated commands from the control to generate the PWM command signals that it outputs to the servo amplifiers.

4C-4

Section 4C

Connecting the 4-axis Servo Module

The functions of the servo module are designed to make the axes run with optimum performance. Generally, the maximum feedrates are limited by the mechanical abilities of the machine. System gain and the maximum allowable following error will also limit the feedrates. These limits are entered as AMP parameters. Refer to the 9/Series CNC 9/230, 9/260, and

9/290 AMP Reference Manual, publication 8520-6.4, for more information.

4C.3

How the Analog/1394 Servo

Module Works

There are two typical analog servo drive configurations for the control.

This servo module functions as a high speed servo processor. It is installed in the component enclosure. The servo amplifier amplifies the signal from the servo module in order to deliver the power necessary to drive the servo motors.

4C-5

Section 4C

Connecting the 4-axis Servo Module

Cabinet or enclosure

9/260 or 9/290

Analog Servo Module

Figure 4C.4 and Figure 4C.5 show typical analog servo drive configurations for a mill and a lathe. For specific details on configuring axes, axis positioning loops, and axis port selection, refer to your AMP reference manual.

Figure 4C.4

Typical Analog Servo Drive Configuration for a Mill

Feedback device

Spindle drive Spindle motor

(configured for three axes and one open loop spindle)

Velocity feedback

(Axis 3)

Term Panel

Drive Signal

(Axis 3)

(Axis 2)

Term Panel

Drive Signal

(Axis 2)

Servo

Amplifier

(Axis 2)

(Axis 1)

Term Panel

Drive Signal

(Axis 1)

Servo

Amplifier

(Axis 1)

Velocity

Feedback

Servomotor

(Axis 1)

Velocity

Feedback

Feedback device

Position feedback

Encoder Power

Velocity

Feedback

Servomotor

(Axis 2)

Servomotor

(Axis 3)

Servo

Amplifier

(Axis 3)

11297-I

4C-6

Section 4C

Connecting the 4-axis Servo Module

Figure 4C.5

Typical Analog Servo Drive Configuration for a Lathe

Cabinet or enclosure

9/260 or 9/290

Analog Servo Module

(configured for two axes and one open loop spindle with feedback)

Spindle drive

(Axis 3)

Term Panel

(Axis 2)

Term Panel

Drive Signal

(Axis 2)

Servo

Amplifier

(Axis 2)

(Axis 1)

Term Panel

Drive Signal

(Axis 1)

Servo

Amplifier

(Axis 1)

Spindle motor

Feedback

Devices

Velocity

Feedback

Drive Signal

(Spindle)

Velocity feedback

Position feedback

Encoder Power

Feedback devices

Servomotor

(Axis 1)

Position feedback

Encoder Power

Velocity

Feedback

Servomotor

(Axis 2)

For additional information on each of the major components refer to the section that covers that component.

Important: In order to use the solid tapping feature that is available on the

9/260 and 9/290 CNC, you must use the the Allen-Bradley 8510 AC spindle drive system.

4C-7

Section 4C

Connecting the 4-axis Servo Module

4C.4

Analog/1394 Servo Module

(8520-SM4)

The Analog/1394 Servo Module is mounted in the component enclosure.

It functions as a high-speed servo processor. The control sends positioning and velocity data to the servo module, which processes the data to generate the necessary analog drive signals. These signals are sent to the analog servo amplifiers, which power the servo motors of the control. Each analog servo module may control up to four closed loop axes and one open loop axis (typically used for a spindle).

Figure 4C.6

Analog Servo Module

(CN1)

TB2

TB1

The servo module receives position data from the axis feedback devices.

It combines this position feedback data with the interpolated commands from the control to generate the command signals that it outputs to the servo amplifiers.

4C-8

Section 4C

Connecting the 4-axis Servo Module

4C.5

Connecting Axes to the

Servo Module

Axes are connected to the D-shell connectors marked J1, J2, J3 and J4.

Axes can be connected in any order on the servo module. However, if a spindle with feedback is configured the spindle must be connected to the first available D-Shell connector after the last connector used by a linear or rotary axis.

ATTENTION: With analog systems, do not insert the plug-type ANALOG OUT terminal block (TB2) into an encoder termination panel DRIVE terminal block or vice versa.

Although these plugs will fit together, pin assignments are different. Switching these connections without rewiring the plug-type terminal block may cause damage to equipment.

4C.5.1

Servo Module Connectors and Pin Assignments

Table 4C.A lists the connectors that are used to integrate the digital servo module with other modules of the control.

Table 4C.A

Servo Module Connectors

This Servo

Module Connector

Connects to: 8520 Drive 1394 Drive Analog Drive

Connector Cable No.

Motherboard

Servo Amplifier

P4, P5 or P6

CNA1

C12

C14/15

P4, P5 or P6

CNC1

C12

C47

P4, P5 or P6 see drive’s documentation

C12

C36-C39

Servo Amplifier

CNA2

CNA3

CNA4

C14/15

CNC2

CNC3

CNC4

C47

C47 see drive’s documentation see drive’s documentation see drive’s documentation

C36-C39

TB1

TB2

Spindle

Touch Probe

Battery Pack

C42

C46

C24

C42

C46

C24

+5V Encoder Power Cable from Main Power Supply

C42

C46

C24

Important:

When 1 servo module is used, it must be connected to P4 of the motherboard. When 2 servo modules are used, the first servo module must be connected to

P4 and the second to connector P6. When three modules are used, connect the first to P4, the second to P6 and the third to P5.

If a spindle incorporates an encoder to supply position feedback to the servo module, the spindle encoder must be interfaced with the last open connector of these 3 connectors. Refer to the 9/260-9/290 AMP Reference Manual, publication 8520-6.4, for more information.

4C-9

Section 4C

Connecting the 4-axis Servo Module

Servo Module Interface Connector - P1

The servo module is interfaced with the motherboard through connector

P1. The control transmits and receives various signals to and from the servo module through this connector.

Servo Connectors - J1, J2, J3, and J4

The servo module sends drive signals to the servo amplifier through the connectors labeled J1, J2, J3, and J4. Figure 4C.7, Figure 4C.8, and

Figure 4C.9 show an end views of one of these connectors and lists the pin assignments for the different versions of 4-axis modules.

Figure 4C.7

Pinout for the Servo Connectors on 8520-ENC4

Signal

Shield

Description

Chassis Ground

Connect

Not Used

Signal

EXT_BAT

Description

Battery +/-- for absolute encoder

+5V Encoder Power Supply

Connect

Feedback Device

2 CHU_HI

3 CHV_HI

Channel U Sense_HI

Channel V Sense_HI

Feedback Device

4 CHW_HI Channel W Sense_HI

5 /PWM_A_LO Current Cmd for Phase A_LO Servo Amplifier

6 /PWM_B_LO Current Cmd for Phase B_LO

7 /PWM_C_LO Current Cmd for Phase C_LO

8 STATUS Amplifier Status_HI

+5V_ENC

GND

Shield

9 CHZ_LO

10 CHB_HI

11 CHA_HI

12 I

FDBK Phase B

(lb)

13 ENABLE

14 I

FDBK Phase A

(la)

15 GND

17 +15V_ENC

19 GND

20 +5V_ENC

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Current sensing from feedback Phase _B

Motor Amplifier Enable_HI

Current sensing from feedback Phase _A

Encoder Return

+15V Encoder Power Supply

Encoder Return

+5V Encoder Power Supply

Feedback Device 31

32 CHU_LO

33 CHV_LO

34 CHW_LO

Servo Amplifier

Feedback Device

PWM_A_HI

PWM_B_HI

38 /STATUS

39 CHZ_HI

40 CHB_LO

41 CHA_LO

FDBK Phase B

(/lb)

43 /ENABLE

FDBK Phase A

(/la)

Encoder Return

Chassis Ground

Channel U Sense_LO

Channel V Sense_LO

Channel W Sense_LO

Current Cmd for Phase A_HI

Current Cmd for Phase B_HI

37 PWM_C_HI Current Cmd for Phase C_HI

Amplifier Status_LO

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Current sensing from feedback Phase _B

Motor Amplifier Enable_LO

Current sensing from feedback Phase _A

Feedback Device

Not Used

Feedback Device

Servo Amplifier

Feedback Device

Servo Amplifier

Feedback Device

4C-10

Section 4C

Connecting the 4-axis Servo Module

Figure 4C.8

Pinout for the Servo Connectors on 8520-SM4 for 1394 Systems

Pin Signal

16 GND

19 GND

20 +5V_ENC

24 +5V_ENC

28 GND

29 GND

30 Shield

31 GND

32 CHU_LO

33 CHV_LO

34 CHW_LO

35 V

38 /STATUS

39 CHZ_HI

40 CHB_LO

41 CHA_LO

43 Return

1 Shield

2 CHU_HI

3 CHV_HI

4 CHW_HI

5 V

8 STATUS

9 CHZ_LO

10 CHB_HI

11 CHA_HI

13 ENABLE

15 GND

Description

Chassis Ground

Channel U Sense_HI

Channel V Sense_HI

Channel W Sense_HI

Command Voltage

Amplifier Status_HI

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Motor Amplifier Enable_HI

Signal Common

Ground 24V input return

Signal Common

+5V Encoder Power for optional feedback systems only (P3 must be connected)

CNC Interface Board

Optional Feedback Device

+5V Encoder Power for optional feedback systems only (P3 must be connected)

Optional Feedback Device

Encoder Return

Signal Common

Chassis Ground

Motor Amplifier Enable_LO

Channel U Sense_LO

Channel V Sense_LO

Channel W Sense_LO

Command Voltage

Amplifier Status_LO

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Drive Return

Signal Destination

N/A

Servo Module

CNC Interface Board

Servo Module

CNC Interface Board

CNC Interface Board n/a

CNC Interface Board

Servo Module

CNC Interface Board

Servo Module

4C-11

Section 4C

Connecting the 4-axis Servo Module

Figure 4C.9

Pinout for the Servo Connectors on 8520-SM4 for Analog Systems

Shield

Signal

STATUS

CHZ_LO

Description

Chassis Ground

Command Voltage

Amplifier Status_HI

Feedback device Channel Z

N/A

Signal Destination

Servo Amplifier

Servo Module or

Termination Panel

CHB_HI

CHA_HI

GND

+15V

GND

+5V_ENC

GND

Shield

/STATUS

CHZ_HI

CHB_LO

CHA_LO

Return

Feedback device Channel B

Feedback device Channel A

Encoder Return

+15V Encoder Power Supply

Encoder Return

+5V Encoder Power Supply

Encoder Return

N/A

Amplifier Status Flag_LO

Feedback device Channel Z

Feedback device Channel B

Feedback device Channel A

Drive Return

Feedback Device

N/A

Servo Amplifier

Servo Module

4C-12

Section 4C

Connecting the 4-axis Servo Module

ANALOG OUT (TB2) Auxiliary Output Connector.

An auxiliary analog output is provided through the connector labeled

ANALOG OUT (TB2). This connector is typically used to command an analog spindle drive system with no position feedback. TB2 is not capable of receiving encoder feedback information. Figure 4C.10 shows the location of ANALOG OUT connector and lists terminal assignments of this connector.

Important: Note that TB2 should only be used for drive applications that do not require a feedback device. If a feedback is required, the output signal to the drive and its corresponding encoder feedback should be wired through one of the servo connectors. A drive application with feedback would typically not use the connector labeled ANALOG OUT (TB2).

However, if necessary, TB2 may be used with encoder feedback configured in AMP to be returned to one of the servo connectors.

Figure 4C.10

Terminal Block ANALOG OUT, 4 Plug-type Terminal Block Connections.

Signal Destination Terminal No.

Signal not connected

Analog Out +

Analog Out -

Shield

Description

+10V Analog with no feedback

Signal Return shield

(typically spindle drive)

(typically spindle drive) connect at module only

4C-13

Section 4C

Connecting the 4-axis Servo Module

2 1

11282-I

Touch Probe Connector - TB1

The servo module receives touch probe feedback through the connector labeled TB1. Figure 4C.11 shows the location of this connector and lists its terminal assignments.

Figure 4C.11

TB1 Connector , 4 Plug-type Terminal Block Connections.

Terminal No.

Signal Description Signal Destination

+5V

PRB_FIRE

Shield

Probe Power

Probe Fired Signal

Touch Probe Common

Probe Shield

Touch Probe

Servo Module

Touch Probe connect at module only

The True level (voltage transition the probe fires) is either “HIGH”or “LOW”as defined by the AMP parameter PROBE TRANSITION. Refer to your AMP reference manual for more information.

Important: The touch probe connector supports only +5V probing device applications.

5V DC Encoder Power Connector - P3

The servo module receives +5V dc power directly from the main power supply through connector P3. This +5V dc power is used only for powering the encoder. If the EXT Power connection on the encoder termination panel is used or if the 15V DC encoder power is used the connection to P3 is not needed. Figure 4C.12 shows an end view of connector P3 and lists the pin assignments. For details on this connection refer to the section on the main power supply connections on page 4D-4.

Figure 4C.12

Connector P3, 2 pin male, Molex 5566-02A

Pin No.

Signal

Not Used

+ 5V dc

Description

Encoder Power

Signal Destination

Main Power Supply

4C-14

Section 4C

Connecting the 4-axis Servo Module

4C.5.2

8520-ENC4 Servo Module

Specifications

Table 4C.B lists the servo module input specifications.

Table 4C.B

Servo Module Input Specifications

Item

Desired Voltage Range of

Encoder Battery Backup

Specification

Input Power Range for Encoders +5V (+10%, -1%)

+15V

(±

7%)

Maximum Input Frequency of

Encoder Feedback

2MHz

3.5V to 4.5V

Remark

From Main Power Supply

Maximum Cable Length Specified

______

Table 4C.C lists the servo module output specifications.

Table 4C.C

Servo Module Output Specifications

PWM Output

(8520 digital only)

Comutated Output

(1394 digital only)

DAC Output

Item

PWM Frequency

PWM Signal Type

Comutated Signal

IA and IB

Output Voltage Range

Resolution

Sampling Frequency

Output Current

Load Capacitance

Specification

Approx. 2.0 KHz

RS-422-A

Approx. 1000 Hz

10V

2.44mV

1000 Hz

5mA Max.

0.01

F Max.

Remark

(

12 bits)

(

12 bits)

4C-15

Section 4C

Connecting the 4-axis Servo Module

4C.5.3

8520-SM4 Servo Module

Specifications

Table 4C.D lists the servo module output specifications. This table is provided as an aid to determining the compatibility of different servo amplifiers and spindle drives. Table 12.A contains a list of compatible analog servos. Input specifications are discussed in sections covering the individual input devices. Refer to Table 4C.E for encoder feedback input specifications.

Table 4C.D

8520-SM4 Servo Module Analog Output Specifications

Item Specification

Output Voltage Range

10V

Analog Output Driver Single Ended

Output Offset Voltage

500 m V Max.

Resolution 1.22mV

Sampling Frequency 500 Hz

Output Current 5mA Max.

Load Range

Conversion Time

>2K ohms

5ms

Differential

Non-Linearity

Gain Error

1 LSB Max.

Load Capacitance

0.01

m F Max.

Remark

Drive return connected to common.

13 bits plus one sign bit (14 total)

Monotonic over the entire temperature range.

LSB means least significant bit.

4C-16

Section 4C

Connecting the 4-axis Servo Module

4C.5.4

Digital Servo Module Battery

Replacement

The Digital Servo Module, 8520-ENC4, provides battery backup for the absolute encoder position register. This register retains position data during power loss. The battery backup power originates from the batteries plugged into the servo board at connector P2.

Important: Battery backup is required for absolute encoders only.

Incremental encoders do not require battery backup.

ABSOLUTE FEEDBACK BATTERY” on the operator panel.

Important: Once the “REPLACE ABSOLUTE FEEDBACK BATTERY” message is displayed, it is essential that the batteries be replaced to avoid loss of absolute position data.

The lithium battery contains heavy metals and must be collected separately from other waste.

4C-17

Section 4C

Connecting the 4-axis Servo Module

To replace the servo module battery, turn all system power OFF and disconnect the old batteries from connector P2 on the servo module.

Battery replacement instructions are included with the battery replacement kit. Before installing new batteries, use a voltage meter to make sure that new battery voltage is higher than 3.5V dc.

Figure 4C.13

Servo Module Battery Connector P2

(CN1)

TB2

TB1

4C-18

Section 4C

Connecting the 4-axis Servo Module

4C.5.5

Servo Module LED

Indicators

4C.5.6

Servo Module Test Points

The servo module is equipped with a set of four LEDs located on the front of the servo module. All four LEDs turn on, then off, at power up. All the

LEDs remain off during normal operation. If a servo fault occurs, the light for the corresponding axis flashes. The servo fault may occur if the module is not receiving feedback, or is receiving interrupted or irregular feedback through the J1, J2, J3 or J4 connector.

A test point is a small metallic pin on the servo module’s circuit board.

There is one test point available in the servo module that you can use to ground an oscilloscope during testing or troubleshooting. You can locate this test point, TP6, with Figure 4C.14.

Figure 4C.14

Servo Module Test Point Location

(CN1)

TP6

TB2

TB1

4C-19

Section 4C

Connecting the 4-axis Servo Module

4C.6

Encoder Termination Panel

Termination panels feature:

D-shell connectors for cables from the servo module

(A-B cable number 8520-TPC)

Plug-type connectors for wiring to user devices

DIN Rail Mounting

All user connections with the exception of the analog out and touch probe connections are routed through the termination panels. User side voltages of +5V dc and +15V dc for encoder power (chosen by wiring to the appropriate connector pin) are available on-board. External power supplies for the encoders may also be routed through the termination panel

(refer to the feedback section).

Figure 4C.15 shows an encoder termination panel.

Figure 4C.15

Encoder Termination Panel

DRIVE

AXIS

DRIVE

RET

SHLD

ENCODER

CH A. HI

CH A. LO

AB SHLD

CH B. HI

CH B. LO

Z SHLD

CH Z. HI

CH Z. LO

ENC POWER

+5V

RET

+15V

EX PWR OUT

SHLD

EXT

POWER

EX PWR IN

EX RET IN

FDBK IO

RET

SHLD

91670401

1771HTE ENCODER TERMINATION PANEL

11305-I

4C-20

4C.7

Compatible

Feedback Devices

Section 4C

Connecting the 4-axis Servo Module

CNCs must return a 5V compatible output signal to the control (1326 motor mounted resolvers have their signals converted by the system module to be compliant with this requirement).

Tachless servo configurations work best if an encoder type feedback device is used and mechanically coupled directly to the servomotor shaft.

spindle feedback

Only the 8520 digital drive system supports absolute feedback.

4C-21

Section 4C

Connecting the 4-axis Servo Module

The 4 axis 9/260 and 9/290 servo cards support:

Feedback Device

Allen-Bradley 845H series differential encoders

Sony Magnascale model GF-45E

Heidenhain Model 704

Futaba Pulscale model FM45NY

Additional hardware

----

Board-type detector model MD10-FR

External interpolation and digitizing model EXE602 D/5-F

PCB interface Module model CZ0180 with cable PCB020EA

Other feedback devices can be compatible if they comply with the specifications listed in Table 4B.L. Refer to the 9/Series CNC AMP

Reference Manual, publication 8520-6.4, for more information.

This manual is written under the assumption that your system is using the

Allen-Bradley 845H series differential encoder. If you are using some other feedback device such as a linear scale, an application note is available through Allen-Bradley CNC Commercial Engineering

Department. Contact your local Allen--Bradley sales representative.

The following table lists feedback specifications for a differential encoder however, this information can be interpreted to select an appropriate linear scale.

4C-22

Section 4C

Connecting the 4-axis Servo Module

Item

Maximum Encoder Channel

Frequency (ECF)

Maximum Axis Speed

Input Signal

Current Drawn from Encoder by

Servo Module

Marker Channel

Encoder Cable Length

Table 4C.E

Encoder Specifications

Specification

Use the following equation to determine the maximum channel frequency

Maximum Encoder Channel Frequency =

Where:

Clock

360

90-Eq x 1.15

Clock -- is the Control’s Feedback Clock Frequency:

5 x 10

-- for 9/230, 9/440, and three axis servo cards.

2.3 x 10

-- for 9/260 or 9/290 systems using a four axis servo card

= Quadrature Error in Degrees

1.15 = Our minimum recommended safety factor

As long as the actual feedback channel frequency does not exceed the maximum channel frequency calculated above, the servo module should process the feedback data without a quadrature fault.

9/Series capability of receiving feedback. Refer to the manufactures specs for encoder and motor hardware RPM limitations.

(ECF x 60)

----------------

(4E) (N) (P)

= Maximum Axis Speed

Where:

Max Axis Speed = Maximum Axis Speed based on encoder feedback (inches or millimeters per minute)

ECF = Maximum encoder channel frequency the control may receive in units of cycles/sec.

E = the number of encoder lines between markers for your encoder

N = the ratio of encoder turns to ballscrew turns

If the maximum axis speed resulting from this equation is less than you would like, you may need to sacrifice some axis resolution by selecting an encoder with fewer lines between markers.

7mA maximum; 44mA peak

Narrow marker (gated) or Wide marker (ungated) type markers are supported

Refer to 9/Series Integration and Maintenance Manual for details on cabling

4C-23

Section 4C

Connecting the 4-axis Servo Module

4C.7.1

Wiring an Incremental

Feedback Device

+5V

To Encoder Interface

Optical Isolation

+5V

Figure 4C.16 shows an incremental feedback device equivalent circuit for feedback channel A.

Figure 4C.16

Incremental Feedback Device Equivalent Circuit

68pf

316

215

Zenor

Protection

Cable

8500-TPC

Ch A HI

Ch A LO

Differential

Line Driver

Customer

Encoder

Encoder Return

Servo Module

Termination Panel

Wiring Position Feedback

If you are using an encoder type feedback device other than the

Allen-Bradley 845H encoder, then use the following examples to determine the correct wiring:

4C-24

Section 4C

Connecting the 4-axis Servo Module

Correct Encoder Wiring results in expected motion

Figure 4C.17

Examples of a Correct and Incorrect Encoder Wiring

Incorrect Encoder Wiring results in a servo fault

A +

A--

B+

B--

Z+

Z--

Encoder

A +

A--

B+

B--

Z+

Z--

Encoder Control

Incorrect Encoder Wiring results in unpredictable motion

A +

A--

B+

B--

Z+

Z--

A +

A--

B+

B--

Z+

Z--

Control

A +

A--

B+

B--

Z+

Z--

Encoder

Incorrect Encoder Wiring results in expected motion

A +

A--

B+

B--

Z+

Z--

Encoder

Feedback. Refer to your AMP reference manual for more information.

A +

A--

B+

B--

Z+

Z--

Control

A +

A--

B+

B--

Z+

Z--

Control

4C-25

Section 4C

Connecting the 4-axis Servo Module

Optional

Customer Supplied

Power Supply

External Power

Ground

Shield

Wiring Power for your Feedback Device (Analog Systems Only)

The control supports feedback devices with 5V compatible output signals.

The voltage that these feedback devices require may vary. The servo module is equipped to supply 5V DC or 15V DC power to feedback devices. These voltages may be accessed directly from the encoder termination panel. However, for the 1394 this power connection is only necessary if you are using optional feedback devices. The 1394 drive supplies feedback power to the 1326 motor resolvers.

Important: Be aware that if the 5V DC encoder power is to be used the connector P3 on the servo module must be directly connected to the power supply. Refer to page 4D-4 for details on this power supply connection.

If your feedback device requires an external power supply, you can incorporate it through the EXT. POWER connector on the termination panel.

Power outputs through the ENC POWER connector terminal labeled

EX PWR OUT. The next figure shows the termination panel connection for

EXT. POWER.

Figure 4C.18

Wiring Optional Customer Supplied Power Supply for Feedback Devices

EXT.

POWER

EXT PWR IN

EXT RET IN

11308-I

4C-26

Section 4C

Connecting the 4-axis Servo Module

4C.8

Wiring a Touch Probe to the

Servo Module

Connect a touch probe to the connector labeled BAT/TP on the servo module (TB1). Connector terminal identification is provided in

Figure 4C.18. Touch probe cable information can be found on page 7A-38.

The motion controller touch probe interface is intended for use with units that offer 5V dc compatible solid state relay outputs (see Figure 4C.19).

Other configurations can be supported as long as the user operates within the published electrical specifications.

Refer to the 9/Series CNC 9/230,9/260, and 9/290 AMP Reference

Manual, publication 8520-6.4, for more information.

The user should make every effort towards the fail-safe operation of the touch probe. Not all vendor’s touch probe control units conform to this safety consideration.

4C-27

Section 4C

Connecting the 4-axis Servo Module

Figure 4C.19 shows the internal servo module circuitry that interfaces to the touch probe connector. It is shown here to assist you in determining whether your touch probe hardware is compatible.

Figure 4C.19

Internal Circuitry Supporting the Touch Probe

Servo Module to encoder interface

1000 ohm

5V common

Shield

GND probe

+5V Power

470 ohm

+5 V dc Encoder Power

11309-I

The following table indicates probing threshold voltages. Maximum Input

Probe Thresholds

Minimum Input Threshold (probe circuit)

Maximum Input Threshold (probe circuit)

Voltage at Threshold

3.06 (min)

2.18V dc (max)

4C-28

Section 4C

Connecting the 4-axis Servo Module

To avoid misfires use the threshold values from the above table to determine the necessary signal voltage for steady state operation (probe not fired). For probes configured to fire on the falling edge the steady state voltage must remain above 3.06 volts. For probes configured to fire on the rising edge the steady state voltage must remain below 2.18 volts.

Wiring a Probe for Rising Edge Configurations

Typical wiring of a simple contactor type touch probe configured to fire on the rising edge of the probe signal, requires the addition of a 1000 ohm pull down resistor. Figure 4C.20 shows a typical wiring diagram compatible with most probe designs configured to trigger on the rising edge of the probes signal.

Figure 4C.20

Typical Wiring of a Touch Probe Configured for Rising Edge Trigger

Servo Module to encoder interface

1000 ohm

5V common

470 ohm

+5 V dc

Probe Contact

1000 ohm pull down resistor

(customer supplied)

4C-29

Section 4C

Connecting the 4-axis Servo Module

Wiring a Probe for Falling Edge Configuration

Figure 4C.21 shows a typical wiring diagram compatible with most probe designs configured to trigger on the falling edge of the probe signal.

Figure 4C.21

Typical Wiring of a Touch Probe Configured for Falling Edge Trigger

Servo Module to encoder interface

1000 ohm

5V common

470 ohm

+5 V dc

Probe Contact

11309-I

Wiring a Probe to Multiple Servo Cards

Figure 4C.22 shows a typical wiring diagram for multiple servo cards.

Servo Module 1 to encoder interface

1000 ohm

5V common

Figure 4C.22

Multiple Servo Card Touch Probe Wiring ( Falling Edge Trigger)

To Additional

Servo Modules

Servo Module 2

5V common

Probe Contact to encoder interface

1000 ohm

470 ohm

+5 V dc

Electrically tie Terminal 5 to 5 and Terminal 4 to 4 of all servo modules in the same 9/Series enclosure that use the same touch probe.

470 ohm

+5 V dc

4C-30

Section 4C

Connecting the 4-axis Servo Module

4C.9

Adaptive Depth Probing

The adaptive depth probe is wired like any A quad B rotary encoder. It is connected to one of the controls feedback ports. Refer to page 7A-1 for details on cabling requirements for a feedback device. 4C-23 lists specifications for an encoder. These same specifications apply to your adaptive depth probe.

If you are using the adaptive depth probe to close the position loop

(selected in AMP) the maximum axis speed calculations from 4C-23 also applies. Refer to your AMP reference manual for details on other configuration required to operate using an adaptive depth probe.

END OF SECTION

4C-31

Section 4C

Connecting the 4-axis Servo Module

4C-32

Power Distribution

Section

4D.0

Section Overview

Figure 4D.1 shows the power distribution from the supply to the control and its components.

Figure 4D.1

Power Distribution from the Supply to the Control and its Components

Indicates fiber optic cable

9/260 or

9/290 CNC

Customer supplied

24V dc

115/230V ac 115/230V ac

E-Stop

Digital I/O

E151/E152/E153

Digital I/O

E154

Analog I/O

24V dc

Customer supplied1

Low current

( < 1.0 amp) pilot relay

CN07

1746

I/O ring adapter

HPG

I/O Ring

MTB

I/O

High density

I/O

Cable C04

On button

COM

Main power supply

8A Fuse ac input

115/230V ac

Auxiliary ac

115/230V ac

5V dc 12V dc

Operator panel power supply

Customer supplied

24V dc

12V dc

Off button

OFF

Color monitor

To power circuitry

5V dc connectors to servo modules (encoder power)

(9/260 and 9/290 only)

May not be necessary on PS2 24V is part of the power supply.

May be mounted on operator panel or portable operator panel interface assembly.

Monochrome monitor

11194-I

4D-1

Section 4D

Power Distribution and Wiring Guidelines

4D.1

Connecting the Main Power

Supply

This section discusses the connections of the main power supply and the operator panel power supply.

Connecting the Main Power Supply to AC Power Source

ATTENTION: To guard against electrical shock hazards, never make connections or disconnections at the ac distribution network unless the main ac disconnect switch is open and locked.

Important: In addition to supplying power to the operator panel power supply, the main power supply also supplies power to the motherboard, the CPU board, and the servo module(s) (9/260 and 9/290 only). As shown in Figure 4D.2, the power cables for these modules originate from the side of the main power supply (for 9/260 and 9/290).

Refer to Figure 4D.2 while performing these steps:

Locate AC-IN, L1, L2, and PE on terminal block BT04.

Connect the ac power source cable (C02) from the external ac power source to AC-IN, L1, L2, and PE on BT04.

Connect the chassis ground terminal to the cabinet’s grounding bus bar.

4D-2

Section 4D

Power Distribution and Wiring Guidlines

Figure 4D.2

Main Power Supply Connection (for the 9/260 and the 9/290)

ALLEN-BRADLEY

AC POWER

250V

5V DC Encoder Power --

Use this table to connect to the servo or optional feedback modules on the 9/260 or 9/290

Module in 9/260 or 9/290 Connector

3-axis Digital Servo

3-axis Analog Servo

4-axis Digital Servo

4-axis Analog/1394 Servo

Optional Feedback

CN13

CN25M

To motherboard power supply connector J1

AUX

COM

OFF

BT04

From ac power source

Switched ac power to operator panel power supply

Power-on switch

Power-off switch

4D-3

Section 4D

Power Distribution and Wiring Guidelines

3-Axis Digital Servo Module

Connect to CN13 for 5V dc encoder power

Connecting the Main Power Supply to the Servo Module for

+5V dc Encoders on 9/260 and 9/290 Systems

The servo modules gets power directly from the motherboard. However,

5V dc encoder power, which runs through the servo module, must come directly from the main power supply.

Important: Some applications may not require the use of the servo module’s 5V dc encoder power (i.e., servo modules 15V dc encoder power or an external power supply is used). For these applications, this connection is not necessary.

The main power supply provides 3 wires (with connectors) for 5V dc encoder power supply. These wires are shown in Figure 4D.2.

Connect any of the 5V dc encoder power wires to connector on your servo module that is shown here:

Figure 4D.3

5V dc Encoder Power Connections to Servo Module

3-Axis Analog Servo Module

Connect to P3 for 5V dc encoder power

4-Axis Servo Modules

Connect to P3 for 5V dc encoder power

CN1

CN11

CN12

CN13

CN8

CN2

CN3

CN4

CN5

CN6

CN7

CN9

CN10

CN1

TB1

TB2

(CN1)

TB2

TB1

4D-4

Section 4D

Power Distribution and Wiring Guidlines

4D.2

Main and Operator Panel

Power Supply Input Power

Specifications

Item

Input

The input power specifications of the main power supply, the operator panel power supply, and the portable operator panel interface module power supply are shown in Table 4D.A and Table 4D.B. For output power specifications of the main power supply (PS1) for 9/260 and 9/290, refer to page 4A-10. For output power specifications of the operator panel power supply, refer to page

9A-7.

Table 4D.A

Main Input Power Specifications

Rated Input

Input Range

Power Consumption

8520-PS1

8520-PS2A

Fuse

Connection

Specifications

115V/230V ac -- 50/60Hz

90-265V ac --- 47-63Hz

225 Watts @ 50

130 Watts @ 50 ° C

8A/250V

Terminal Block

Remark

168 Watts @ 60 min. 25 CFM

96.4 Watts @ 60

25 CFM

C or 225 Watts with

° C or 130 Watts with

Protects power supply module and sub-power supply and the color CRT

4D-5

Section 4D

Power Distribution and Wiring Guidelines

Connecting the Main Power Supply to the Monochrome

Operator Panel Power Supply

You connect the operator panel power supply directly to the main power supply. Refer to Figure 4D.2 and Figure 4D.4 when performing these steps:

Use the ac power supply cable (C03) to connect terminals AUX-AC

L1 and L2 of terminal block BT04 on the main power supply to terminals L1 and L2 of terminal block BT02 on the operator panel power supply.

Connect the chassis ground terminal on the operator panel power supply to the cabinet’s grounding bus bar.

Important: The chassis ground terminal connects to the operator panel chassis and designated cable shields. Power supply common is AC coupled to chassis ground. It is the users responsibility to determine if a direct connection to cabinet ground bus is required.

Figure 4D.4

Power Supply Connector on Monochrome Operator Panel

HPG

GND

HPG

GND

HPG

GND

12V

MTB

GND

BT02

A C

5 V

G N D

5 V

G N D

5 V

G N D

1 2 V

G N D

T o H P G

T o M T B p a n e l

I/O m o d u le

19450

4D-6

Section 4D

Power Distribution and Wiring Guidlines

Connecting the Main Power Supply to the Portable

Operator Panel Interface Assembly Power Supply

You connect the Portable Operator Panel Interface Assembly power supply directly to the main power supply. Refer to Figure 4D.2 and Figure 4D.5

when performing these steps:

Use the ac power supply cable (C03) to connect terminals AUX-AC

L1 and L2 of terminal block BT04 on the main power supply to terminals L1 and L2 of terminal block BT02 on the power supply for the portable operator panel interface module.

Connect the chassis ground terminal on the portable operator panel interface assembly power supply to the cabinet’s grounding bus bar.

Figure 4D.5

Power Supply Connector on Portable Operator Panel Interface Assembly

G N D

1 2 V

G N D

5 V

G N D

5 V

G N D

5 V

T o M T B p a n e l

T o H P G

A C

4D-7

Section 4D

Power Distribution and Wiring Guidelines

Connecting Main Power Supply to the Color Operator Panel

You connect the operator panel power supply directly to the main power supply. The operator panel power supply receives power from the color

CRT power supply through an internal jumper from the AC (L1 and L2) terminals.

Figure 4D.6

Color Operator Panel Power Supply Connection

HPG

GND

HPG

GND

HPG

GND

12V

MTB

GND

BT02

A C

5 V

G N D

5 V

G N D

5 V

G N D

1 2 V

G N D

T o H P G

T o M T B p a n e l

I/O m o d u le

19450

Connect terminals AUX-AC L1 and L2 of terminal block BT04 on the main power supply to the color CRT power supply terminals AC L1 and

AC L2, which are located on the rear of the color operator panel, using the power supply cable C03.

Important: The chassis ground terminal connects to the operator panel chassis and designated cable shields. Power supply common is AC coupled to chassis ground. It is the users responsibility to determine if a direct connection to cabinet ground bus is required.

4D-8

Section 4D

Power Distribution and Wiring Guidlines

Connecting the Power Supply to the MTB Panel ON/Off Switch

Terminal block BT04 terminals ON-SW, COM and the OFF-SW are connected to terminal block BT-20 terminals ON, COM and OFF on the

MTB panel using the ON/OFF signal cable C01. Figure 4D.7 shows terminal block BT-20 on the MTB panel.

Figure 4D.7

MTB Panel ON/OFF Switch Connection

To Main Power

Supply (BT04)

To Motherboard/

Processor Board

(TB1)

PWR

COM

PWR

OFF

ESTOP

COM

RESET

BT20

+12V

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

CN52

I/O ring fault indicator

MTB Panel

Table 4D.B

Operator Panel or Portable Operator Panel Interface Assembly

Power Supply Input Power Specifications

Item

Input Rated Input

Input Range

Power Consumption

Fuse

Connection

Specifications

115/230V ac --- 50/60Hz

90-265V ac --- 47-63Hz

55 Watts

2A/250V

Terminal Block

Remark

4D-9

Section 4D

Power Distribution and Wiring Guidelines

4D.3

Protective Grounding

There are two types of grounds used in electrical system design, chassis and earth. Chassis ground is defined as the internal ground of a cabinet.

Earth ground is defined as the central ground for all electrical equipment and ac power within any factory.

from the cabinet -- each cabinet is connected separately to the earth ground.

ATTENTION: To guard against damage to the machine, do not interconnect chassis ground wires between the components.

This would place ground wires in series and cause their noise voltages to be additive. The resulting increased noise energy can interfere with proper control and machine functions.

A general system grounding diagram, which shows both chassis ground and earth ground, is shown in Figure 5A.21.

4D-10

Section 4D

Power Distribution and Wiring Guidlines

Earth GND (typically AWG 8)*

Chassis GND (typically AWG 10)*

Chassis GND (typically AWG 12)*

Signal GND

GND through mounting

Shield

Protective Earth (PE)

(typically AWG 8)*

Refer to local standards and codes for wire sizing.

Machine Tool

Figure 4D.8

System Grounding Diagram for 9/260 and 9/290 control

Encoders

Analog

I/O input output

Digital

I/O (dc)

Servo motor

Spindle motor

Operator Cabinet

Operator Panel

(see below)

Chassis

GRND Stud

MTB Panel

I/O module

Chassis

GRND Stud

Drives Cabinet

Servo

Amplifier

Spindle

Drive

Digital

I/O (ac)

HPG

Component Enclosure

9/260 or 9/290 Servo module

High Density

I/O

Main power supply

Single point

GND

Line Filter/

Transformer

Color Operator Panel

Color

CRT

Keyboard interface

Chassis

GRND Stud

RS-422 or RS-232

Terminal

Monochrome Operator Panel

Monochrome

CRT

Keyboard interface

Chassis

GRND Stud

Portable Operator Panel

Interface Assembly

Operator Panel

Interface Module

Chassis

GRND Stud

Keyboard interface

Operator Panel power supply

END OF SECTION

4D-11

Section 4D

Power Distribution and Wiring Guidelines

4D-12

Publication 8520-6.2.4 -- August 1998

I--2

Index

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.4 -- August 1998

PN176438

9/Series Hardware

TAB 5

9/440 CNC Systems

8520-6.2.5 -- August 1998 PN--176439

5A.0

Section Overview

5A.1

Hardware Overview

9/440 Resolver--based

System Module

Status LED

(system module)

Section

The 9/440 Resolver--based

CNC/Drive System

The 9/440 Resolver--based CNC/Drive system is a unique machining solution that incorporates a CNC with a digital drive as a single cohesive unit. This system improves machine performance as well as decreasing cost, system integration time and cabling. The 9/440 Resolver--based

CNC/Drive supports up to four closed loop axes and two closed loop analog systems (typically spindles).

This system is designed to interface to Allen-Bradley 1326 digital servo motors.

The following figure shows some of the key features of the

9/440 Resolver--based CNC/Drive:

Axis Modules

Status LED

(axis module)

Slider Interconnect with Termination Panel

Motor Power & Ground

Connections

5A-1

Section 5A

9/440 Resolver--based CNC/Drive System

System Module -- This is the largest module in the 9/440

Resolver--based CNC/Drive system (leftmost module). It contains the following circuit boards:

9/440 Resolver--based CNC Assembly Section

- Processor Board -- This board provides the CNC logic as well as connections to the 9/Series Fiber optic I/O ring, serial ports A and B,

E--Stop connection, and video connection.

- Feedback Board -- The 1326 motors’resolver is wired to this board which also provides power for resolver excitation. Additional encoder feedback ports are also available for spindle feedback, optional feedback, or analog axis feedback.

Power Assembly

- Power Supply -- This supplies power to the system module as well as the axis modules. Attach incoming AC three-phase power and 24 V logic power to this supply.

Interconnecting Power and 9/440 Resolver--based CNC Assembly

Section

- Wiring Board -- spindle outputs, touch probe connections, and RIO connection are located on this board which also interfaces the 9/440

Resolver--based CNC assembly with the power portion of the 9/440.

There are three versions of the 9/440 resolver--based system module available. This manual assumes you are using the 4--axis 9/440 resolver--based version. The number of axes supported and the feedback available for these systems is as follows:

5A-2

Section 5A

9/440 Resolver--based CNC/Drive System

1 Axis 9/440

(8520- 1Sx)

3 Axis 9/440

(8520- 3Sx)

4 Axis 9/440

(8520- 4Sx)

1 Axis Module (max)

1 Resolver Feedback Port

2 Analog Output

No Encoder Feedback Ports

3 Axis Modules (max)

2 Analog Outputs

1 Encoder Feedback Port ¶

4 Axis Modules (max)

3 Resolver Feedback Ports ¶ 4 Resolver Feedback Ports ·

2 Analog Outputs

3 Encoder Feedback Ports ·

A total of three feedback devices can be connected. If three resolvers are used, then the encoder port (J11) is not available. If the encoder feedback port (J11) is used, then the third resolver feedback (J3) is disabled.

A total of six feedback devices can be connected. If four resolvers are used, then the last encoder port (J11) is not available. If all three encoder feedback ports are used, the third resolver feedback (J3) is disabled.

9/440 Resolver--based

System Module

9/440 Resolver--based

CNC Assembly

Wiring Board

Press cover release to open

Open cover

PE Stud

E--Stop connections

(TB1)

3rd Encoder Port

(J11)

Power Terminal Block

This chapter only covers the 9/440 Resolver--based CNC assembly and the interconnecting wiring board. The 9/440 Resolver--based CNC assembly consists of a CNC processor board and a CNC feedback board both connected into a mounting bracket. For details on the drive/power portion of the 9/440 resolver--based system module, refer to your 1394 Digital AC

Multi-Axis Motion Control System Users Manual (publication 1394-5.0).

5A-3

Section 5A

9/440 Resolver--based CNC/Drive System

Axis Module - Connect up to four axis modules to the 9/440

Resolver--based CNC/Drive system (depending on your system module selection). Axis modules convert the DC power supplied by the system module to a variable AC voltage (460V AC input provides 460 AC out, derated 380V AC input provides 380V AC out). This voltage will have controlled phase, amplitude and frequency for regulating the speed, torque and direction of the 1326 AC Servomotors. The axis modules are available in a wide range of power ratings with continuous peak capabilities of 200% of continuous rating for short durations.

Make motor connections for power, ground, brake, and thermal sensor to each axis module. Each motor is wired to its own axis module.

1326 motors are described in the 1326 Servomotor Product Data

(publication 1326A-2.9). The 1326 series of motors operate at either

460V AC or 380V AC. Connection of these motors is made directly to the Axis Module.

Each 1326 motor is equipped with a resolver required for motor commutation. This resolver can also be used for positioning feedback, or an external A quad B encoder can be used for positioning. Resolvers are connected to the feedback board found in the system module.

5A-4

Section 5A

9/440 Resolver--based CNC/Drive System

Figure 5A.1

9/440 Resolver- based System Overview

Incoming

120V AC

Power

Control

Module

External

E--Stop

24V

Transformer

Incoming

380/460 VAC

Remote I/O

Port A (RS-232)

9/440 Resolver-based CNC

System Module

Axis

Module

Axis

Module

Axis

Module

Operator Panel or

ROPI assembly

Spindle drive

Touch Probe

1746 I/O

HPG

Encoder

MTB

Panel

MTB I/O

E-Stop Reset to processor

Port B

(RS--232/

RS--422)

High

Density

I/O

Digital

I/O

Analog

I/O

Machine

24Vdc

Machine Machine

115/230V ac

24V dc

115/

230V ac

Resolver

Motor 1

Resolver

Motor 2

Resolver

Motor 3

Optical signal cable

Terminal type connection

5A-5

Section 5A

9/440 Resolver--based CNC/Drive System

5A.2

CNC Processor Board

The CNC processor board contains the main CPU. It provides connection for the 9/Series: fiber optic I/O ring

E--Stop string connection to peripheral devices (two serial ports A and B) video connection

CNC Processor Board

Front of

System Module

Optional

RAM

SIMMS

Flash

SIMMS

Option

Chip

Serial Port A

Serial Port B

R--I/O

LED

I/O Ring

Connectors

Video

Xilinx LED

Watchdog LED

E--Stop

Connector

TB1

5A-6

Section 5A

9/440 Resolver--based CNC/Drive System

E- Stop Plug

Connection of the E--Stop string is shown in the following figure. More details on E--Stop connections to the 9/Series are given on page 6-1.

9/440 Resolver--based System Module

E--Stop

Connector

TB1

E--Stop button

E--Stop reset button

On MTB panel

CR customer supplied fuse (size to protect K1b contact and your E-Stop status relay)

Customer

E--Stop string

E--Stop status relay contact connection

Open Cover

5A-7

Section 5A

9/440 Resolver--based CNC/Drive System

The E--Stop string is a 12V dc string protected by a .25 AMP 115 V fuse located on the 9/440 Resolver--based CNC processor board. You must remove the CNC assembly from the system module to replace this fuse

(see page 15B-58 for details).

CNC Processor Board

Front of

System Module

1/4 AMP fuse (spare)

1/4 AMP E--Stop String Fuse

E--Stop

Connector

TB1

Video Monitor Connector

The video monitor connector is used to interface the video monitor with the control. Figure 5A.1 shows this connector and lists the pin assignments.

Figure 5A.1

Video Monitor Connector-J8 (has pin sockets) and Pin Assignments

Pin No.

Signal Name Pin No.

Signal Name

GND (SHIELD)

RED (H)

GREEN (H)

BLUE (H)

CLOCK (H)

H-SYNC (H)

V-SYNC (H)

RED (L)

GREEN (L)

BLUE (L)

CLOCK (L)

H-SYNC (L)

V-SYNC (L)

11257-I

5A-8

Section 5A

9/440 Resolver--based CNC/Drive System

Port A

RS-232 Port (Port A)

Serial port A is used to transmit data to and from peripheral devices. It is configured for RS-232 communications only. Figure 5A.2 shows this connector and lists the pin assignments of Port A. For more information on the signals of each pin, refer to page 8-2.

Figure 5A.2

Port A-J6 (has pin sockets) and Pin Assignments

Pin

8-15

Assignment

Chassis GND

Send Data

Receive Data

Request to Send

Clear to send

No connection

Signal GND

Not Used

Port B

Serial port B transmits data to and from peripheral devices. Port B can be configured for either RS-232 or RS-422 communications using the softkeys on the operator panel (see your 9/Series Operation and

Programming manual). Figure 5A.3 shows this connector and lists the pin assignments of Port B.

The MTB panel may have the optional serial interface connector mounted on it. This connector provides an external interface port for RS-232 or

RS-422 interface from a peripheral to the control. It communicates with ports A or B with cable C07. Refer to the page 7A-22 for additional information on cable C07. For more information on the signals of each pin, refer to page 8-7.

5A-9

Section 5A

9/440 Resolver--based CNC/Drive System

5A.3

Connecting Feedback

Figure 5A.3

Port B-J7 (has pin sockets) and Pin Assignments

Port B

Pin Assignment Pin Assignment

Chassis GND

Send Data A

9 Send Data B

10 Receive Data B

Receive Data A 11 Request to Send B

Request to Send A 12 Clear to Send B

Clear to Send A

Data Set RDY A

Signal GND

Data Term RDY A

13 Data Set RDY B

14 Data Term RDY B

15 Not Used

The feedback board is used to receive feedback from the resolvers on the

1326 motors and from external encoders. The full 9/440 resolver--based control can support up to six feedback devices (any combination that does not exceed a maximum of four resolvers or a maximum of three encoders).

For example 3 resolvers and 3 encoders or 4 resolvers and 2 encoders.

Feedback Board

Front of

System Module

Wiring Board Connector

Resolver 1

Resolver 2

Resolver 3

Resolver 4

Encoder 1

Encoder 2

J10

Encoder 3

J11

5A-10

Section 5A

9/440 Resolver--based CNC/Drive System

Important: Each feedback port must be configured in AMP to identify which motor the feedback is from as well as the type, direction, and resolution of the feedback. Refer to your 9/Series AMP Reference manual for details.

Video Output

Signal

Fiber Optic

OUT

Serial Port B

Serial Port A

System Module

Bottom View

Front of System Module

Encoder 2

J10

Encoder 1

Resolver 4

Resolver 3

Resolver 2

Resolver 1

Bottom View

Note: Encoder 3 input connector (J11) is accessible only through the front cover.

5A-11

Section 5A

9/440 Resolver--based CNC/Drive System

5A.3.1

Connecting Resolver

Feedback

Maximum Axis Speeds

Axis feedback resolution (for 1326 motor resolvers) is selected in AMP to be either 8192 counts/rev or 32768 counts/rev. The maximum motor RPM when set for 8192 counts/rev is 6000 RPM. The maximum motor RPM when set for 32768 counts/rev is 3000 RPM. Actual final axis speed is based on gearing and lead screw pitch. Exceeding this motor speed can result in feedback overflow on the 9/440 resolver--based feedback board and a feedback or maximum speed error will be generated. The encoder ports do not have this same restriction.

The 1326 motors are equipped with resolvers used to generate velocity feedback and provide motor commutation. These resolvers can also be used as positioning devices for the axis. Resolver feedback is converted into A quad B encoder type feedback on the 9/440 resolver--based feedback board before being transferred to the 9/440 resolver--based processor. Resolution of the resolvers is selectable through ODS as either

32768 counts or 8192 counts per revolution.

Resolver feedback is wired directly from the motor mounted resolver to the

9/440 resolver--based feedback board found in the system module. This cable can be purchased directly from Allen-Bradley (cat. no. 1326-CCUx).

5A-12

Connect Resolver to

9/440 Resolver--based

Feedback Board

(cable 1326-CCUx)

Section 5A

9/440 Resolver--based CNC/Drive System

System Module

Bottom View

Front of System Module

1326 Servo Motor

Resolver 4

J4**

Resolver 3

J3*

Resolver 2

J2*

Resolver 1

* not available on 1--axis 9/440 Resolver-based (cat 8520-1Sx) system

** not available on 1--axis 9/440 Resolver-based (cat 8520-1Sx) and 3--axis 9/440

Resolver--based (cat 8520-3Sx) systems

Important: If you are using the 1--axis 9/440 (cat. no. 8520-1Sx) resolver ports J2, J3, and J4 are not available. If you are using the 3 axis 9/440 (cat.

no. 8520-3Sx) resolver port J4 is not available.

If you are using encoder port (J11) for encoder feedback, refer to page

5A-14 for details.

Figure 5A.4

Pin Configuration for the Resolver Connectors on the 9/440 Resolver- based

CNC/Drive

Pin

1 R1

2 Shield

3 S1

4 S2

5 Shield

6 R2

7 Shield

8 C1

9 C2

10 Shield

Signal Description

Resolver Excitation +

Shield Excitation (R1/R2)

Feedback Sin +

Feedback Cos +

Shield Cos. (C1/C2)

Resolver Excitation --

Shield Sin (S1/S2)

Feedback Sin --

Feedback Cos --

Overall Shield

Signal Destination

Resolver

Feedback Board

Resolver

Feedback Board

5A-13

Section 5A

9/440 Resolver--based CNC/Drive System

5A.3.2

Encoder Feedback

(Optional Feedback)

Bottom View

The encoder ports are intended for systems that use either spindles with position feedback, to provide positioning feedback if you are using optional feedback for one of the 1326 servo motors, or to provide feedback for an analog servo you are controlling from one of the analog output ports. Up to three encoder ports are available.

Important: If you use encoder 3 (connector J11 accessed through the front of the system module), resolver 3 (connector J3) is disabled. You can not use both J3 and J11 at the same time.

Front View

9/440

Resolver--based

System Module

Encoder 2

J10**

Encoder 1

J9**

Press Cover

Release to Open

Open Cover

Feedback Board

Encoder 3*

J11

See page 7A-60 for details on making this cable.

AB 845H

Encoder

* Encoder 3 (J11) is only available if the third resolver port (J3) is not used. J11 is not available on the single axis 9/440.

** These encoder ports are not available on the single axis and three axis 9/440.

16 AWG for encoder power pins 6 and 12 (use four 22 gauge)

Important: If you are using the 1--axis 9/440 resolver--based (cat. no.

8520-1Sx) system, no encoder ports are available. If you are using the

3--axis 9/440 resolver--based (cat. no. 8520-3Sx) system, only one encoder port (J11) is available. Note, if you use J11, you can not use your third resolver port.

5A-14

Section 5A

9/440 Resolver--based CNC/Drive System

Figure 5A.5

Pin Configuration for the Encoder Connectors on the 9/440 Resolver- based

CNC/Drive

Pin Signal

1 CHA_HI

2 Shield

3 CHB_HI

4 N/C

5 CHZ_HI

6 GND

7 CHA_LO

8 Shield

9 CHB_LO

10 N/C

11 CHZ_LO

12 +5V_ENC

Description

Feedback device Channel A

Chassis Ground

Feedback device Channel B

(connect to B_LO on 845H) no connection

Feedback device Channel Z

Encoder Return

Feedback device Channel A

Chassis Ground

Feedback device Channel B

(connect to B_HI on 845H) no connection

Feedback device Channel Z

+5V Encoder Power Supply

Compatible Optional Feedback Devices and Spindle Feedback

This section discusses optional feedback devices that are compatible with the 9/440. The 9/440 resolver--based control supplies these devices with

+5V power. Feedback devices must return a 5V compatible output signal to the control.

This feedback device can be used to provide: auxiliary position feedback -- Digital systems require the motor mounted feedback device, provided on our standard digital servo motors, be used for velocity loop feedback. This motor mounted feedback device can also be used to close the position loop or an additional auxiliary feedback device, as discussed in this section, can be used for the position loop. You can not replace or bypass the motor mounted feedback device. The motor mounted feedback device must be used for velocity feedback and to attain proper motor commutation on digital servo systems.

spindle feedback -- Provide position feedback for your spindle using these encoder ports.

analog servo feedback -- If you are using one of the two analog ports to control an axis these encoder ports can be used for its position feedback.

5A-15

Section 5A

9/440 Resolver--based CNC/Drive System

The 9/440 resolver--based control supports:

Feedback Device

Allen-Bradley 845H series differential encoders

Sony Magnascale model GF-45E

Heidenhain Model 704

Futaba Pulscale model FM45NY

Additional hardware

----

Board-type detector model MD10-FR

External interpolation and digitizing model EXE602 D/5-F

PCB interface Module model CZ0180 with cable PCB020EA

Other feedback devices can be compatible if they comply with the specifications listed in Table 5A.C. Refer to the 9/Series CNC AMP

Reference Manual, publication 8520-6.4, for more information.

This manual is written under the assumption that your system is using the

Allen-Bradley 845H series differential encoder. If you are using some other feedback device such as a linear scale, an application note is available through the Allen-Bradley CNC Commercial Engineering

Department bulletin board at (440) 646-3963. For more information about linear scales, refer to the Home Parameters chapter in your AMP reference manual.

The following table lists feedback specifications for a differential encoder however, this information can be interpreted to select an appropriate linear scale.

5A-16

Section 5A

9/440 Resolver--based CNC/Drive System

Item

Maximum Encoder Channel

Frequency (ECF)

Maximum Axis Speed

Input Signal

Current Drawn from Encoder by

Servo Module

Marker Channel

Encoder Cable Length

Table 5A.C

Encoder Specifications

Specification

Use the following equation to determine the maximum channel frequency

Maximum Encoder Channel Frequency =

Where:

Clock

360

90-Eq x 1.15

Clock -- is the Control’s Feedback Clock Frequency:

5 x 10

-- for 9/230, 9/440, and three axis servo cards.

2.3 x 10

-- for 9/260 or 9/290 systems using a four axis servo card

= Quadrature Error in Degrees

1.15 = Our minimum recommended safety factor

As long as the actual feedback channel frequency does not exceed the maximum channel frequency calculated above, the servo module should process the feedback data without a quadrature fault.

9/Series capability of receiving feedback. Refer to the manufactures specs for encoder and motor hardware RPM limitations.

(ECF x 60)

----------------

(E) (N) (P)

= Maximum Axis Speed

Where:

Max Axis Speed = Maximum Axis Speed based on encoder feedback (inches or millimeters per minute)

ECF = Maximum encoder channel frequency the control may receive in units of cycles/sec.

E = the number of encoder lines between markers for your encoder

N = the ratio of encoder turns to ballscrew turns

If the maximum axis speed resulting from this equation is less than you would like, you may need to sacrifice some axis resolution by selecting an encoder with fewer lines between markers.

7mA maximum; 44mA peak

Narrow marker (gated) or Wide marker (ungated) type markers are supported

Refer to 9/Series Integration and Maintenance Manual for details on cabling

5A-17

Section 5A

9/440 Resolver--based CNC/Drive System

+5V

To Encoder Interface

Optical Isolation

+5V

Wiring an Incremental Feedback Device

Figure 5A.6 shows an incremental feedback device equivalent circuit for feedback channel A.

Figure 5A.6

Incremental Feedback Device Equivalent Circuit

68pf

316 W 215 W

Zenor

Protection

Cable

8500-TPC

Ch A HI

Ch A LO

Differential

Line Driver

Customer

Encoder

Encoder Return

9/440

Termination Panel

Wiring Position Feedback

If you are using an encoder type feedback device other than the

Allen-Bradley 845H encoder, then use the following examples to determine the correct wiring:

5A-18

Section 5A

9/440 Resolver--based CNC/Drive System

Correct Encoder Wiring results in expected motion

Figure 5A.7

Examples of Correct and Incorrect Encoder Wiring

Incorrect Encoder Wiring results in a servo fault

A +

A--

B+

B--

Z+

Z--

Encoder

A +

A--

B+

B--

Z+

Z--

Encoder Control

Incorrect Encoder Wiring results in unpredictable motion

A +

A--

B+

B--

Z+

Z--

A +

A--

B+

B--

Z+

Z--

Control

A +

A--

B+

B--

Z+

Z--

Encoder

Incorrect Encoder Wiring results in expected motion

A +

A--

B+

B--

Z+

Z--

Encoder

Feedback. Refer to your AMP reference manual for more information.

A +

A--

B+

B--

Z+

Z--

Control

A +

A--

B+

B--

Z+

Z--

Control

5A.4

9/440 Resolver- based CNC

Wiring Board

The CNC wiring board provides an easy location to wire additional hardware. It provides connection for: analog outputs (typically for spindles) touch probe remote I/O interface between the CNC assembly and power assembly

The main fuse for the 9/440 Resolver--based CNC assembly is also located on this board.

5A-19

Section 5A

9/440 Resolver--based CNC/Drive System

Battery Backup

Connection

Wiring Board

XILINX

Fuse

[ALL FUSES]

[3A/125V]

J14

Drive Interface

Remote I/O

Plug

WATCHDOG

Spare

Fuse

TB4

Analog Out 1

(spindle 1)

TB5

TB2 TB3

Analog Out 2

(spindle 2)

Touch Probe Connection

5A.4.1

Wiring a Touch Probe to the

9/440

Wiring Board

XILINX

J14

WATCHDOG

TB2 TB3

TB4

TB5

The 9/440 resolver--based system module touch probe connection is made to connector TB5 on the wiring board. Table 5A.A shows the location of this connector and lists its terminal assignments.

Table 5A.A

TB5 Connector , 4 Plug-type Terminal Block Connections

Terminal Description Signal Destination

+5V

TP IN

GND

SHLD

Probe Power

Probe Fired Signal

Touch Probe Common

Probe Shield

Touch Probe

Servo Position Latch

Touch Probe connect at module only

The True level (voltage transition the probe fires) is either “HIGH”or “LOW”as defined by the AMP parameter PROBE TRANSITION. Refer to your AMP reference manual for more information.

Important: The touch probe connector supports only +5V probing device applications.

5A-20

Section 5A

9/440 Resolver--based CNC/Drive System

The time delay between the 9/440 resolver--based control receiving the touch probe trigger and latching the current axis position is negligible.

However, you should be aware of any external delays that may introduce position “staleness” in the probing operation, especially at high probing speeds.

The touch probe interface is intended for use with units that offer 5V dc compatible solid state relay outputs (see Figure 5A.8). Other configurations can be supported as long as the user operates within the published electrical specifications.

The touch probe circuitry resident on the 9/440 resolver--based control only responds to the trigger probe edge changes. Polarity transition (high to low or low to high) is selectable through the AMP parameter Probe

Transition. Specify the probe transition in AMP as rising edge or falling edge. Once the active edge occurs, position data is captured by the module, and additional occurrences of the trigger signal have no effect until the probe is re-enabled under program control.

Refer to the 9/Series CNC AMP Reference Manual, publication 8520-6.4, for more information.

The user should make every effort towards the fail-safe operation of the touch probe. Not all vendor’s touch probe control units conform to this safety consideration.

5A-21

Section 5A

9/440 Resolver--based CNC/Drive System

Figure 5A.8 shows the internal servo module circuitry that interfaces to the touch probe connector. It is shown here to assist you in determining whether your touch probe hardware is compatible.

Figure 5A.8

Internal Circuitry Supporting the Touch Probe

9/440 Resolver--based Control

Wiring Board

5V common to encoder interface

1000 ohm

Shield

GND

TP IN

+5V Power

470 ohm

+5 V dc Encoder Power

11309-I

The following table indicates probing threshold voltages. Maximum Input

Probe Thresholds

Minimum Input Threshold (probe circuit)

Maximum Input Threshold (probe circuit)

Voltage at Threshold

3.06 (min)

2.18V dc (max)

5A-22

Section 5A

9/440 Resolver--based CNC/Drive System

To avoid misfires use the threshold values from the above table to determine the necessary signal voltage for steady state operation (probe not fired). For probes configured to fire on the falling edge the steady state voltage must remain above 3.06 volts. For probes configured to fire on the rising edge the steady state voltage must remain below 2.18 volts.

Wiring a Probe for Rising Edge Configurations

Typical wiring of a simple contactor type touch probe configured to fire on the rising edge of the probe signal, requires the addition of a 1000 ohm pull down resistor. Figure 5A.9 shows a typical wiring diagram compatible with most probe designs configured to trigger on the rising edge of the probes signal.

Figure 5A.9

Typical Wiring of a Touch Probe Configured for Rising Edge Trigger

9/440 Resolver--based Control

Wiring Board

5V common to encoder interface

1000 ohm

470 ohm

+5 V dc

Probe Contact

1000 ohm pull down resistor

(customer supplied)

5A-23

Section 5A

9/440 Resolver--based CNC/Drive System

Wiring a Probe for Falling Edge Configuration

Figure 5A.10 shows a typical wiring diagram compatible with most probe designs configured to trigger on the falling edge of the probe signal.

Figure 5A.10

Typical Wiring of a Touch Probe Configured for Falling Edge Trigger

9/440 Resolver--based Control

Wiring Board

5V common to encoder interface

1000 ohm

470 ohm

+5 V dc

Probe Contact

11309-I

5A-24

5A.4.2

9/440 Resolver- based

Control Remote I/O

Connection

Section 5A

9/440 Resolver--based CNC/Drive System

The remote I/O circuitry and connector are integral parts of the wiring board in the 9/440 resolver--based system module. Figure 5A.11 shows the remote I/O connector mounted on the 9/440 resolver--based control wiring board.

Wire connections for the remote I/O communications are made through the

TB4 NODE ADAPT connector. Connect the wires for remote I/O as shown in the following figure. Refer to your 1771 I/O documentation for details on making remote I/O connections.

Figure 5A.11

Remote I/O Connector in System Module

9/440 Resolver--based System Module

Remote I/O

Plug

TB4

Open Cover

9/440 Resolver- based Control Remote I/O LED

Assuming you have: made all necessary remote I/O communication connections on your

1771 I/O network configured your remote I/O port for the remote I/O network in AMP written PAL to set $RMON true during the first PAL foreground execution, and to handle input and output words ($RMI1 -- $RMI8 inputs to PAL and $RMO1 -- $RMO8 outputs from PAL.)

5A-25

Section 5A

9/440 Resolver--based CNC/Drive System

CNC Processor Board

Front of

System Module

Serial

Port A

R--I/O

LED

Video

You are ready to start receiving and transmitting remote I/O information.

An LED is provided on the 9/440 resolver--based CNC processor board and is visible from the bottom of the system module. As remote I/O responds to commands, you should see this LED pattern:

LED

Green

R- I/O LED

Status Description

ON Active Link to PLC. This is the normal state when the

RIO link is active.

FLASHING The remote I/O link is active but the PLC is currently in program mode.

OFF Remote I/O link is offline. The port is not being used, not configured in AMP correctly, not turned on with

$RMON, or not attached to a 1771 device.

5A.4.3

9/440 Resolver- based

Analog Out

(TB2 and TB3)

Two auxiliary analog outputs are provided through the connectors labeled

TB2 and TB3 of the 9/440 resolver--based wiring board. These connectors are typically used to command external analog spindle drive systems but can also be configured in AMP to control additional analog servo systems.

Figure 5A.12 shows the location of ANALOG OUT connector and lists terminal assignments of this connector.

Important: If positioning feedback is required for the spindle or analog servo system, its corresponding encoder feedback should be wired through one of the encoder feedback connectors and indicated as such in AMP.

Figure 5A.12

Terminal Block TB2 and TB3, Plug-type Terminal Block Connections.

Wiring Board

WATCHDOG

J14

TB2 TB3

XILINX

TB2 TB3

TB4

Analog Out 1

(spindle 1)

Analog Out 2

(spindle 2)

5A-26

Section 5A

9/440 Resolver--based CNC/Drive System

5A.4.4

Battery Backup

Connector

Analog Out

RET

SHLD

Description

± 10V Analog with no feedback

Signal Return shield

Signal Destination

(typically spindle drive)

(typically spindle drive) connect at wiring board only

The memory for part programs, tool offset/compensation data, work coordinate offset data, etc... is stored on the processor board. In the case of a power failure, there is a super capacitor on the processor board that backs up this data for up to 5 days (at 40 ° C) on systems without extended program storage. This super capacitor re-charges within 1 hour of power turn on if completely discharged. If you want to extend this backup time install the lithium battery pack that supports the data for:

9/440 Resolver- based Memory Option:

standard with extended program storage

Time (at 40°C Discharge):

3 years

1 year

Connect the battery pack to P1 on the wiring board.

Wiring Board

This battery pack is connected to the lithium battery connector (P1) on the wiring board as shown in Figure 5A.13. Batteries and the battery cable are included with the battery replacement kit.

Figure 5A.13

Lithium Battery

9/440 Resolver--based

System Module

Mount the battery pack to the inside of the module cover.

Press cover release to open

The lithium battery contains heavy metals and must be collected separately from other waste.

5A-27

Section 5A

9/440 Resolver--based CNC/Drive System

5A.5

Power Terminal Block

Connection

All external power connections to the 9/440 Resolver--based CNC/Drive are wired through the system modules power strip, located behind the front cover in the lower right corner. Input power is wired to this strip in two different voltages:

24 V Logic Power -- this is 24 volt AC or 24 volt DC. The logic power is used to operate the processors in the system module, axis module logic boards, and power the resolvers/encoders.

Drive Power -- this is 324-528 V AC, three phase, 50/60 Hz. The drive power is used to supply the drive portion of the 9/440 resolver--based control the voltages necessary to power the axis modules and the servo motors.

To this Power

Strip Connector

Connect:

+24 V Logic Power

24 V Logic Power common

U, V, W 380/460V AC, three phase power

(not phase sensitive)

System Ground Bar PE

DC+, INT, COL Shunt resistor connection. When the jumper exists between INT and COL the internal 200 W shunt is used. When using the optionally purchased 1000 W shunt the jumper is removed and the new shunt is installed between DC+ and COL.

All connectors on the power strip support a maximum of AWG 12 gauge solid wire.

5A-28

Section 5A

9/440 Resolver--based CNC/Drive System

9/440 Resolver--based

System Module

Wiring Board

Power Terminal Block

DC+

INT

COL

E--Stop

Connections (TB1)

3rd Encoder Port

(J11)

5A.5.1

On/Off Control and

24V Logic Power

24 Volt logic power is supplied to the 9/440 resolver--based control to run the processor board and axis module logic boards. The 24 volts are provided from a customer supplied transformer. Specifications for this supply are:

Transformer Input Voltage 9/440 Resolver- based Input Voltage Range

(Transformer Output)

125/240 V AC

(85-265 V AC @50/60 Hz)

24V ac (19 -- 28V ac, single phase @50/60 Hz) or

Number of Axis Modules

1 2 3 4

On/Off connections are made through the Allen-Bradley On/Off Control assembly (8520-OFC). This assembly allows connection to the standard

MTB panel on/off switch and should be used to supply power to your 24 V transformer.

5A-29

Section 5A

9/440 Resolver--based CNC/Drive System

Figure 5A.14

On/Off Control Assembly

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

AC IN

AUX AC

ON SW

COMMON

OFF SW

Incoming AC Power

85--265 Volts AC

Switched AC Out

85--265 Volts AC 8 amp max

To MTB panel

ON/OFF switch

Logic power should be wired so that if the 24 V is not available to the system module, it will open the drive contactors and disable 3 phase drive power (see Figure 5A.18).

5A-30

Section 5A

9/440 Resolver--based CNC/Drive System

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

AC IN

AUX AC

ON SW

COMMON

OFF SW

ON/OFF

Control Assembly

Figure 5A.15

Connecting On/Off Power Control Assembly and 24V Transformer

9/440 Resolver--based Power Strip

Incoming Power

85--265 V ac

To local cabinet ground bus

BT02

Monochrome or Color operator panel power supply

Low High

DC+

INT

COL

4 amp max draw

COM

OFF

E--Stop

COM

RESET

MTB Panel

Input 85-265 V ac

Customer supplied

24V transformer

Output 24 V ac or

24 V dc non-polarized

Noise suppressor

15 AMP

Customer Supplied

Fuses

ATTENTION: You must make sure logic power (24V) is applied to the system module and the system module is out of

E--Stop before you allow 3 phase power to be enabled.

5A-31

Section 5A

9/440 Resolver--based CNC/Drive System

If 24 V power is required for other devices in your machine system, you can use a 24 V power supply in place of the 24 V transformer as shown in

Figure 5A.16.

Figure 5A.16

Connecting On/Off Power Control Assembly and 24V Power Supply

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

AC IN

AUX AC

ON SW

COMMON

OFF SW

Incoming Power

85--265 V ac

To local cabinet ground bus

BT02

Monochrome or Color operator panel power supply

Low High

ON/OFF

Control Assembly

COM

OFF

E--Stop

COM

RESET

Customer supplied

24V Power Supply

Output 24 V ac or

24 V dc non-polarized

MTB Panel

9/440 Resolver--based Power Strip

DC+

INT

COL

Noise suppressor

199-ISMAxx

On Off Relay

Bulletin 100

A30--Nxx

15 AMP

Customer Supplied

Fuses

5A.5.2

Drive Power 3 Phase

Three--phase power to the 9/440 resolver--based control must be 324-528 V

AC, 50/60 Hz. The drive power is used to supply the drive portion of the

9/440 resolver--based control the voltages necessary to power the axis modules and the servo motors.

All power connectors on the 9/440 Resolver--based power strip accept

AWG 12 gauge solid wire. Refer to local codes for required wire type and gauge.

5A-32

Section 5A

9/440 Resolver--based CNC/Drive System

Grounded vs Ungrounded Three Phase

The 9/440 Resolver--based CNC/Drive comes from the factory set for three phase grounded systems. If your facility uses an ungrounded three phase

360/480 volt system, you must move a jumper in the 9/440 Resolver--based system module. This jumper will connect an internal resistor that helps keep high voltage static, that can be typical of ungrounded three phase systems, from building up in the system module.

Jumper Setting

J27 to J26 (factory setting)

J27 to GND3

Three Phase Power

Grounded system

Ungrounded systems

Figure 5A.17

Three- phase Jumper

Wire Jumper

Open cover

9/440 Resolver--based

System Module

5A-33

Section 5A

9/440 Resolver--based CNC/Drive System

Figure 5A.18

Recommended Connection of 3- phase Drive Power

9/440 Resolver--based Power Strip

Bussman FRS--R--20A (class RK-5)

600 V AC (qty 3)

Three-phase input

360 or 480V AC m3 m2 m1 m

Bulletin 100

Contactor Power

Customer supplied

24V Power Supply

Output 24 V ac or

24 V dc

DC+

INT

COL

U V

PE c1

AC Bulletin 100--A30N x 3 (surge protector required) or

DC Bulletin 100--A30NZ x 3

Noise suppressor

Customer

Supplied

Fuse c

Customer Supplied

E--Stop Control Relay

Noise suppressor

Other Customer Controlled

E--Stop Status Relays

E--Stop

Connector TB1

E--Stop status contact

(30V dc 1.4A)

5A-34

Section 5A

9/440 Resolver--based CNC/Drive System

Power

Supply

ATTENTION: The E--Stop status relay (or your customer--supplied E--Stop control relay) should not be the only method through which axis brakes are directly released (see the illustration below). Brakes should be released by a combination of the PAL logic when it determines that the 9/440 system is in full control of the servo motors and the control’s E--Stop status contact and an external hardware E--Stop contact. Refer to the description of the PAL flags $AXME and $STME for details about testing drive status.

Brake

PAL--controlled

9/440 E--Stop

Status Relay

5A-35

Section 5A

9/440 Resolver--based CNC/Drive System

5A.6

Connecting Axis Modules

The Axis Module provides terminating points for the motor power, thermal sensor and brake. Axis module wiring is identical for all module ratings.

Refer to Figure 5A.19 and the paragraphs that follow for detailed information.

Figure 5A.19

Axis Module Connections

5A-36

PE1

PE2

PE3

TB1 and TB2

(Located on Bottom of Module)

Motor Wiring

Allen-Bradley 1326-CPB1xxx cables must be used for connection to the motor. The motor wiring size is determined by the continuous and overload current requirements (RMS Duty Cycle), NEC and local codes. In general, motors operated with the 1394 should not require wire sizes larger than those accepted by the motor terminal blocks. In addition, the motor leads must be twisted throughout their entire length to minimize radiated electrical noise. The maximum motor wire sizes that the 1394 Axis Module terminal block will accept are dependent upon axis module selection (see your 1394 users manual).

Section 5A

9/440 Resolver--based CNC/Drive System

See page 5A-12 for details on resolver cables (1326-CCUxxx).

1326 servo motors have integral thermal protection. This contact must be connected in the E--Stop string for motor overload protection.

Connections are performed through the front panel terminal block as shown in Figure 5A.19. Refer to the information below and the

Interconnect Drawings on page 5A-41 for further information.

Table 5A.B

Motor Power Terminations

Terminal

PE1

PE2

PE3

Description

Motor Power A

Motor Power B

Motor Power C

Axis Ground

Motor Ground

Overall Shield

Wire/Pin Number

Ground Bar

Thermal and Brake Leads

The motor thermal sensor and brake leads (if used) are connected to the

Axis Module at TB1 & TB2. See Figure 5A.19 for location and

Table 5A.C for terminations.

5A-37

Section 5A

9/440 Resolver--based CNC/Drive System

Table 5A.C

Thermal Sensor and Brake Terminations

Terminal

TB1-1, 2

TB1-3, 4

TB2-1, 2

TB2-3, 4

Description

Thermal Sensor Input from Motor Cable

Brake 24V DC Input from Motor Cable

Wire/Pin Number

string axis modules user brake

Brake 24V DC To Brake Control 5, 9

Thermal Sensor Output to Fault System 4, 6

TB2

Axis module 1

Thermal

String

(connect to E--Stop String)

User Brake

Control

TB1

All Axis modules

Axis Module

6 4 5 9

Motor

(applying 24V DC releases brake)

Brake

Thermostat

TB2

Axis module 2

TB2

Axis module 3

User Brake

Control

User Brake

Control

TB2

Axis module 4

User Brake

Control

ATTENTION: Brake control should not be directly released by the E--Stop status relay (or your customer supplied E--Stop control relay). Brakes should only be released by the PAL logic when it has determined that the 9/440 resolver--based control is in full control of the servo motors and the control is out of

E--Stop. See the description of the PAL flag $PFLT.15 for detail on how to test drive status.

5A-38

Section 5A

9/440 Resolver--based CNC/Drive System

5A.7

9/440 Resolver- based LEDs

9/440 Resolver--based CNC/Drive has 4 LEDs on the system module and one LED on each axis module in the system. The LEDs operate as follows.

System Module LEDs

The system module has 4 LEDs. They are:

LED

XILINX

WATCHDOG

R--I/O

STATUS

Indicates

Under normal operation this LED is on. If it turns off while the system module is under power it indicates a XILINX hardware fault.

Contact your local Allen--Bradley Service.

Under normal operation this LED is on. If it turns off while the system module is under power it indicates the watchdog has timed out and a processor failure has occurred. Contact your local Allen-Bradley Service.

Only available on systems with remote I/O. This

LED illuminates when the remote I/O link is communicating. See page 5A-26.

This is identical to the Watchdog LED but is visible through the system modules front cover.

9/440 Resolver--based

System Module

Wiring Board

XILINX

WATCHDOG

Press Cover

Release to Open

Open Cover

Status LED

R-I/O LED

(visible from under system module in front of serial port B)

5A-39

Section 5A

9/440 Resolver--based CNC/Drive System

5A.8

General Wiring Overview

Check your 9/Series CRT for any drive faults that may have occurred and are displayed as an error.

Axis Module LEDs

The Axis module has a Status LED visible thru the front cover. It is:

LED Indicates

STATUS Steady Green

Flashing Green

Flashing Red/Green ready, bus not up

Flashing Red

Steady Red bus up, axis enabled bus up, axis not enabled fault present hardware malfunction

For more details on how to diagnose and troubleshoot your axis module refer to the 1394 Digital AC

Multi-Axis Motion Control System Users Manual (publication 1394-5.0)

The following figure shows a typical interconnect diagram for a 9/440

Resolver--based CNC to 1326 motors. Note this figure illustrates only one servo motor with optional feedback encoder. The 9/440 Resolver--based

CNC can support up to four servo’s and two spindle drives.

5A-40

Section 5A

9/440 Resolver--based CNC/Drive System

Fiber Optic

I/O Ring

Video Port

Serial Port B

Serial Port A

Figure 5A.20

Wiring Overview For 9/440 Resolver- based CNC

Processor Board

TB1

MTB E--Stop

Connections

External Customer

E--Stop String

E--Stop Status

String

1394 Axis Module

Thermostat and Brake Feedthru

TB1

U1 V1 W1 PE1 PE2 PE3 4 3 2 1

TB2

4 3 2 1

Analog Out 1

Analog Out 2

Remote I/O

TB2

TB3

Wiring Board

RIO1

SHLD

RIO2

TB4

TB5

User Supplied

24V AC or 24V DC

(non-polarized), 15A

Three-phase input

360-480V AC

To Cabinate

Ground Bar

9/440 Resolver- based

System Module

INT

DC+

COL

9/440

Resolver-based

Power

Supply

Feedback Board

Resolver Inputs

J1, J2, J3, or J4

Encoder Inputs

J9, J10, or J11

Touch Probe

1 2 3

T1 T2 T3

Resolver

Servo

Motor

8 7 6 4 5 9

GND B2 B1 K2 K1

Brake

AB 845H

Encoder

Thermostat

1326 Motor

To next axis and User Brake

Control Input

Ground Bar

5A-41

Section 5A

9/440 Resolver--based CNC/Drive System

9/440

Resolver--based CNC

Assembly

PE Stud

System Grounding

Figure 5A.21 illustrates the recommended 9/440 Resolver--based grounding scheme. All grounds terminate on a single point. Note there are two separate ground wires going to the system module. One ground connects to PE of the system module power terminal block, the other connects to the ground stud found just beneath the wiring board on the mounting bracket for the 9/440 Resolver--based CNC assembly.

9/440 Resolver--based

System Module

Power Terminal Block

Open cover

DC+

INT

COL

PE Power Terminal Block Ground

5A-42

Section 5A

9/440 Resolver--based CNC/Drive System

Earth GND (typically AWG 8)*

Chassis GND (typically AWG 10)*

Chassis GND (typically AWG 12)*

Signal GND

GND through mounting

Potential Earth (PE)

(typically AWG 8)*

* Refer to local standards and codes for wire sizing.

Machine Tool

Analog

I/O input output

Digital

I/O (dc)

Figure 5A.21

System Grounding Diagram for 9/440 Resolver- based control

Resolvers

Encoder

Servo motor

Spindle motor

Operator Cabinet

Operator Panel

(see below)

Chassis

GRND Stud

MTB Panel

I/O module

Chassis

GRND Stud

HPG

Component Enclosure

High Density

I/O

Drives Cabinet

Ground Stud on 9/440

Resolver--based

CNC assembly

9/440 Resolver--based CNC/Drive

System

Module

PE on power supply

Axis Modules (PE1)

Spindle

Drive

Digital

I/O (ac)

Single point

GND

Transformer

Color Operator Panel

Color

CRT

Keyboard interface

Chassis

GRND Stud

RS-422 or RS-232

Terminal

Monochrome Operator Panel

Monochrome

CRT

Keyboard interface

Chassis

GRND Stud

Portable Operator Panel Interface Assembly

Operator Panel

Interface Module

Keyboard interface

Operator Panel power supply

Chassis

GRND

Stud

5A-43

Section 5A

9/440 Resolver--based CNC/Drive System

5A-44

5B.0

Section Overview

5B.1

Hardware Overview

9/440HR System Module

Section

The 9/440HR CNC/Drive System

The 9/440HR CNC/Drive system offers you a unique, high--resolution machining solution that incorporates a CNC with a digital drive as a single cohesive unit. This system improves machine performance, system integration time, and cabling. The 9/440HR CNC/Drive system supports up to four closed--loop axes and two closed--loop analog axes (typically spindles).

This 9/440HR system is designed to interface to Allen-Bradley 1326AB digital servo motors with high--resolution feedback. These 1326AB servo motors are equipped with either incremental (2 million counts/rev) or absolute (1 million counts/rev) high--resolution feedback devices.

The following figure shows some of the key features of the

9/440HR CNC/Drive:

Axis Modules

Status LED

(axis module)

Slider Interconnect with Termination Panel

Status LED

(system module)

Motor Power & Ground

Connections

5B-1

Section 5B

9/440HR CNC/Drive System

System Module -- This is the largest module in the 9/440HR CNC/Drive system (left most module). It contains the following circuit boards:

9/440HR CNC Assembly Section

- Processor Board -- This board provides the CNC logic as well as connections to the 9/Series fiber optic I/O ring, serial ports A and B,

E-Stop connection, and video connection.

- Feedback Board -- Each 1326AB motor’s high--resolution feedback device (up to 4 available) is wired to this board, which also provides encoder power. Additional encoder feedback ports are available for spindle feedback, optional feedback, or analog axis feedback.

Power Assembly

- Power Supply -- This supplies power to the system module as well as the axis modules. Attach incoming AC three-phase power and 24 V logic power to this supply.

Interconnecting Power and 9/440HR CNC Assembly Section

- Wiring Board -- spindle outputs, touch probe connections, and the

RIO connection are located on this board, which also interfaces the

9/440HR CNC assembly with the power portion of the 9/440.

The number and type of available feedback ports supported on your

9/440HR system are defined by options installed at the factory. Some ports may not be enabled. To determine what ports are operational on your system, refer to the system configuration label located on the outer left side of your system module. The following table shows catalog numbers and the feedback ports enabled by them.

Stegmann HIPERFACE

(absolute or incremental)

A quad B

(with single or distance--coded marker)

—

8520- A1

8520- A2 8520- A3

J2 J3

— —

8520- A4 8520- 2Q

J4 —

— J9, J10

8520- 4Q

—

J11, J12

5B-2

Section 5B

9/440HR CNC/Drive System

9/440HR System Module

9/440HR CNC Assembly

Wiring Board

Power Assembly

Press cover release to open

Open cover

PE Stud

E-Stop connections

(TB1)

Power Terminal Block

This chapter only covers the 9/440HR CNC assembly and the interconnecting wiring board. The 9/440HR CNC assembly consists of a

CNC processor board and a high--resolution CNC feedback board both connected into a mounting bracket. Refer to the section entitled

Connecting Feedback for details on the high--resolution CNC feedback board and refer to the section entitled 9/440HR CNC Wiring Board for details on the interconnecting wiring board. For details on the drive/power portion of the 9/440HR system module, refer to your 1394 Digital AC

Multi-Axis Motion Control System Users Manual (publication 1394-5.0) and the section entitled Power Terminal Block Connection.

5B-3

Section 5B

9/440HR CNC/Drive System

Axis Module - Connect up to four axis modules to the 9/440HR

CNC/Drive system (depending on your system module selection). Axis modules convert the DC power supplied by the system module to a variable AC voltage (460V AC input provides 460 AC out, derated

380V AC input provides 380V AC out). This voltage will have controlled phase, amplitude, and frequency for regulating the speed, torque, and direction of the 1326AB AC Servomotors. The axis modules are available in a wide range of power ratings with continuous peak capabilities of 200% of continuous rating for short durations.

Make motor connections for power, ground, brake, and thermal sensor to each axis module. Each 1326AB servomotor is wired to its own axis module.

1326AB motors are described in the 1326AB Servomotor Product Data

(publication 1326A-2.9). The 1326AB series of motors operate at either

460V AC or 380V AC. Connection of these motors is made directly to the Axis Module.

Each 1326AB motor can be equipped with incremental or absolute high--resolution feedback devices that use the HIPERFACEÒ electrical interface. An external A quad B feedback device can also be used for positioning feedback. These high--resolution feedback devices are connected to the feedback board found in the system module.

5B-4

Section 5B

9/440HR CNC/Drive System

Figure 5B.1

9/440HR System Overview

Power

Control

Module

External

E--Stop

24V

Transformer

Incoming

380/460 VAC

Incoming

120V AC

Remote I/O

Port A (RS-232)

9/440HR CNC

System Module

Axis

Module

Axis

Module

Axis

Module

Axis

Module

Spindle Drive

Touch Probe

Operator Panel or

ROPI assembly

1746 I/O

HPG

A quad B

E-Stop Reset to processor

Port B

(RS--232/422)

MTB

Panel

MTB I/O

High

Density

I/O

Digital

I/O

Analog

I/O

Machine

24Vdc

Machine Machine

115/230V ac

24V dc

115/

230V ac

HIPERFACE

Sincoder

Motor 4

HIPERFACE

Sincoder

Motor 3

HIPERFACE

Sincoder

Motor 2

HIPERFACE

Sincoder

Motor 1

Optical signal cable

Terminal type connection

5B-5

Section 5B

9/440HR CNC/Drive System

5B.2

CNC Processor Board

The CNC processor board contains the main CPU. It provides connection for the 9/Series: fiber optic I/O ring

E-Stop string connection to peripheral devices (two serial ports: A and B) video connection

CNC Processor Board

Front of

System Module

Optional

RAM

SIMMS

Flash

SIMMS

Option

Chip

Serial Port A

Serial Port B

R--I/O

LED

I/O Ring

Connectors

Video

Xilinx LED

Watchdog LED

E-Stop

Connector

TB1

5B-6

Section 5B

9/440HR CNC/Drive System

E-Stop Plug

Connection of the E-Stop string is shown in the following figure. More details on E-Stop connections to the 9/Series are given on page 6-1.

9/440HR System Module

E-Stop

Connector

TB1

E-Stop button

E-Stop reset button

On MTB panel

CR customer supplied fuse (size to protect K1b contact and your E-Stop status relay)

Customer

E-Stop string

E-Stop status relay contact connection

Open Cover

5B-7

Section 5B

9/440HR CNC/Drive System

The E-Stop string is a 12V dc string protected by a .25 AMP 115 V fuse located on the 9/440HR CNC processor board. You must remove the CNC assembly from the system module to replace this fuse (see page 15B-58 for details).

CNC Processor Board

Front of

System Module

1/4 AMP fuse (spare)

1/4 AMP E-STOP String Fuse

E-Stop

Connector

TB1

Video Monitor Connector

The video monitor connector is used to interface the video monitor with the control. Figure 5B.2 shows this connector and lists the pin assignments.

Figure 5B.2

Video Monitor Connector-J8 (has pin sockets) and Pin Assignments

Pin No.

Signal Name Pin No.

Signal Name

GND (SHIELD)

RED (H)

GREEN (H)

BLUE (H)

CLOCK (H)

H-SYNC (H)

V-SYNC (H)

RED (L)

GREEN (L)

BLUE (L)

CLOCK (L)

H-SYNC (L)

V-SYNC (L)

11257-I

5B-8

Section 5B

9/440HR CNC/Drive System

Port A

RS-232 Port (Port A)

Serial port A is used to transmit data to and from peripheral devices. It is configured for RS-232 communications only. Figure 5B.3 shows this connector and lists the pin assignments of Port A. For more information on the signals of each pin, refer to page 8-2.

Figure 5B.3

Port A-J6 (has pin sockets) and Pin Assignments

Pin

8-15

Assignment

Chassis GND

Send Data

Receive Data

Request to Send

Clear to send

No connection

Signal GND

Not Used

Port B

Programming manual). Figure 5B.4 shows this connector and lists the pin assignments of Port B.

The MTB panel may have the optional serial interface connector mounted on it. This connector provides an external interface port for RS-232 or

5B-9

Section 5B

9/440HR CNC/Drive System

5B.3

Connecting Feedback

Figure 5B.4

Port B-J7 (has pin sockets) and Pin Assignments

Port B

Pin Assignment Pin Assignment

Chassis GND

Send Data A

9 Send Data B

10 Receive Data B

Receive Data A 11 Request to Send B

Request to Send A 12 Clear to Send B

Clear to Send A

Data Set RDY A

Signal GND

Data Term RDY A

13 Data Set RDY B

14 Data Term RDY B

15 Not Used

The high--resolution feedback board is used to receive feedback from the devices on the 1326AB motors and from the external high--resolution feedback devices. The full 9/440HR system can support up to eight feedback devices.

High--resolution

Feedback Board

Front of

System Module

Wiring Board Connector

J12 J11 J10 J9

Optional Feedback Ports

J4 J3 J2 J1

Motor--mounted

Feedback Ports

5B-10

Section 5B

9/440HR CNC/Drive System

Important: Each feedback port must be configured in AMP to identify which axis the feedback is from as well as the type, direction, and resolution of the feedback. Refer to your 9/Series AMP Reference Manual for details.

Video Output

Signal

Fiber Optic

OUT

System Module

Bottom View

Front of System Module

Serial Port B

Serial Port A

J10

J11

J12

Bottom View

Note: The number and type of available feedback ports supported on your 9/440HR system are defined by the options that you purchased through the factory. To determine which options are enabled on your system, refer to the table on page 5B-2.

5B-11

Section 5B

9/440HR CNC/Drive System

Maximum Axis Speeds

Axis feedback resolution (for 1326AB motors with high--resolution feedback devices) for single (SinCoder) and multiturn (SinCos) absolute high--resolution feedback devices is selected in AMP. The axis feedback resolution is 2,097,152 counts/rev or 1,048,576 counts/rev, respectively.

The maximum motor RPM for both devices is based on the maximum speed on the 1326AB motor plate found on the side of your motor’s housing. Actual final axis speed is based on gearing and lead screw pitch.

Motor Plate

5B.3.1

Connecting the 1326AB

Motor- mounted Feedback

Device

The 1326AB motors are equipped with devices used to generate velocity feedback and provide motor commutation. These devices can also be used as positioning devices for the axis. Resolution of the high--resolution feedback devices depends on the motor type (SinCos or SinCoder feedback) your system requires.

The high--resolution feedback device’s feedback is wired directly from the motor--mounted high--resolution feedback device to the 9/440HR Feedback board found in the system module. This cable can be purchased directly from Allen-Bradley (cat. no. 1326-CECU--x).

Connect High--resolution

Feedback Device to

9/440HR Feedback Board

(cable 1326-CECU--x)

System Module

Bottom View

Front of System Module

1326AB Servo Motor

Motor

Feedback Board

J10

J11

J12

5B-12

Section 5B

9/440HR CNC/Drive System

4 3

View of connector on the end of the feedback cable

Important: Not all system modules have each of the eight feedback ports enabled. The number and type of available feedback ports supported on your 9/440HR system are defined by the options you purchased through the factory. To determine which of the eight feedback ports are enabled on your system, refer to page 5B-2.

Important: The 9/440HR feedback device is capable of achieving a maximum of 2,097,152 cnts/mm (53,267,660.8 cnts/in.). Exceeding this number of feedback counts forces your system into E--Stop, causing an error message to display.

Figure 5B.5

Connecting the 1326 HIPERFACE Motor- mounted Devices on the 9/440HR

CNC/Drive

Pin Signal Description Wire Color

1 Overall Shield

2 Supply GND

3 Supply Power

4 Wire Pair Shield

5 RS485_LO

6 RS485_HI

7 Wire Pair Shield

Encoder Supply Ground

Encoder Supply Power

Serial Data Low

Serial Data High

Green/Yellow

White

Black

Clear

Green

Black

Clear

8 CHB_LO

9 CHB_HI

Feedback Device Channel B Low Black

Feedback Device Channel B High Blue

10 Wire Pair Shield

11 CHA_LO

Feedback Device Channel A Low

Clear

Black

12 CHA_HI Feedback Device Channel A High Red

HIPERFACE devices (J1--J4) use 9.7V. A quad B devices (J9--J12) use 5Vdc.

ATTENTION: You cannot mount an auxiliary feedback device to the rear of a 1326AB motor. By removing the back cover of the motor, you will void the motor warranty and possibly permanently disable it.

ATTENTION: Only auxiliary feedback devices are replaceable. HIPERFACE devices are permanently mounted by the factory and should not be removed. By removing it, you will void the warranty and possibly permanently disable it.

5B-13

Section 5B

9/440HR CNC/Drive System

CHA_LO

CHB_LO

2.5V (typ)

(2.2 -- 2.8)

CHB_HI

Figure 5B.6

Signal Specification of HIPERFACE Devices

CHA_HI

0.5V

typ

90_min.

*RS--485 reference pulse

0.5V

typ

630_max.

The reference pulse signal is output once per revolution on the RS485 interface, after power up initialization.

During the power up initialization, the RS485 channel is used to determine: rotational position for incremental HIPERFACE devices absolute position and rotational position for absolute HIPERFACE devices

5B-14

Section 5B

9/440HR CNC/Drive System

5B.3.2

Connecting A Quad B

Optional Feedback Ports

Front of System Module

High--resolution feedback device ports J9 through J12 are intended for systems that use either spindles with position feedback, to provide positioning feedback if you are using optional feedback for one of the

1326AB servo motors, or to provide feedback for an analog servo you are controlling from one of the analog output ports. Up to four optional

A quad B ports are available.

9/440HR System

Module

Bottom View

(C56)

See page 7A-63 for details on making this cable.

AB 845H

Encoder

All 22 AWG wire

(C56)

J10

J11

J12

Shield

CHA_HI

CHA_LO

CHB_HI

CHB_LO

CHZ_HI

CHZ_LO

+5V_PWR

GND

+SENSE

--SENSE

All 22 AWG wire

Heidenhein

Distance--coded

Marker Scale

5B-15

Section 5B

9/440HR CNC/Drive System

Figure 5B.7

Pin Configuration for the Encoder Connectors on the 9/440HR CNC/Drive

Center

Tab

14 13

View of connectors on 9/440 board.

Pin Signal

1 Shield

2 GND

3 +5V PWR

4 Shield

5 CHZ_LO

6 CHZ_HI

7 Shield

8 CHB_LO

9 CHB_HI

10 Shield

11 CHA_LO

12 CHA_HI

13 N/C

14 N/C

15 +SENSE

16 --SENSE

Description

Encoder Supply Ground

+5V Encoder Power Supply

No connection

Feedback device Channel Z

No connection

Feedback device Channel B

No connection

Feedback device Channel A

No connection

Encoder Sense Power

Encoder Sense Ground

Important: For proper operation, you must connect pins 15 and 16 to the supply loading device.

Compatible Optional Feedback Devices and Spindle Feedback

This section discusses optional feedback devices that are compatible with the 9/440. The 9/440HR supplies these devices with +5V power.

Feedback devices must return a 5V--compatible output signal to the control.

This feedback device can be used to provide: auxiliary position feedback -- Digital systems require the motor--mounted feedback device, provided on our standard digital servo motors, be used for velocity--loop feedback. This motor--mounted feedback device can also be used to close the position loop or an additional auxiliary feedback device, as discussed in this section, can be used for the position loop. You can not replace or bypass the motor--mounted feedback device. The motor--mounted feedback device must be used for velocity feedback and to attain proper motor commutation on digital servo systems.

spindle feedback -- Provide position feedback for your spindle using these high--resolution feedback device ports.

5B-16

Section 5B

9/440HR CNC/Drive System

Item

Maximum Encoder Channel

Frequency (ECF) analog servo feedback -- If you are using one of the two analog ports to control an axis these high--resolution feedback device ports can be used for its position feedback.

The 9/440HR supports:

Feedback Device Additional hardware

Allen-Bradley 845H Series Differential Encoders ----

Sony Magnascale Model GF-45E Board-type detector model MD10-FR

Heidenhain Model 704 External interpolation and digitizing model EXE602 D/5-F

Futaba Pulscale Model FM45NY

Heidenhain Distance--coded Marker

PCB interface Module model CZ0180 with cable PCB020EA

LS176

Refer to your vendor’s catalog for a complete listing of additional hardware you may need to support distance--coded markers.

Other feedback devices can be compatible if they comply with the specifications listed in Table 5B.A. Refer to the 9/Series CNC AMP

Reference Manual, publication 8520-6.4, for more information.

The following table lists feedback specifications for a differential encoder however, this information can be interpreted to select an appropriate linear scale.

Table 5B.A

Encoder Specifications

Specification

Use the following equation to determine the maximum channel frequency

Maximum Encoder Channel Frequency =

Where:

Clock

360

90-Eq x 1.15

Clock -- is the Control’s Feedback Clock Frequency:

5 x 10

-- for 9/230, 9/440, and three--axis servo cards.

2.3 x 10

-- for 9/260 or 9/290 systems using a four--axis servo card

= Quadrature Error in Degrees

1.15 = Our minimum recommended safety factor

As long as the actual feedback channel frequency does not exceed the maximum channel frequency calculated above, the servo module should process the feedback data without a quadrature fault.

5B-17

Section 5B

9/440HR CNC/Drive System

Maximum Axis Speed Use the following equation to determine the maximum axis speed. Note that this equation does not take into consideration any mechanical deficiencies in the encoder or motor. It is only concerned with the

9/Series capability of receiving feedback. Refer to the manufactures specs for encoder and motor hardware RPM limitations.

(ECF x 60)

----------------

(E) (N) (P)

= Maximum Axis Speed

Where:

Max Axis Speed = Maximum Axis Speed based on encoder feedback (inches or millimeters per minute)

ECF = Maximum encoder channel frequency the control may receive in units of cycles/sec.

E = the number of encoder lines between markers for your encoder

E = 1024 sin/cos cycles per revolution for HR Single--turn Absolute (SinCoder)

E = 512 sin/cos cycles per revolution for HR Multiturn Absolute (SinCos)

N = the ratio of encoder turns to ballscrew turns

If the maximum axis speed resulting from this equation is less than you would like, you may need to sacrifice some axis resolution by selecting an encoder with fewer lines between markers.

Input Signal Encoder feedback must be differential format with 5V--compatible (9.7V for HIPERFACE feedback devices) output signals, single-ended open-collector outputs are not supported, i.e., channels A, B, and Z must have source and sink current capability, 8830 line driver outputs or equivalent.

20 mA maximum; 50 mA peak/differential output

Current Drawn from Encoder by

Servo Module

Marker Channel Narrow (gated), Wide (ungated), and Distance--coded type markers are supported.

Encoder Cable Length Refer to chapter 7 for details on cabling.

Applies to A quad B feedback ports (J9 -- J12) only. Current drawn is rated for each channel (A and B) output.

5B-18

Section 5B

9/440HR CNC/Drive System

+5V

To Encoder Interface

Optical Isolation

+5V

Wiring an Incremental Feedback Device

Figure 5B.8 shows an incremental feedback device equivalent circuit for feedback channel A.

Figure 5B.8

Incremental Feedback Device Equivalent Circuit for

A Quad B High- resolution Feedback Devics (J9 - J12)

68pf

0 W

178 W

Zenor

Protection

Cable

8500-TPC

CHA_HI

CHA_LO

Differential

Line Driver

Customer

Encoder

Encoder Return

Termination Panel

9/440

Wiring Position Feedback

Feedback devices used with the control must be configurable such that the marker Z is true at the same time that channels A and B are true. If you are using an Allen-Bradley 845H encoder this requirement will already be met if you wire them as shown in the cable diagrams on page 7A-63.

If you are using an encoder type feedback device other than the

Allen-Bradley 845H encoder, then use the following examples to determine the correct wiring:

5B-19

Section 5B

9/440HR CNC/Drive System

Correct Encoder Wiring results in expected motion

Figure 5B.9

Examples of Correct and Incorrect Encoder Wiring

Incorrect Encoder Wiring results in a servo fault

A +

A--

B+

B--

Z+

Z--

Encoder

A +

A--

B+

B--

Z+

Z--

Encoder Control

Incorrect Encoder Wiring results in unpredictable motion

A +

A--

B+

B--

Z+

Z--

A +

A--

B+

B--

Z+

Z--

Control

A +

A--

B+

B--

Z+

Z--

Encoder

Incorrect Encoder Wiring results in expected motion

A +

A--

B+

B--

Z+

Z--

Encoder

Feedback. Refer to your AMP reference manual for more information.

A +

A--

B+

B--

Z+

Z--

Control

A +

A--

B+

B--

Z+

Z--

Control

5B.4

9/440HR CNC Wiring Board

The main fuse for the 9/440HR CNC assembly is also located on this board.

5B-20

Section 5B

9/440HR CNC/Drive System

Battery Backup

Connection

Wiring Board

XILINX

Fuse

[ALL FUSES]

[3A/125V]

J14

Drive Interface

Remote I/O

Plug

WATCHDOG

Spare

Fuse

TB4

Analog Out 1

(spindle 1)

TB5

TB2 TB3

Analog Out 2

(spindle 2)

Touch Probe Connection

5B.4.1

Wiring a Touch Probe to the

9/440

Wiring Board

XILINX

J14

WATCHDOG

TB2 TB3

TB4

TB5

The 9/440HR system module touch probe connection is made to connector

TB5 on the wiring board. Table 5B.A shows the location of this connector and lists its terminal assignments.

Table 5B.A

TB5 Connector , 4 Plug-type Terminal Block Connections

Terminal Description Signal Destination

+5V

TP IN

GND

SHLD

Probe Power

Probe Fired Signal

Touch Probe Common

Probe Shield

Touch Probe

Servo Position Latch

Touch Probe connect at module only

The True level (voltage transition the probe fires) is either “HIGH”or “LOW”as defined by the AMP parameter PROBE TRANSITION. Refer to your AMP reference manual for more information.

Important: The touch probe connector supports only +5V probing device applications.

5B-21

Section 5B

9/440HR CNC/Drive System

The time delay between the 9/440HR receiving the touch probe trigger and latching the current axis position is negligible. However, you should be aware of any external delays that may introduce position “staleness” in the probing operation, especially at high probing speeds.

The touch probe interface is intended for use with units that offer 5V dc compatible solid state relay outputs (see Figure 5B.10). Other configurations can be supported as long as the user operates within the published electrical specifications.

The touch probe circuitry resident on the 9/440HR only responds to the trigger probe edge changes. Polarity transition (high to low or low to high) is selectable through the AMP parameter Probe Transition. Specify the probe transition in AMP as rising edge or falling edge. Once the active edge occurs, position data is captured by the module, and additional occurrences of the trigger signal have no effect until the probe is re-enabled under program control.

Refer to the 9/Series CNC AMP Reference Manual, publication 8520-6.4, for more information.

ATTENTION: From a safety standpoint, it is preferred that the touch probe relay be closed at rest and open when the touch probe stylus deflects. Then, if a wire breaks or shorts to ground, it will appear to the system as a probe fired and the probing cycle in process will stop commanding motion towards the part.

The user should make every effort towards the fail-safe operation of the touch probe. Not all vendor’s touch probe control units conform to this safety consideration.

5B-22

Section 5B

9/440HR CNC/Drive System

Figure 5B.10 shows the internal servo module circuitry that interfaces to the touch probe connector. It is shown here to assist you in determining whether your touch probe hardware is compatible.

Figure 5B.10

Internal Circuitry Supporting the Touch Probe

9/440HR Wiring Board

5V common to encoder interface

1000 ohm

Shield

GND

TP IN

+5V Power

470 ohm

+5 V dc Encoder Power

11309-I

The following table indicates probing threshold voltages. Maximum Input

Probe Thresholds

Minimum Input Threshold (probe circuit)

Maximum Input Threshold (probe circuit)

Voltage at Threshold

3.06 (min)

2.18V dc (max)

5B-23

Section 5B

9/440HR CNC/Drive System

To avoid misfires use the threshold values from the above table to determine the necessary signal voltage for steady state operation (probe not fired). For probes configured to fire on the falling edge the steady state voltage must remain above 3.06 volts. For probes configured to fire on the rising edge the steady state voltage must remain below 2.18 volts.

Wiring a Probe for Rising Edge Configurations

Typical wiring of a simple contactor type touch probe configured to fire on the rising edge of the probe signal, requires the addition of a 1000 ohm pull down resistor. Figure 5B.11 shows a typical wiring diagram compatible with most probe designs configured to trigger on the rising edge of the probes signal.

Figure 5B.11

Typical Wiring of a Touch Probe Configured for Rising Edge Trigger

9/440HR Wiring Board

5V common to encoder interface

1000 ohm

470 ohm

+5 V dc

Probe Contact

1000 ohm pull down resistor

(customer supplied)

5B-24

Section 5B

9/440HR CNC/Drive System

Wiring a Probe for Falling Edge Configuration

Figure 5B.12 shows a typical wiring diagram compatible with most probe designs configured to trigger on the falling edge of the probe signal.

Figure 5B.12

Typical Wiring of a Touch Probe Configured for Falling Edge Trigger

9/440HR Wiring Board to encoder interface

1000 ohm

5V common

470 ohm

+5 V dc

Probe Contact

11309-I

5B-25

Section 5B

9/440HR CNC/Drive System

5B.4.2

9/440HR Remote I/O

Connection

The remote I/O circuitry and connector are integral parts of the wiring board in the 9/440HR system module. Figure 5B.13 shows the remote I/O connector mounted on the 9/440HR wiring board.

Wire connections for the remote I/O communications are made through the

TB4 NODE ADAPT connector. Connect the wires for remote I/O as shown in the following figure. Refer to your 1771 I/O documentation for details on making remote I/O connections.

Figure 5B.13

Remote I/O Connector in System Module

9/440HR System Module

Remote I/O

Plug

TB4

Open Cover

9/440HR Remote I/O LED

Assuming you have: made all necessary remote I/O communication connections on your

5B-26

Section 5B

9/440HR CNC/Drive System

CNC Processor Board

Serial

Port A

Front of

System Module

R--I/O

LED

Video

5B.4.3

9/440HR Analog Out

(TB2 and TB3)

You are ready to start receiving and transmitting remote I/O information.

An LED is provided on the 9/440HR CNC processor board and is visible from the bottom of the system module. As remote I/O responds to commands, you should see this LED pattern:

LED

Green

R- I/O LED

Status Description

ON Active Link to PLC. This is the normal state when the

RIO link is active.

FLASHING The remote I/O link is active but the PLC is currently in program mode.

OFF Remote I/O link is offline. The port is not being used, not configured in AMP correctly, not turned on with

$RMON, or not attached to a 1771 device.

Two auxiliary analog outputs are provided through the connectors labeled

TB2 and TB3 of the 9/440HR Wiring Board. These connectors are typically used to command external analog spindle drive systems but can also be configured in AMP to control additional analog servo systems.

Figure 5B.14 shows the location of ANALOG OUT connector and lists terminal assignments of this connector.

Figure 5B.14

Terminal Block TB2 and TB3, Plug-type Terminal Block Connections.

Wiring Board

WATCHDOG

J14

TB2 TB3

XILINX

TB2 TB3

TB4

Analog Out 1

(spindle 1)

Analog Out 2

(spindle 2)

5B-27

Section 5B

9/440HR CNC/Drive System

5B.4.4

Battery Backup

Connect the battery pack to P1 on the wiring board.

Wiring Board

Connector

Analog Out

RET

SHLD

Description

± 10V Analog with no feedback

Signal Return shield

Signal Destination

(typically spindle drive)

(typically spindle drive) connect at wiring board only

The memory for such items as part programs, tool offset/compensation data, and work coordinate offset data is stored on the processor board. In the case of a power failure, there is a super capacitor on the processor board that backs up this data for up to 5 days (at 40 ° C) on systems without extended program storage. This super capacitor recharges within 1 hour of power turn on if completely discharged. If you want to extend this backup time install the lithium battery pack that supports the data for:

9/440HR Memory Option:

standard with extended program storage

Time (at 40

3 years

1 year

C Discharge):

This battery pack is connected to the lithium battery connector (P1) on the wiring board as shown in Figure 5B.15. Batteries and the battery cable are included with the battery replacement kit.

Figure 5B.15

Lithium Battery

9/440HR System Module

Mount the battery pack to the inside of the module cover.

Press Cover Release to Open

The lithium battery contains heavy metals and must be collected separately from other waste.

5B-28

Section 5B

9/440HR CNC/Drive System

5B.5

Power Terminal Block

Connection

9/440HR System Module

All external power connections to the 9/440HR CNC/Drive are wired through the system modules power strip, located behind the front cover in the lower right corner. Input power is wired to this strip in two different voltages:

24 V Logic Power -- this is 24 V AC or 24 V DC. The logic power is used to operate the processors in the system module, axis module logic boards, and power the encoders.

Drive Power -- this is 324-528 V AC, three phase, 50/60 Hz. The drive power is used to supply the drive portion of the 9/440HR the voltages necessary to power the axis modules and the servo motors.

To this Power

Strip Connector

Connect:

+24 V Logic Power

24 V Logic Power common

U, V, W

DC+, INT, COL

380/460V AC, three--phase power

(not phase sensitive)

System Ground Bar

Shunt resistor connection. When the jumper exists between INT and COL the internal 200 W shunt is used. When using the optionally purchased 1000 W shunt the jumper is removed and the new shunt is installed between DC+ and COL.

All connectors on the power strip support a maximum of AWG 12 gauge solid wire.

Wiring Board

Power Terminal Block

E-Stop connections

(TB1)

DC+

INT

COL

5B-29

Section 5B

9/440HR CNC/Drive System

5B.5.1

On/Off Control and

24V Logic Power

24 Volt logic power is supplied to the 9/440HR to run the processor board and axis module logic boards. The 24 volts are provided from a customer supplied transformer. Specifications for this supply are:

Transformer Input Voltage 9/440HR Input Voltage Range (Transformer Output) Number of Axis Modules

125/240 V AC

(85-265 V AC @50/60 Hz)

24V ac (19 -- 28V ac, single phase @50/60 Hz) or

1 2 3 4

On/Off connections are made through the Allen-Bradley On/Off Control assembly (8520-OFC). This assembly allows connection to the standard

MTB panel on/off switch and should be used to supply power to your 24 V transformer.

Figure 5B.16

On/Off Control Assembly

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

AC IN

AUX AC

ON SW

COMMON

OFF SW

Incoming AC Power

85--265 Volts AC

Switched AC Out

85--265 Volts AC 8 amp max

To MTB panel

ON/OFF switch

5B-30

Section 5B

9/440HR CNC/Drive System

Logic power should be wired so that if the 24 V is not available to the system module, it will open the drive contactors and disable 3 phase drive power (see Figure 5B.20).

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

AC IN

AUX AC

ON SW

COMMON

OFF SW

ON/OFF

Control Assembly

Figure 5B.17

Connecting On/Off Power Control Assembly and 24V Transformer

9/440HR Power Strip

Incoming Power

85--265 V ac

To local cabinet ground bus

BT02

Monochrome or Color operator panel power supply

Low High

DC+

COL

INT

4 amp max draw

COM

OFF

E-STOP

COM

RESET

MTB Panel

Input 85-265 V ac

Customer supplied

24V transformer

Output 24 V ac or

24 V dc non-polarized

Noise suppressor

15 AMP

Customer Supplied

Fuses

ATTENTION: You must make sure logic power (24V) is applied to the system module and the system module is out of

E-STOP before you allow 3 phase power to be enabled.

5B-31

Section 5B

9/440HR CNC/Drive System

If 24 V power is required for other devices in your machine system, you can use a 24 V power supply in place of the 24 V transformer as shown in

Figure 5B.18.

Figure 5B.18

Connecting On/Off Power Control Assembly and 24V Power Supply

ALLEN--BRADLEY

AC POWER

FUSE

8A/250V

AC IN

AUX AC

ON SW

COMMON

OFF SW

Incoming Power

85--265 V ac

To local cabinet ground bus

BT02

Monochrome or Color operator panel power supply

Low High

ON/OFF

Control Assembly

COM

OFF

E-STOP

Customer--supplied

24V Power Supply

Output 24 V ac or

24 V dc non-polarized

COM

RESET

MTB Panel

9/440HR Power Strip

DC+

COL

INT

Noise suppressor

199-ISMAxx

On Off Relay

Bulletin 100

A30--Nxx

15 AMP

Customer--supplied

Fuses

5B.5.2

Drive Power Three- phase

Three--phase power to the 9/440HR must be 324-528 V AC, 50/60 Hz.

The drive power is used to supply the drive portion of the 9/440HR the voltages necessary to power the axis modules and the servo motors.

All power connectors on the 9/440HR power strip accept AWG 12 gauge solid wire. Refer to local codes for required wire type and gauge.

5B-32

Section 5B

9/440HR CNC/Drive System

Grounded vs Ungrounded Three- phase

The 9/440HR CNC/Drive comes from the factory set for three--phase grounded systems. If your facility uses an ungrounded three--phase

360/480 volt system, you must move a jumper in the 9/440HR system module. This jumper will connect an internal resistor that helps keep high voltage static, that can be typical of ungrounded three phase systems, from building up in the system module.

Jumper Setting

J27 to J26 (factory setting)

J27 to GND3

Three Phase Power

Grounded system

Ungrounded systems

Figure 5B.19

Three- phase Jumper

Wire Jumper

Open cover

9/440HR System Module

5B-33

Section 5B

9/440HR CNC/Drive System

Figure 5B.20

Recommended Connection of Three- phase Drive Power

9/440HR Power Strip

Bussman FRS--R--20A (class RK-5)

600 V AC (qty 3)

Three-phase input

360 or 480V AC m3 m2 m1 m

Bulletin 100

Contactor Power

Customer supplied

24V Power Supply

Output 24 V ac or

24 V dc

DC+

COL

INT

U V

PE c1

AC Bulletin 100--A30N x 3 (surge protector required) or

DC Bulletin 100--A30NZ x 3

Noise suppressor

Customer

Supplied

Fuse c

Customer Supplied

E-STOP Control Relay

Noise suppressor

Other Customer Controlled

E-STOP Status Relays

E-STOP

Connector TB1

E-STOP status contact

(30V dc 1.4A)

ATTENTION: Brake control should not be directly released by the E-STOP status relay (or your customer supplied E-STOP control relay). Brakes should only be released by the PAL logic when it has determined that the 9/440HR is in full control of the servo motors and the control is out of E-STOP. See the description of the PAL flag $PFLT.15 for detail on how to test drive status.

5B-34

Section 5B

9/440HR CNC/Drive System

5B.6

Connecting Axis Modules

The Axis Module provides terminating points for the motor power, thermal sensor and brake. Axis module wiring is identical for all module ratings.

Refer to Figure 5B.21 and the paragraphs that follow for detailed information.

Figure 5B.21

Axis Module Connections

PE1

PE2

PE3

TB1 and TB2

(Located on Bottom of Module)

Motor Wiring

5B-35

Section 5B

9/440HR CNC/Drive System

See page 5B-12 for details on high--resolution feedback device cables

(1326-CECU--x).

1326AB servo motors have integral thermal protection. This contact must be connected in the E-STOP string for motor overload protection.

Connections are performed through the front panel terminal block as shown in Figure 5B.21. Refer to the information below and the

Interconnect Drawings on page 5B-40 for further information.

Table 5B.B

Motor Power Terminations

Terminal

PE1

PE2

PE3

Description

Motor Power A

Motor Power B

Motor Power C

Axis Ground

Motor Ground

Overall Shield

Wire/Pin Number

Ground Bar

Thermal and Brake Leads

The motor thermal sensor and brake leads (if used) are connected to the

Axis Module at TB1 & TB2. See Figure 5B.21 for location and

Table 5B.C for terminations.

5B-36

Section 5B

9/440HR CNC/Drive System

Table 5B.C

Thermal Sensor and Brake Terminations

Terminal

TB1-1, 2

TB1-3, 4

TB2-1, 2

TB2-3, 4

Description

Thermal Sensor Input from Motor Cable

Brake 24V DC Input from Motor Cable

Wire/Pin Number

string axis modules user brake

Brake 24V DC To Brake Control 5, 9

Thermal Sensor Output to Fault System 4, 6

TB2

Axis module 1

Thermal

String

(connect to E-STOP String)

User Brake

Control

TB1

All Axis modules

Axis Module

6 4 5 9

Motor

(applying 24V DC releases brake)

Brake

Thermostat

TB2

Axis module 2

TB2

Axis module 3

User Brake

Control

User Brake

Control

TB2

Axis module 4

User Brake

Control

5B-37

Section 5B

9/440HR CNC/Drive System

5B.7

9/440HR LEDs

9/440HR CNC/Drive has 4 LEDs on the system module and one LED on each axis module in the system. The LEDs operate as follows.

System Module LEDs

The system module has 4 LEDs. They are:

LED

XILINX

WATCHDOG

R--I/O

STATUS

Indicates

Under normal operation this LED is on. If it turns off while the system module is under power it indicates a XILINX hardware fault.

Contact your local Allen--Bradley Service.

Only available on systems with remote I/O. This

LED illuminates when the remote I/O link is communicating. See page 5B-27.

This is identical to the Watchdog LED but is visible through the system modules front cover.

9/440HR System Module

XILINX

WATCHDOG

Wiring Board

Status LED

Press Cover

Release to Open

Open Cover

R-I/O LED

(visible from under system module in front of serial port B)

Check your 9/Series CRT for any drive faults that may have occurred and are displayed as an error.

5B-38

Section 5B

9/440HR CNC/Drive System

5B.8

General Wiring Overview

Axis Module LEDs

The Axis module has a Status LED visible thru the front cover. It is:

LED Indicates

STATUS Steady Green

Flashing Green

Flashing Red/Green ready, bus not up

Flashing Red

Steady Red bus up, axis enabled bus up, axis not enabled fault present hardware malfunction

For more details on how to diagnose and troubleshoot your axis module refer to the 1394 Digital AC

Multi-Axis Motion Control System Users Manual (publication 1394-5.0)

The following figure shows a typical interconnect diagram for a 9/440HR

CNC to 1326AB motors. Note this figure illustrates only one servo motor with optional feedback encoder. The 9/440HR CNC can support up to four servo’s and two spindle drives.

5B-39

Section 5B

9/440HR CNC/Drive System

Fiber Optic

I/O Ring

Video Port

Serial Port B

Serial Port A

Analog Out 1

Analog Out 2

Remote I/O

TB2

TB3

Wiring Board

RIO1

SHLD

RIO2

TB4

TB5

9/440HR System Module

User--supplied

24V AC or 24V DC

(non-polarized), 15A

Three-phase input

360-480V AC

9/440HR

Power

Supply

DC+

COL

INT

Feedback Board

Encoder Inputs

J1, J2, J3, or J4

To Cabinet

Ground Bar

Ground Stud

Encoder Inputs

J9, J10, J11, or J12

Figure 5B.22

Wiring Overview For 9/440HR CNC

Processor Board

TB1

MTB E-Stop

Connections

External Customer

E-Stop String

E-STOP Status

String

Touch Probe

1394 Axis Module

Thermostat and Brake Feedthru

TB1

U1 V1 W1 PE1 PE2 PE3 4 3 2 1

TB2

4 3 2 1

1 2 3

T1 T2 T3

8 7 6 4 5 9

GND B2 B1 K2 K1

To next axis and User Brake

Control Input

Brake

Servo

Motor

Thermostat

Ground Bar

Encoder

AB 845H

Encoder

1326AB Motor

5B-40

9/440HR CNC

Assembly

PE Stud

Section 5B

9/440HR CNC/Drive System

System Grounding

Figure 5B.23 illustrates the recommended 9/440HR grounding scheme.

All grounds terminate on a single point. Note there are two separate ground wires going to the system module. One ground connects to PE of the system module power terminal block, the other connects to the ground stud found just beneath the wiring board on the mounting bracket for the

9/440HR CNC assembly.

9/440HR System Module

Power Terminal Block

Open cover

DC+

COL

INT

PE Power Terminal Block Ground

5B-41

Section 5B

9/440HR CNC/Drive System

Machine Tool

Earth GND (typically AWG 8)*

Chassis GND (typically AWG 10)*

Chassis GND (typically AWG 12)*

Signal GND

GND through mounting

Potential Earth (PE)

(typically AWG 8)*

Refer to local standards and codes for wire sizing.

Analog

I/O

Digital

I/O (dc) input output

Figure 5B.23

System Grounding Diagram for 9/440HR Control

Encoders

Encoder

Servo

Motor

Servo

Motor

Spindle

Motor

Operator Cabinet

Operator Panel

(see below)

Chassis

GRND Stud

MTB Panel

I/O Module

Chassis

GRND Stud

HPG

Component Enclosure

High Density

I/O

Drives Cabinet

9/440HR CNC/Drive

System

Module

Ground Stud on 9/440HR

CNC Assembly

Axis Modules (PE1)

PE on Power Supply

Spindle

Drive

Color Operator Panel

Color

CRT

Single point

GND

Transformer

Digital

I/O (ac)

Keyboard

Interface

Chassis

GRND Stud

RS-422 or RS-232

Terminal

Monochrome Operator Panel

Monochrome

CRT

Keyboard

Interface

Chassis

GRND Stud

Portable Operator Panel Interface Assembly

Operator Panel

Interface Module

Keyboard interface

Operator Panel

Power Supply

Operator Panel

Power Supply

Operator Panel

Power Supply

Chassis

GRND

Stud

END OF SECTION

5B-42

Publication 8520-6.2.5 -- August 1998

I--2

Index

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.5 -- August 1998

PN176439

9/Series Hardware

TAB 6

Emergency STOP Design

8520-6.2.6 -- August 1997 PN--176274

6.0 Section Overview

Section

Emergency Stop Design

Emergency stop (E-Stop) is a function of the control that disables all axis and spindle drives if a major anomaly is detected.

To guard against damage to the machine and injury to personnel, the system installer must make the necessary E-Stop connections to the proper terminals on the control components. E-Stop is required to safely de-energize the axes and spindle drives and place all I/O in a safe state

(including motor brakes) when an Emergency Stop condition occurs.

ATTENTION: All axis and spindle drives must be disabled by the emergency stop. Otherwise uncontrolled axis motion may cause injury to personnel and/or damage to the machine tool.

This section describes connections that must be made to help the control detects emergency situations and responds appropriately. Topics covered include:

E-Stop Connections

E-Stop String

Events when E-Stop occurs

6-1

Section 6

Emergency STOP Design

6.1 E-Stop Connections

Connect the emergency stop circuit to the pluggable E-Stop connector on as illustrated in Figure 6.1.

On MTB panel

Customer

E-Stop string

E-Stop status relay contact connection

+ customer supplied fuse

(size to protect K1b contact and your E-Stop status relay)

E-Stop reset button

Figure 6.1

E-Stop Component Connection

Pluggable E-Stop Connector (TB1 )

E-Stop button

E-Stop status relay

1 E-Stop

2 Common

3 Reset

8 If your control has, terminal 8, then connect it to chassis ground. If terminal

8 is not present on your control, then this type of grounding is not necessary.

Figure 6.2 shows a typical emergency stop circuit. This varies depending on machine tool configuration, and the devices implemented by the system installer.

6-2

Section 6

Emergency STOP Design

MTB PANEL

MACHINE

Extreme overtravel switches

Reset button

Figure 6.2

Typical Emergency Stop Circuit

E-Stop button

Motherboard/Processor Board

250mA filter

Reduced to 12 V dc

15 V dc from main power supply

Remote

E-Stop button

Drive System Ready

Software controlled

E-Stop circuit

Motor thermal switches may be connected directly

Customer-supplied dc power +

E-Stop status relay

DRIVES ENCLOSURE

SYSTEM INSTALLER OPTIONS customer supplied fuse (size to protect K1b contact and your E-Stop status relay)

Contactors for E-Stop status controlled devices (servo amp contactor, indicators, brakes, coolant pumps, etc.)

E-Stop relay K

12 V dc coil

Contact ratings:

30 V dc

1.4 A common

Important:

Connections to all pins on the 9/Series E--Stop terminal are DC only. AC connection to any of these terminals can cause damage to your 9/Series CNC.

If your control has terminal 8, connect it to chassis ground. If terminal 8 is not present on your control, then this type of grounding is not necessary.

Important: We recommend that all contactors used on the 12V E-Stop string are rated for use at low level operation (dry circuit contactors). This may increase initial expense of the circuit but will provide more reliable

E-Stop string operation over time. Use of non-dry E-Stop devices may result in nuisance E-Stop faults or failure to establish a closed circuit when the E-Stop reset push button is closed. Corrosion build-up on non-dry contactors are not cleaned by the control’s operation. Dry contactors are more immune to corrosive effects.

If non-dry contactor devices are used as elements of the E-Stop string, we recommend the use of a pilot relay in conjunction with a customer-supplied power supply operating independent of the control’s 12

Vdc string. Select a pilot relay with a dry contact rated for use in the

E-Stop string.

6-3

Section 6

Emergency STOP Design

Important: You may need to add a pilot relay if your E-Stop has one of these characteristics: the E-Stop string is very long devices on the string cause a such a large line drop in the string that the

E-Stop relay will not latch.

In these cases, the control may: not come out of E-Stop enter E-Stop at different times during operation when the E-Stop string voltage varies slightly

If your application requires a separate E-Stop pilot relay, you must provide an external power supply to power the E-Stop string. The contactors of this pilot relay are used to break the controls 12V E-Stop string. A typical layout for this E-Stop string is shown in Figure 6.3.

ATTENTION: E-Stop wiring with a pilot relay requires circuit continuity for normal operation (a customer’s E-Stop string should be a normally closed circuit). Loss of power to the external power supply should constitute an E-Stop condition.

Failing to do this may cause injury to personnel or damage to the machine tool.

ATTENTION: Contact ratings on the control are DC only.

MACHINE

Extreme overtravel switches

Motor thermal switches may be connected directly

DRIVES ENCLOSURE

Figure 6.3

Typical Customer E-Stop String with Pilot Relay

Remote

E-Stop button

E-Stop connector (TB1) on Motherboard for 9/260 or 9/290 and on the processor board for the 9/230

Drive System Ready,

(DROK TB1 on 1394)

(internally Connected on 9/440)

Customer Supplied

External Power Supply for E-Stop String

Pilot Relay

11250-I

6-4

6.2 E-Stop String

Section 6

Emergency STOP Design

The E-Stop string begins at the E-Stop connector, then may contain: remote E-Stop pushbutton(s) whose contacts open when the button is pushed to cause E-Stop.

axes overtravel limit switches whose contacts open when an axis travels over the switch.

auxiliary machine fault detection equipment whose contacts open when an auxiliary device fails.

contacts associated with the servo drives that open when a fault condition occurs in the drive.

contacts associated with the spindle that open when a fault condition occurs.

motor over temperature (thermal) sensors that cause the E-Stop string to open when they sense an over temperature condition.

The E-Stop string terminates on one side of the 12 V dc relay coil. The opposite side of the coil connects to the supply common through a software-controlled E-Stop request transistor. This permits the coil to be energized when there is series continuity through the E-Stop string.

ATTENTION: The E-Stop button is designed to be used in emergency situations to protect equipment or personnel. Make sure that it performs properly by wiring the E-Stop string with the following considerations:

The E-Stop string must be hardwired and working before enabling drives. This provides a safe and reliable way of de-energizing the drives if an E-Stop condition should occur when the drives are enabled.

Current always flows through the string when there is no

E-Stop condition. This makes sure that the control will go into E-Stop should a wire be broken.

Triggering the E-Stop string should be exclusively a hardware function that can be monitored or induced by software, but never dependant on software. This makes sure that a software failure or loss of logic power does not prevent an E-Stop condition.

Do not use devices on the fiber optic ring to trigger

E-Stop.

6-5

Section 6

Emergency STOP Design

6.3 E-Stop Status

6.4 Events When E-Stop Occurs

Use the contact on TB1-6,7 in the E-Stop string for status control of peripheral machine tool devices, such as: alarms emergency braking devices (9/440 systems refer to page 5B-34) axes drive equipment coolant pumps remote status indicators spindle drive

Table 6.A

Contact Ratings, 9/230, 9/440, 9/260, and 9/290 E-Stop Relay (K

)

Item

Max. Allowable Power

(resistive load)

Max. Allowable Voltage

Max. Allowable Current

Rating

30W

30 Vdc

1.4A

When E-Stop occurs: the position loop is disabled and issues no motion commands the following error is cleared part program execution stops it is the OEM’s responsibility to assure that the axes decelerate appropriately

Important: Note that E--Stop condition is not the same as a power loss condition or a hardware failure.

Controlled Stop on E-Stop

The controlled stop on E--Stop feature is used for servo systems that use the 9/Series to close the velocity loop on these servo hardware platforms:

9/440 systems

9/260 and9/290s that use the 8520-ENC4 or 8520-SM4

9/230’s connected to the 8520 or 1394 digital drive interface.

Important: The controlled stop feature, as described in this section, is only available on standard systems using a system executive of 10.02 or higher (some custom executives may not support controlled stop on

E--Stop) and have the appropriate servo hardware.

The controlled-stop feature can be used in conjunction with your own machine-braking system to help decelerate or hold axes in position when an E--Stop event occurs.

6-6

Section 6

Emergency STOP Design

On systems that support the controlled-stop feature, the velocity loop remains enabled and the velocity command is reduced exponentially to zero after an E-Stop occurs. This results in the velocity loop attempting to bring the motor to a stop and/or hold it steady. After 2 seconds, the controls software disables the velocity loop.

The control will also maintain the axis/drive enable signal to 1394 and

8520 digital servo amplifiers for this 2 second interval after E--Stop.

The commands sent to the drive (torque commands) are limited by the torque limits defined for the axis in AMP (“MAXIMUM PERCENT

RATED TORQUE...”).

Important: If problems (such as amplifier faults) occur from overcurrent conditions caused during a worst case E-Stop (E--Stop during rapid move), you must reduce the AMP configured maximum percent rated torque limits.

ATTENTION: We strongly recommend that the high-voltage input to the amplifiers be disconnected by a contactor when the

E-Stop string opens. As a result of this power loss to the drive, the only current available to the drive to bring the motor to a stop and hold it is the residual bus energy stored in the drives.

The velocity loop from the control will attempt to stop and hold the axes for 2 seconds after an E-Stop occurs. The amount of time the drive system can actually pull current from the motor to bring the axis to a stop and hold it in position varies depending on machine factors (e.g., the size of the motor, the speed at which it is traveling or its static load, and the amplifier size)

Resetting E-Stop

Once the cause of the error has been corrected, press E-Stop reset.

the E-Stop string will reset and return system control to system software.

depending on the value of the AMP parameter Control Reset on

E-Stop Reset, the control will either execute a control reset, which returns the part program pointer to the top of the program, or leaves the pointer at the block being executed when the E-Stop occurred.

END OF SECTION

6-7

Section 6

Emergency STOP Design

6-8

Publication 8520-6.2.6 -- August 1997

I--2

Index

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.6 -- August 1997

PN176274

9/Series Hardware

TAB 7

Making Cables and Noise Prevention Techniques

N.C.

Belden 9507 -- 24 Gauge

Shield

RDA

RDB

SDA

SDB

CSA

CSB

RSA

RSB

DMA

DMB

TRA

TRB

GND

RRA

N.C.

852062--RM007A--EN--P -- November 2000

PN--176960

Cable Diagrams

Section

7A.0

Connecting the Components and Modules

The following sections contain information to be used when connecting the modules and components. Included is information on intermodule connections, maximum cable lengths, cable types, and connector types.

For detailed information on a specific connector, refer to the section that covers the module on which the connector is located.

ATTENTION: Electrostatic discharge can degrade performance or damage the system components. Observe the following precautions to guard against such damage:

Touch a grounded object to eliminate static discharge from your body before handling any of the components. It is also recommended practice to wear a wrist strap (such as

Allen--Bradley cat. no. 8000-ESD) that provides a low resistance path to ground.

Do not touch the connectors or the connector pins.

Do not touch other circuit components when you are setting switches or jumpers. If available, use a static-safe workstation.

Keep the components that are packaged in static-shield bags in their bags when they are not used.

For more information about electrostatic discharge and how to guard against it, refer to publication 8000-4.5.2, Guarding

Against Electrostatic Damage: Using the ESD Kit.

7A.1

System Cabling Diagrams

The internal system connection diagram is shown in the following figures.

The intermodule and intercomponent connections and their corresponding cables and connectors are covered in the following section.

7A-1

Section 7A

Connecting Components

Scanner

Remote I/O Port

Battery

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

Main

Power

Supply

Figure 7A.1

9/260 & 9/290 CNC’s System Connection Diagram

External

E-Stop

9/260 or 9/290

6 7

2 ac power source

Port A (RS-232)

Fast I/O

Operator Panel or

ROPI assembly

MTB

Panel

MTB

I/O

Port B

(RS-232/

RS-422)

12 12

10 10 10 10

Servo

Module

(third)

9/290 0nly

1746 I/O

HPG

High

Density

I/O

Digital

I/O

Analog

I/O

Servo

Module

(first)

15 16 32 33

34 35

30 31

Servo

Module

(second)

Machine

Machine Machine

115/230V ac

24V dc

115/230V ac

24V dc

115/

230V ac

Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the system I/O ring. Refer to the 9/Series 9/230, 9/260, and 9/290 PAL

Reference Manual, publication 8520-4.3, for more information.

7A-2

Section 7A

Connecting Components

Figure 7A.2

9/230 Analog CNC System Connection Diagram

Main

Power

Supply

Scanner

Remote I/O Port

To MTB

External

E--Stop

Battery

9/230

Touch

Probe

Analog

Out

36 36 36

Operator Panel or

ROPI assembly

1746 I/O

HPG

MTB Panel

Port B

(RS--232/

RS--422)

MTB I/O

High

Density

I/O

Digital

I/O

Analog

I/O

Term Panel

39 38

Term Panel

39 38

Term Panel

15 16

32 33 34 35

30 31

Machine

24Vdc

Machine Machine

115/230V ac

24V dc

115/

230V ac

Drive

Power

Servo AMP

Drive

Power

Servo AMP

Drive

Power

Servo AMP

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

Motor

Encoder

Motor

Encoder

Motor

Encoder

7A-3

Section 7A

Connecting Components

External

E--Stop

Battery

Touch Probe

Spindle drive

8520 Digital Servo

Drive Connection

230V ac

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

Servo Amp

9/230

8520 Digital

Main

Power

Supply

14 14

Figure 7A.3

9/230 8520 Digital CNC System Connection Diagram

Motor

Encoder

Motor

Encoder

Motor

Operator Panel or

ROPI assembly

E-Stop Reset to processor

MTB

Panel

Port B

(RS--232/

RS--422)

26 27

MTB I/O

10 10

1746 I/O

HPG

High

Density

I/O

Digital

I/O

Analog

I/O

15 16

32 33 34 35

30 31

Machine

24Vdc

Machine Machine

115/230V ac

24V dc

115/

230V ac

7A-4

Section 7A

Connecting Components

Figure 7A.4

9/230 1394 Digital CNC System Connection Diagram

External

E--Stop

9/230

1394 Digital

Battery

Touch Probe

Spindle drive

Main

Power

Supply

47 47 47

Operator Panel or

ROPI assembly

1394 Digital Drive connection.

Other 1394 Drive connections are illustrated in Appendix H.

1746 I/O

HPG

1394 Digital

CNC System Module

Axis

Module

Axis

Module

Axis

Module

Resolver

Motor

Resolver

Motor

Resolver

Motor

15 16

Refer to publication 1394-5.0,

1394 Multi-Axis ac Servo

System Control User Manual, for information on connecting motors and resolvers.

E-Stop Reset to processor

MTB

Panel

Port B

(RS--232/

RS--422)

26 27

MTB I/O

High

Density

I/O

Digital

I/O

Analog

I/O

32 33 34 35

30 31

Machine

24Vdc

Machine Machine

115/230V ac

24V dc

115/

230V ac

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

7A-5

Section 7A

Connecting Components

Battery

Touch Probe

Spindle drive

230V ac

3 Æ

Battery

8520 Digital Servo

Drive Connection

Figure 7A.5

9/260 and 9/290 Connections from the 3-Axis Servo Module to 8520 Digital Drives

9/260 or 9/290

Control Motherboard

8520 Digital Servo Drive Connection with Optional Feedback Module

Non-motor Mounted

Feedback Devices

44 44 44

8520 Digital

Servo Module

Servo Amp

20 20

Motor

Encoder

Motor

Encoder

Motor

18 18 18

Optional Feedback

Module

Touch Probe

Spindle drive

230V ac

3 Æ

Servo Amp

8520 Digital

Servo Module

Motor

Encoder

Motor

Encoder

Motor

18 18 18

Battery

Touch Probe

Spindle drive

8520 Digital

Servo Module

230V ac

20 20 20

Servo Amp

Motor

Encoder

Motor

Encoder

Motor

18 18 18

8520 Digital Servo

Drive Connection (for 9/290 only)

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

11204-I

7A-6

Section 7A

Connecting Components

Figure 7A.6

9/260 and 9/290 Connections from the 4-axis Servo Module to 8520 Digital Drives

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

Battery

Touch Probe

Spindle drive

8520 Digital

4-axis Servo Module

14 14 14

9/260 or 9/290

Control Motherboard

12 12

8520 Digital

4-axis Servo Module

8520 Digital

4-axis Servo Module

230V ac

Servo Amp

Motor

Encoder

Motor

Encoder

Motor

230V ac

Servo Amp

Motor

Encoder

7A-7

Section 7A

Connecting Components

Figure 7A.7

9/260 and 9/290 Connections from the 3-axis Servo Module to Analog Drives

9/260 or 9/290

Control Motherboard

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

Term Panel

Analog

Servo Module

Term Panel

36 36 ANALOG OUT

BAT/TP

Term Panel

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Motor

Encoder

Motor

Encoder

Motor

Encoder

Analog

Servo Module

Analog

Servo Module

11205-I

7A-8

Section 7A

Connecting Components

Figure 7A.8

9/260 and 9/290 Connections from the 4-axis Servo Module to

Analog Drives and the 1394 Drive

9/260 or 9/290

Control Motherboard

AB supplied cables

Customer supplied cables

Optical signal cable

Terminal type connection

ANALOG OUT

BAT/TP

Analog/1394

4-axis Servo Module

51 51 51

Term Panel

39 38

Term Panel

39 38

Term Panel

39 38

Term Panel

39 38

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Drive

Power

Servo Amp

Motor

Encoder

Motor

Encoder

Motor

Encoder

Motor

Encoder

Analog/1394

4-axis Servo Module

Analog/1394

4-axis Servo Module

50 50 50

ANALOG OUT

BAT/TP

1394 Digital

CNC System Module

Axis

Module

Axis

Module

Axis

Module

Resolver

Motor

Resolver

Motor

Resolver

Motor

Refer to publication 1394-5.0,

1394 Multi-Axis ac Servo

System Control User Manual, for information on connecting motors and resolvers.

7A-9

Section 7A

Connecting Components

Figure 7A.9

9/440 CNC System Connection Diagram

Incoming

120V ac

Power

Control

Module

External

E--Stop

24V

Transformer

Incoming

380/460 V ac

Battery

Port A (RS-232)

9/440 CNC

System Module

Spindle Drive

Touch Probe

Axis

Module

Axis

Module

Axis

Module

For 9/440 Resolver--based servo connections, refer to page 7A-11.

For 9/440HR servo connections, refer to page 7A-12.

1746 I/O

15 16

Operator Panel or

ROPI Assembly

HPG

High

Density

I/O

E-Stop Reset to Processor

MTB

Panel

Port B

(RS--232/

RS--422)

27 26

MTB I/O

Digital

I/O

Analog

I/O

32 33

34 35

Machine

24Vdc

Machine Machine

115/230V ac

24V dc

115/

230V ac

Optical signal cable

Terminal type connection

7A-10

Section 7A

Connecting Components

Figure 7A.10

9/440 Resolver- based Servo Connections

9/440 CNC

System Module

Axis

Module

Axis

Module

Axis

Module

Encoder

Resolver

Motor 1

Resolver

Motor 2

Resolver

Motor 3

Terminal type connection

7A-11

Section 7A

Connecting Components

Figure 7A.11

9/440HR Servo Connections

9/440HR CNC

System Module

Axis

Module

Axis

Module

Axis

Module

Axis

Module

A quad B

HIPERFACE

Sincoder

Motor 4

HIPERFACE

Sincoder

Motor 3

HIPERFACE

Sincoder

Motor 2

HIPERFACE

Sincoder

Motor 1

Terminal type connection

7A-12

Section 7A

Connecting Components

7A.2

Cable Diagrams

The cables and connectors shown in the previous figures are covered in the following table. For detailed information on a specific connector, refer to the section that covers the module on which the connector is located.

ATTENTION: Incorrect wiring of the following cables and connectors may cause damage to their respective modules.

Cable No.

Control

C01 9/230

Table 7A.A

Cable and Connector List

From Module and Connector

Main Power Supply BT04

Cable Name To Module and Connector

ON/OFF Switch Signal Cable MTB Panel BT20

Cat. No.

Prepared by Customer

C01

Connector On End of Cable

Miscellaneous

COM

OFF

24V dc

RTRN

L2 ac

AUX ac

COM

OFF

E-Stop

COM

RESET

19419

Cable Type

Belden 9491

Power Supply

MTB Panel

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limit

7A-13

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

C01

Control

9/260 and

9/290 only

From Module and

Connector

Main Power Supply BT04

BT04

L2 ac

AUX ac

COM

OFF

Cable Name To Module and Connector

ON/OFF Switch Signal Cable MTB Panel BT20

Cat. No.

Prepared by Customer

C01

BT20

COM

OFF

E-Stop

COM

RESET

19574

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9491

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limit

Cable No.

C01

Control From Module and

Connector

Cable Name To Module and Connector

On/Off Power Control Module ON/OFF Switch Signal Cable MTB Panel BT20 9/440 (all) only

On/Off Power Control Module

L2 ac

AUX ac

ON SW

COMMON

OFF SW

C01

BT20

COM

OFF

E-Stop

COM

RESET

Cat. No.

Prepared by Customer

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9491

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limit

7A-14

Section 7A

Connecting Components

Control

9/230

Table 7A.A

Cable and Connector List (continued)

Cable No.

From Module and Connector

C02 Main Power Supply BT04

Cable Name

ac Power Source Cable

To Module and Connector

External ac Power Source

Cat. No.

Prepared by Customer

COM

OFF

24V dc

RTRN

BT04

PE ac

AUX ac

C02

AC power source

High

Low

Ground

19420

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

Cable No.

Control

C02 9/260 and

9/290

From Module and Connector

Main Power Supply BT04

Cable Name

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limit ac Power Source Cable

To Module and Connector

External ac Power Source

Cat. No.

Prepared by Customer

L1 ac

AUX ac

COM

OFF

BT04

C02

ac power source ac power source

High

Low

Ground

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

11207-I

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limit

7A-15

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C02 9/440 (all)

From Module and Connector

On/Off Power Control Module

On/Off Power Control Module

Cable Name

ac Power Source Cable

C02

L1 ac IN

AUX ac

ON SW

COMMON

OFF SW

To Module and Connector

External ac Power Source

Cat. No.

Prepared by Customer ac power source ac power source

High

Low

Ground

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limit

7A-16

Section 7A

Connecting Components

Cable No.

Control

C03 9/230

Table 7A.A

Cable and Connector List (continued)

From Module and Connector

Main Power Supply BT04

Cable Name

Power Supply Cable

To Module and Connector

Operator Panel Power Supply on Operator Panel or on

Removable Operator Panel

Interface Assembly

Cat. No.

Prepared by Customer

COM

OFF

24V dc

RTRN

L2 ac

AUX ac

C03

High

Low

Monochrome

Operator or color

Panel

Power Supply

Power Supply

To local cabinet ground bus

BT02

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9409

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-17

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C03 9/260 and

9/290

From Module and Connector

Main Power Supply BT04

Cable Name

Power Supply Cable

To Module and Connector

Operator Panel Power Supply on Operator Panel or on

Removable Operator Panel

Interface Assembly

Cat. No.

Prepared by Customer

BT04

BT02

AUX ac

COM

OFF

L1 ac

C03

High

Low

Monochrome or color

Operator Panel

Power Supply

To local cabinet ground bus

Power Supply

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9409

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-18

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C03 9/440 (all)

From Module and Connector

On/Off Power Control Module

Cable Name

Power Supply Cable

To Module and Connector

Operator Panel Power Supply on Operator Panel or on

Removable Operator Panel

Interface Assembly

Cat. No.

Prepared by Customer

On/Off Power Control Module

BT02

L1 ac

AUX ac

ON SW

COMMON

OFF SW

C03

High

Low

Monochrome or color

Operator Panel

Power Supply

To local cabinet ground bus

Power Supply

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9409

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

Cable No.

Control

C04 9/260 and

9/290

9/230

From Module and Connector

Main Power Supply BT04

Cable Name

dc Output Cable pwr fail (white)

5.15 vdc main gnd/gnd sense (black) gnd (black)

--15 vdc (yellow)

5.15 v main/5 v sense

5.15 vdc main (red) gnd (black)

+15 vdc (brown)

5.35 vdc pigtail to servo card (blue)

To Module and Connector

Motherboard J1

Processor Board P12

1 pwr fail (white)

5.15 vdc main gnd/gnd sense (black) gnd (black)

--15 vdc (yellow)

5.15 v main/5 v sense

5.15 vdc main (red) gnd (black)

+15 vdc (brown)

5.35 vdc pigtail to servo card (blue)

Cat. No.

Included with Main

Power Supply

7A-19

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C05 9/260 and

9/290

From Module and Connector

Motherboard TB1

9/230 Processor Board TB1

9/440 (all) System Module TB1

Cable Name

E-Stop String Cable

To Module and Connector

Machine Circuits

Cat. No.

Prepared by Customer

TB1

Remote

E-Stop button

MacHINE

Extreme overtravel switches

E-Stop

Common

Reset

Customer

E-Stop

String

E-Stop

Status

Contacts

C05

Drive System Ready

Motor thermal switches

DRIVES ENCLOSURE

If your control has terminal 8, then connect it to chassis ground. If terminal 8 is not present on your control, then this type of grounding is not necessary.

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9407

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-20

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C06 9/260 and

9/290

From Module and Connector

Motherboard TB1

9/230 Processor Board TB1

9/440 (all) System Module TB1

TB1

Cable Name

E-Stop Reset Cable

To Module and Connector

MTB Panel BT20

Cat. No.

Prepared by Customer

E-Stop

Common

Reset

Customer

E-Stop

String

E-Stop

Status

Contacts

C06

COM

OFF

E-Stop

COM

RESET

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9491

Important:

If your control has terminal 8, then connect it to chassis ground. If terminal 8 is not present on your control, then this type of grounding is not necessary.

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-21

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C07 9/260 and

9/290

From Module and Connector

Motherboard Port B J7

9/230 Processor Board Port B J7

9/440 (all) System Module Port B J7 shield rda rdb sda sdb csa csb rsa rsb dma dmb tra trb gnd not used

N.C.

Cable Name

RS-232/RS-422 Serial

Interface Cable

To Module and Connector

MTB Panel CN56F

Cat. No.

Prepared by Customer

Belden 9507 -- 24 Gauge

Connector On End of Cable Cable Type Connector On End of Cable Max. Cable Length

15--pin D-shell (has pins)

8520-D15M

Belden 9507 25--pin D-shell (has sockets)

8520-D25FS

The maximum length of this cable depends on the length of cable C25. The combined length of cables C07 and C25 may not exceed 15 m

(50 ft).

N.C.

8 shield rda rdb sda sdb csa csb rsa rsb dma dmb tra trb gnd not used rra

7A-22

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C08

--------------

9/260,

9/290, and

9/440 (all)

N/A on the

9/230

From Module and Connector

Port A

-----------------------------shield sd rd rs cs signal ground

Cable Name

RS-232

Serial Interface Cable

--------------------------------------

To Module and Connector

I/O Device

----------------------------------

7 shield sd rd rs cs signal ground

Cat. No.

Prepared by Customer

--------------------------

Connector On End of Cable

15--pin D-shell (has pins)

8520-D25M

Cable Type

Belden 9504

Connector On End of Cable Max. Cable Length

Miscellaneous 15m (50 ft)

7A-23

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C09 9/260 and

9/290

From Module and Connector

Motherboard J8

Cable Name

Video Signal Cable

To Module and Connector

CN19M on Operator Panel or on Portable Operator Panel

Interface Assembly

Cat. No.

Prepared by Customer

9/230 Processor Board J8

9/440 (all) System Module J8 gnd (shield) red (l) red (h) green (l) green (h) blue (l) blue (h) not used not used clock (l) clock (h) h--sync (l) h--sync (h) v--sync (l) v--sync (h)

N.C.

2 rsb dma dmb tra trb gnd shield rda rdb sda sdb csa csb rsa rra

Shield (pin 1) on the monochrome operator panel is not internally connected to signal common or chassis ground.

Monochrome monitor

gnd (shield) red (l) red (h) green (l) green (h) blue (l) blue (h) not used clock (l) clock (h) h--sync (l) h--sync (h) v--sync (l) v--sync (h)

N.C.

Connector On End of Cable

15--pin D-shell (has pins)

8520-D15M

N.C.

Cable Type

Belden 9830 (monochrome)

Belden 9832 (color)

8 rsb dma dmb tra trb gnd shield rda rdb sda sdb csa csb rsa rra

Shield (pin 1) on the color operator panel is internally connected to signal common and chassis ground.

Color monitor

Indicates twisted pairs

11211-I

Connector On End of Cable Max. Cable Length

15--pin D-shell (has sockets)

8520-D15F

15m (50 ft)

7A-24

Section 7A

Connecting Components

Cable No.

Control

C10 9/Series

(All)

Table 7A.A

Cable and Connector List (continued)

From Module and Connector

XMIT Connector (Red)

Cable Name

Fiber Optic Cable

To Module and Connector

Output Connector (Black)

Cat. No.

Prepared by Customer

Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to appendix A for additional information on fiber optic cables and connectors.

Connector Kit

8500-FOPS

Cable Type

8500-FOC1 (100 ft)

8500-FOC5 (500 ft)

Connector Kit

8500-FOPS

Max. Cable Length

27m (90 ft)

Optical connectors are provided with each module. The catalog number listed under the connector type refers to a spare connector kit.

Each kit contains an optical input connector and an optical output connector.

7A-25

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C11 9/260 and

9/290

------------

From Module and Connector

Motherboard P3

16 fast_I1 com fast_I2 com fast_I3 com fast_I4 com fast_O2 com fast_O3 com fast_O4 com fast_O5 com

Cable Name

Fast I/O Interface Cable

To Module and Connector

Miscellaneous I/O Devices

(examples shown)

Cat. No.

Purchased by customer from independent vendor.

---------------------------------N/A on the

9/230 and

9/440 (all)

--------------------------------------------------------------------------------------------------------------------------------

Fast_O2

COM

Fast_O3

Fast_O4

COM

Fast_O1

COM

Fast_I4

COM

Fast_I3

COM

Fast_I2

COM

Fast_I1

COM

Input

+ Input

Input

---

Output

+ Output

11212-I

Allen-Bradley recommends that you use a terminal block to simplify the wiring of the fast I/O. Refer to the section on fast I/O in 10A-63.

Allen-Bradley also recommends that you purchase a pre-made cable to connect the terminal block to the control.

Important: The Fast I/O feature is an application specific feature. For additional information on this feature contact your Allen-Bradley sales office.

Connector On End of Cable

16--pin (has sockets)

Cable Type

Ribbon

Connector On End of Cable Max. Cable Length

Miscellaneous --------------------

7A-26

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C12 9/260 and

9/290

------------

C13

From Module and Connector

Analog or Digital Servo Module(s)

CN1

N/A on the

9/230

----------------------------------------------

9/Series All Motherboard or

Processor Board P1

Cable Name To Module and Connector

Servo Module Interface Cable Motherboard P4, P5, P6

(P5 available on 9/290 only)

-----------------------------------------------------------------------------------

Battery Backup Cable (dc) Lithium Battery

Cat. No.

Included with Servo

Module

----------------------------------

Part of Battery

Assembly

7A-27

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control From Module and Connector

C14

With 5V dc incremental encoders

44- pin D-shell

9/230, 9/260,

9/290

8520 Digital pwm_u_hi

/pwm_u_lo pwm_v_hi

/pwm_v_lo pwm_w_hi

/pwm_w_lo

a a b b

not used

+5v_enc

+5v_enc chu_hi chu_lo chv_hi chv_lo chw_hi chw_lo not used not used cha_hi cha_lo chb_hi chb_lo chz_hi chz_lo gnd gnd gnd gnd gnd not used

9/230 Processor (8520-DSP only) servo connectors (J1,J2, or J3) or

4-axis Digital Servo Module

(8520-ENC4) Servo Connector

(J1, J2, J3, or J4)

Cable Name

Drive and Inc. Encoder

Signal Cable

To Module and Connector

8500 Servo Motor Encoder and 8520 Digital Servo

Amplifier CNA1-CNA3

2 b channel output

/b channel output z channel output

/z channel output

+5v dc enable

/enable shield status

/status pwm_a

/pwm_a pwm_b pwm_c l

/pwm_c

b b a

1 u channel output

/u channel output

2 v channel output

/v channel output

2 w channel output

/w channel output frframe ground

Cat. No.

Prepared by Customer

Incremental

Encoder

Connection

Indicates twisted pair

Shield wires, no connection at control end for either shield wire.

Drive Connection

Connector On End of Cable

44--pin Miniature D-shell (has pins)

8520-MD44M

Cable Type

Belden 8312 (encoder cable)

Belden 9833 (drive signal cable)

Connector On End of Cable Max. Cable Length

MS Style E20-29S

8520-C17F to encoder

25m (82 ft)

Honda MR-25LF (has sockets) 8520-H25F to drive

These cables are 22 AWG twisted pairs. Multiple lines (4) must be used to provide the equivalent of 16 AWG encoder power leads.

The U, V, and W channels are used for motor phasing only.

7A-28

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

C14

Control

9/230, 9/260,

9/290

8520 Digital

From Module and Connector

9/230 Processor (8520-DSP only) servo connectors (J1,J2, or J3) or

4-axis Digital Servo Module

(8520-ENC4) Servo Connector

(J1, J2, J3, or J4)

Cable Name

Drive and Abs. Encoder

Signal Cable

To Module and Connector

8500 Servo Motor Encoder and 8520 Digital Servo

Amplifier CNA1-CNA3

Cat. No.

Prepared by Customer

With 5V dc absolute encoders

44- pin D-shell

cha_hi cha_lo chb_hi chb_lo chz_hi chz_lo gnd gnd gnd gnd

/enable

+5v_enc

+5v_enc chu_lo ext_bat not used not used enable not used not used status pwm_u_hi

/pwm_u_lo pwm_v_hi

/pwm_v_lo pwm_w_hi

/pwm_w_lo

b b a a

J a channel output

/a channel output b channel output

/b channel output z channel output

/z channel output

5v (power supply) encoder reset pin

0v (battery)

+v (battery) frame ground

2 enable

/enable shield status

/status l

/l pwm_a

/pwm_a pwm_b pwm_c l

/pwm_c

a a

b b

Indicates twisted pair

Absolute

Encoder

Connection

Shield wires, no connection at control end for either shield wire.

Drive Connection

Connector On End of Cable

44--pin Miniature D-shell (has pins)

8520-MD44M

Cable Type

Belden 8312 (encoder cable)

Belden 9833 (drive signal cable)

Connector On End of Cable Max. Cable Length

MS Style E20-29S

8520-C17F to encoder

25m (82 ft)

Honda MR-25LF (has sockets) 8520-H25F to drive

The Z channel output is used for the marker signal.

These cables are 22 AWG twisted pairs. Multiple lines (4) must be used to provide the equivalent of 16 AWG encoder power leads.

7A-29

Section 7A

Connecting Components

Cable No.

Control

C15 All

9/Series

Table 7A.A

Cable and Connector List (continued)

From Module and Connector

1746 I/O Rack

Cable Name

1746 I/O Device Cable

To Module and Connector

External I/O

(Analog and Digital)

Cat. No.

Prepared by Customer

1746-IA16

1746 Digital Input Modules

+dc

1746-IB16

100/120

V ac

IN 0

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

IN 8

IN 9

IN 10

IN 11

IN 12

IN 13

IN 14

IN 15 ac COM ac COM

---dc

V dc

IN 0

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

IN 8

IN 9

IN 10

IN 11

IN 12

IN 13

IN 14

IN 15 dc COM dc COM

100/240

V ac

COMMONS CONNECTED INTERNALLY

1746 Digital Output Modules

1746-OA16

V ac1

OUT 1

OUT 0

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

+dc or L1

V dc

V ac dc COM or

V ac 2

OUT 9

OUT 8

OUT 11

OUT 10

OUT 13

OUT 12

OUT 15

OUT 14

100/240

V ac

COMMONS CONNECTED INTERNALLY

1746-OW16

V dc or

V ac 1 OUT 0

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

OUT 9

V dc or

V ac 2

OUT 8

OUT 11

OUT 10

OUT 13

OUT 12

OUT 15

OUT 14

+dc or L1 dc COM or

7A-30

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (C15 continued)

1746 Analog I/O Modules

Connector On End of Cable

Terminal Strip

OUTPUT INPUT

POWER

ANALOG

1746- NIO4V

Cable Type

Determined by I/O device

(0) IN 0+

(1) IN 0--

(2) ANL COM

(3) IN 1+

(4) IN 1--

(5) ANL COM

(6) NOT USED

(7) OUT 0

(8) ANL COM

(9) NOT USED

(10) OUT 1

(11)ANL COM

(0) IN 0+

(1) IN 0--

(2) ANL COM

(3) IN 1+

(4) IN 1--

(5) ANL COM

(6) NOT USED

(7) OUT 0

(8) ANL COM

(9) NOT USED

(10) OUT 1

(11)ANL COM

Jumper unusedinputs

Do not jumper unused outputs

Analog source

Analog load

Connector On End of Cable Max. Cable Length

Determined by I/O device Determined by I/O Device

7A-31

Section 7A

Connecting Components

Cable No.

Control

C16 All

9/Series

From Module and Connector

1746 I/O Rack

Voltage Selection Jumper

100/120 V

Table 7A.A

Cable and Connector List (continued)

Cable Name

1746 I/O Power Cable

To Module and Connector

Customer Power Supply

Cat. No.

Prepared by Customer

Power Connection

200/240 V push latch up from underneath to open the door

ATTENTION:

Turn off power lines before connecting power; failure to do so could cause injury to personnel and/or equipment.

PWR OUT +24 V dc

PWR OUT COM

L1 — 120/240 V

L2 — V ac NEUTRAL

— PROTECTIVE EARTH

Connector On End of Cable

Supplied

Cable Type

#14 AWG

Cable No.

Control

C17 All

9/Series

From Module and Connector

Remote I/O Port

Cable Name

1770-CD

Connector On End of Cable Max. Cable Length

To customer power supply N/A

To Module and Connector

PLC Scanner

Cat. No.

Purchased from

Allen-Bradley

Cat. no. 1770-CD

7A-32

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

C18

Control

9/260 and

9/290

5 gnd gnd enc_5v enc_5v enc_15v enc_15v n.c.

/pu pv

/pv pw

/pw pz

/pz pa

/pa pb

/pb shield

From Module and Connector

3 Axis Digital Servo Module

CN5-CN7

24 AWG wire

16 AWG wire

Cable Name

Encoder Signal Cable

To Module and Connector

Servo Motor Encoder

Cat. No.

Prepared by Customer

N.C.

/a channel output

Shield wire, no connection at encoder end

Indicates twisted pair

With 5V dc incremental encoders

24 AWG wire

16 AWG wire gnd

5 enc_5v enc_15v enc_15v bat_+ not used not used not used not used reset not used pz

/pz pa

/pa

/pb shield

N.C.

D ground

With absolute encoders

Shield wire, no connection at encoder end

11213-I

Connector On End of Cable

Honda MR-20LM (has pins)

8520-H20M

Cable Type

Belden 8310 (Incr. encoder)

Belden 8308 (Abs. encoder)

Connector On End of Cable

MS Style E20-29S

8520-C17F

Max. Cable Length

25m (82 ft)

These cables are 22 AWG twisted pairs. Multiple lines (4) must be used to provide the equivalent of the 16 AWG encoder power leads.

Instructions are provided in the connector kit.

7A-33

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C19 9/230, 9/260 and 9/290

From Module and Connector

8520 Digital Servo Amplifier

TB1, TB4

Cable Name

8520 Digital Servo Motor

Power Cable (230V ac)

To Module and Connector Cat. No.

8520 Digital Servo Motor

Power Connector

Prepared by Customer

Example for the 2AX--D Amplifier connections to motor one (Series A or B, without brake)

1 2 3 4 TB4

C19

TB1

Shield

For 1326-CB-AB 12 Ga.

3 conductor 12 Ga. -- Motor

2 conductor 16 Ga. -- Thermal

1 conductor 16 Ga. -- Ground

2 conductor 16 Ga. -- not used

1 Shld.

N.C.

Thermal Protector

Tie Shield to ground at both TB1 and Servo Motor

Connector On End of Cable

Miscellaneous

Cable Type

10 Ga. (TBD)

12 Ga.

1326-CP-AB100 (100 ft)

” ” -AB200 (200 ft)

” ” ” ”

1326-CP-AB1500 (1500 ft)

Connector On End of Cable Max. Cable Length

(E24-10S)

(8520-BC7F)

20m (65 ft)

MS Style E20-15S 8520-ac7F

An example of the 2AX-D 8520 digital servo amplifier connection to an A and B series 8520 digital servo motor with brake is shown in the next cable drawing.

ATTENTION: The pin layout and pin assignments of the connector on the A series servo motor with brake are different than the pin layout and pin assignments of the connector on the

B series 8520 digital servo motor with brake. Refer to appendix

B for additional information.

7A-34

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C19 9/230, 9/260 and 9/290

------------

From Module and Connector

8520 Digital Servo Amplifier

TB1, TB4

----------------------------------------------

Cable Name

8520 Digital Servo Motor

Power Cable (230V ac)

--------------------------------------------

To Module and Connector

8520 Digital Servo Motor

Power Connector

----------------------------------------

Cat. No.

Prepared by Customer

----------------------------------

Example for the 2AX--D Amplifier connectors to motor one (Series A, with brake)

TB1

1 2 3 4

TB4

C19

Shield

N.C.

Shield

From Brake energizing circuit

Thermal Protector

For 1326-CB-AB 12 Ga.

3 conductor 12 Ga. -- Motor

2 conductor 16 Ga. -- Thermal

1 conductor 16 Ga. -- Ground

2 conductor 16 Ga. -- Customer Brake Circuit

1 Shld.

Tie Shield to ground at both TB1 and Servo Motor

Example for the 2AX--D Amplifier connectors to motor one (Series B, with brake)

1 2 3 4

TB1

TB4

Shield

C19

From Brake energizing circuit

Thermal Protector

For 1326-CB-AB 12 Ga.

3 conductor 12 Ga. -- Motor

2 conductor 16 Ga. -- Thermal

1 conductor 16 Ga. -- Ground

2 conductor 16 Ga. -- Customer Brake Circuit

1 Shld.

N.C.

Tie Shield to ground at both TB1 and Servo Motor

Connector On End of Cable

Miscellaneous

Cable Type

10 Ga. (TBD)

12 Ga.

1326-CB-AB100 (100 ft)

” ” -AB200 (200 ft)

” ” ” ”

1326-CB-AB1500 (1500 ft)

Connector On End of Cable Max. Cable Length

(E24-11S)

(8520-BC9F)

20m (65 ft)

MS Style E20-18S 8520-ac9F

7A-35

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C20 9/260 and

9/290 enable

/enable shield shield shield

/status pwm_a pwm_b

/pwm_b pwm_c

/pwm_c la

/la shield shield lb

/lb

N.C.

From Module and Connector

8520 3 Axis Digital Servo Module

CN2-CN4

Cable Name

8520 Digital Servo Amplifier

Signal Cable (PWM)

N.C.

22 enable

/enable shield shield shield

/status pwm_a pwm_b

/pwm_b pwm_c la

/la shield shield lb

/lb not used not used

To Module and Connector

8520 Digital Servo Amplifier

CNA1-CNA3

Cat. No.

Prepared by Customer

For connection to the 9/230

8520 Digital CNC refer to cable

C18

Indicates twisted pairs

Connector On End of Cable

Honda MR-20LF (has sockets)

8520-H20F

Cable Type

Belden 9508 or

Belden 9808

Connector On End of Cable Max. Cable Length

Honda MR-25LF (has sockets) 8520-H25F

25m (82 ft)

7A-36

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C21 9/230, 9/260,

9/290

8520 Digital

-----------N/A on the

9/230

From Module and Connector

8520 Digital Servo Amplifier

----------------------------------------------

1 2 3 4 5

TB1

Cable Name

8520 Digital Servo Amp.

Power Source Cable

(230V ac)

--------------------------------------------

To Module and Connector Cat. No.

External ac Power Source Prepared by Customer

-------------------------------------------------------------------------

1 f 200v/230v - 2

1 f 200v/230v - 1

200v/230v f 3

3f 200v/230v f 2

3f 200v/230v f 1

From fuses and/or contactors provided by customer

C21

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

11217-I

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

Cable No.

Control

C22 9/260 and

9/290

From Module and Connector

8520 3--Axis Digital Servo Module

(CN08F)

Cable Name To Module and Connector

Analog Spindle Signal Cable Analog Out Port

N.C.

Analog signal + 10 V

Analog signal ground

Shield

Connector On End of Cable

Honda MR-8LM (has pins)

8520-H8M

Cable Type

Belden 9501

Cat. No.

Prepared by Customer

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-37

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C23 9/260 and

9/290

From Module and Connector

8520 3--Axis Digital Servo Module

(CN09M)

Cable Name

Touch Probe Signal Cable

Connector On End of Cable

Honda MR-8LF (has sockets)

8520-H8F

N.C.

Cable Type

Belden 9502

To Module and Connector

Touch Probe

+5V dc touch probe power

Touch Probe signal input

Touch Probe signal ground

Shield

Cat. No.

Prepared by Customer

11218-I

Connector On End of Cable Max. Cable Length

Miscellaneous 3 m (10 ft)

Cable No.

Control

C24

C25

9/260 and

9/290

From Module and Connector

Digital Servo Module (CN10M)

All 9/Series MTB Panel CN56F

Cable Name

Battery Backup Cable (dc)

RS--232 Serial Interface

Cable

To Module and Connector

Lithium Battery

I/O Device

Cat. No.

Part of Battery

Assembly

Prepared by Customer

For cable wiring examples, refer to page 8-3.

Also refer to the manual included with the I/O device being connected.

Connector On End of Cable Cable Type Connector On End of Cable Max. Cable Length

25--pin D-shell (has pins)

8520-D25M

Belden 9508 Miscellaneous 4

The maximum length of this cable depends on the length of cable C07. The combined length of cables C07 and C25 may not exceed 15 m

(50 ft).

7A-38

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

C26

C27

C28

Control

All 9/Series

From Module and Connector

MTB Panel Input Ribbon Cable

Cable Name

MTB Panel Output Cable

To Module and Connector Cat. No.

MTB Panel I/O Module CN51 Included with MTB

Panel I/O Module

All 9/Series

MTB Panel Output Ribbon Cable

Power Supply Connector BT02 on Operator Panel or Removable

Operator Panel Interface

Assembly

MTB Panel Output Cable

MTB Panel I/O Power Cable

MTB Panel I/O Module CN52 Included with MTB

Panel I/O Module

MTB Panel I/O Module

+12V, GND

Prepared by Customer

BT02 ac

L1 ac L2

+5V

GND

+ 12V

GND

+5V

GND

+5V

GND

C28

+12V dc

GND

Connector On End of Cable

Miscellaneous

Cable Type

Belden 8719

Connector On End of Cable Max. Cable Length

Miscellaneous 5m (16 ft)

7A-39

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C29 All 9/Series

From Module and Connector

Power Supply Connector BT02 on Operator Panel or Removable

Operator Panel Interface

Assembly

Cable Name

HPG Power Supply Cable

To Module and Connector

HPG BT23, +5V, GND

Cat. No.

Prepared by Customer

+ 5V

GND

AC L1

AC L2

+ 5V

GND

+ 5V

GND

+ 5V

GND

BT02

C29

BT23

Connector On End of Cable

Miscellaneous

Cable Type

Belden 8719

Connector On End of Cable Max. Cable Length

Miscellaneous 5m (16 ft)

7A-40

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C30 All 9/Series

From Module and Connector

High Density I/O CN61M,

CN62M, CN63F

Cable Name

High Density Signal Cables

To Module and Connector

Miscellaneous I/O Devices

(examples shown)

Cat. No.

Prepared by Customer

CN61M or CN62M

D1 or D34

D2 or D35

D3 or D36

D4 or D37

D5 or D38

D6 or D39

D7 or D40

D8 or D41

D9 or D42

D10 or D43

D11 or D44

C30

Typical

Inputs

D33 or D66 reserved reserved reserved reserved

CN63F

Share current between these four +24V pins

C30

Typical

Outputs

Lamp

Relay

Lamp

Relay

D36 not used

N.C.

BT33 on High Density I/O Module

Module power and

Input Device Power

Customer--supplied Power supply for output device

Com

TB1 TB2

Com

+24 V dc

Com

+24 V dc

We recommend that you connect the 24V common to the electrical cabinet PE BUS at the power supply output.

Connector On End of Cable

37--pin D-shells

Cable Type

Belden 9319

2 8520-D37F

1 8520-D37M

Pins 34, 35, 36, and 37 are reserved for common points.

Suppression circuit and preheat resistors are not shown here for clarity. Refer to page 7C-4 for details on suppression circuits.

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-41

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

C31

Control

All 9/Series

From Module and Connector

High Density I/O BT33

Cable Name

High Density I/O Power

Source Cable (24V dc)

To Module and Connector

External dc Power Source

Cat. No.

Prepared by Customer

Module power supply

Power supply for output device

+24 V dc

Com

+24 V dc

BT33 on High Density

I/O Module

C31

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9411

We recommend you connect the 24V common to the electrical cabinet ground BUS at the power supply output.

To electrical cabinet ground BUS 14AWG

+24 V dc

Common

Customer 24V dc power supply or from PS2 on the 9/230

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-42

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C32 All 9/Series

From Module and Connector

Digital I/O BT31, BT32

Cable Name

Digital I/O Signal Cable

To Module and Connector

Miscellaneous I/O Devices

(examples shown)

Typical

Inputs

Cat. No.

Prepared by Customer

Customer power supply

COM COM A01

COM COM B01

A02 A03

B02 B03

A04 A05

B04 B05

A06 A07

B06

A08 A09

B07 B08 B09

A10

B10

COM

Terminal

Block

Label

Suppression circuit and pre-heat resistors are not shown here for clarity. Refer to page 7C-4 for details on suppression circuits.

A11

V ac

A12 A13 A14 A15 A16

NOT

USED

B11

V ac

B12 B13 B14 B15 B16

NOT

USED Example using type E153

Customer power supply

Motor

Typical

Outputs

Noise suppress or

Lamp

Customer power supply

Relay

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

11223-I

7A-43

Section 7A

Connecting Components

115 V ac connection

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C33 All 9/Series

From Module and Connector

Digital I/O BT31

Cable Name

Digital I/O Power Source

Cable (115/230V ac, 24V dc)

To Module and Connector Cat. No.

External ac/dc Power Source Prepared by Customer

C33

Ground ac power, 115 V ac neutral ac power, 115 V ac

230 V ac connection

C33 ac power, 230 V ac neutral

Ground ac power, 230V ac

Terminal

Block

Terminal

Block

230V ac

NEUT

CHASSIS

GND

115V ac

NEUT

NOT

USED

115/230

V ac

Label

24 V dc connection

230V ac

NEUT

CHASSIS

GND

115V ac

NEUT

NOT

USED

115/230

V ac

Label

C33

Ground dc power, 24V dc common dc power, +24V dc

Terminal

Block

NOT

USED

CHASSIS

GND

24V dc

COM

NOT

USED

+24

V dc

Label

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

11224-I

7A-44

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C34 All 9/Series

From Module and Connector

E-Series Analog I/O

Cable Name

Analog I/O Signal Cable

C34

To Module and Connector

Miscellaneous Analog

Devices

Cat. No.

Prepared by Customer

Shield wire, no connection at device end

(com)

0 to +10V dc from analog device

( + )

Single

Input

NOT

USED

INPUT

( -- )

Terminal

Block

Differential

Input

PE PE

NOT

USED

Label

NOT

USED

INPUT

( -- )

NOT

USED

C34

Shield wire, no connection at device end

( -- )

--10 to 0V dc from analog device

(com)

0 to +10V dc from analog device

( + )

Output

Terminal

Block

NOT

USED

COM

OUT-

PUT

NOT

USED

NOT

USED

NOT

USED

Label

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9501 or 9502

C34

Shield wire, no connection at device end

(com)

0 to +10V dc or

--10 to +10V dc to analog device

( + )

PE = Protective Earth

11225-I

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-45

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C35 All 9/Series

From Module and Connector

E-Series Analog I/O

Cable Name

Analog I/O Power Source

Cable (115/230V ac)

C35

115 V ac connection

To Module and Connector

External ac Power Source

Cat. No.

Prepared by Customer

230 V ac connection

C35

Ground ac power, 115 V ac neutral ac power, 115V ac ac power, 230 V ac neutral

Ground ac power, 230V ac

Terminal

Block

Terminal

Block

230V ac

NEUT

CHASSIS

GND

115V ac

NEUT

NOT

USED

115/230

V ac

Label

Connector On End of Cable

Miscellaneous

Cable Type

Per Local Codes

CHASSIS

GND

230V ac

NEUT

115V ac

NEUT

NOT

USED

115/230

V ac

Label

Connector On End of Cable

Miscellaneous

Max. Cable Length

Line Drop Limitation

11226-I

7A-46

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C36 9/230,

9/260, and

9/290

From Module and Connector

3-axis Analog Servo Module or

Processor Board J1, J2, and J3

Servo

Mod.

Cable Name

Encoder and Analog Drive

Signal Cable

C36

To Module and Connector

1771-HTE Enc. Termination

Panel AXIS terminal

Cat. No.

Purchased from

Allen-Bradley

8500-TPC

Term

Panel

Not Used

CHA_HI

CHA_LO

SHLD_CHA

CHB_HI

CHB_LO

SHLD_CHB

CHZ_HI

CHZ_LO

SHLD_CHZ

+5_ENC

SIGNAL COMM

SHLD_+5V

SW_5V_ENC

SIGNAL COMM

SHLD_SEN

DRIVE

DRIVE.RET

SHLD_DRV

+5V_ENC

+15V_ENC

Connector On End of Cable

26--pin D-shell (has pins)

Cable Type

8500-TP (A-B part number)

Not Used

CHA_HI

CHA_LO

SHLD_CHA

CHB_HI

CHB_LO

SHLD_CHB

CHZ_HI

CHZ_LO

SHLD_CHZ

+5_ENC

SIGNAL COMM

SHLD_+5V

SW_5V_ENC

SIGNAL COMM

SHLD_SEN

DRIVE

DRIVE.RET

SHLD_DRV

+5V_ENC

À +15V_ENC

Connector On End of Cable Max. Cable Length

26--pin D-shell (has pins) 120 inch

+5.5”or -1.5”

11227-I

This pin is not connected on the 9/230 CNC

7A-47

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C37 9/230,

9/260, and

9/290

From Module and Connector

1771-HTE Enc. Termination

Panel DRIVE terminal

DRIVE

RET

SHLD

DRIVE

Cable Name

Analog Servo Amplifier Signal

Cable

To Module and Connector

Analog Servo Amplifier

Cat. No.

Prepared by Customer or purchase with

AB-Drives

Shield wire, no connection at amplifier end.

C37

Analog Drive

Amplifier

(Refer to appendix D for connection to AB drives)

The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

EXT.

POWER

EXT PWR IN

EXT RET IN

To Electrical Cabinet PE Bus. 14 Guage.

Repeat for each axis term panel.

Connector On End of Cable

none

Cable Type

Belden 9501

Connector On End of Cable Max. Cable Length

Miscellaneous 25 m (82 ft) (measured from TERM panel)

11228-I

7A-48

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

From Module and Connector

C38 1771-HTE Enc. Termination

Panel ENCODER terminal

CH A. HI

CH A. LO

AB SHLD

CH B. HI

CH B. LO

Z SHLD

CH Z. HI

CH Z. LO

ENCODER

Cable Name

Analog Servo Feedback

Encoder Cable

C38

To Module and Connector

A-B 845H Optical Encoder

Cat. No.

Prepared by Customer or purchase with

AB-Drives

Return

Ground

A-B 845H

Optical

Encoder

To comply with the 9/Series encoder timing, the 845H B high terminal must be connected to the 9/Series B low terminal, and the 845H B low terminal must be connected to the

9/Series B high terminal. For the 9/Series encoder timing diagram refer to the description of parameter Position Feedback Type in your AMP reference manual.

Connector On End of Cable

none

Cable Type

Belden 9730

Connector On End of Cable Max. Cable Length

Miscellaneous 25 m (82 ft) (measured from TERM panel)

7A-49

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C39 9/230,

9/260, and

9/290

From Module and Connector

1771-HTE Enc. Termination

Panel ENC POWER terminal

Cable Name

Analog Servo Encoder Power

Cable

To Module and Connector

A-B 845H Optical Encoder

Note 1: Be aware that this connection is dependent on the necessary encoder voltage. If 5V dc encoders are used connect this wire as shown below. If a 15V dc encoder is used, connect this wire to the terminal labeled +15. If a different encoder power supply is used, you must connect your encoder as discussed on page 4C-26. Note that if the +5V connection is made, the power supply connection to connector P3 on the analog servo module must be made.

+5V

RET

+15V

EX PWR OUT

SHLD

ENC POWER

Motor Mounted Encoder

C39

Note 1

Cat. No.

Prepared by Customer or purchase with

AB-Drives

A-B 845H

Optical

Encoder

Connect G to Motor Frame or Drive PE Stud.

+5V

RET

+15V

EX PWR OUT

SHLD

Non-Motor Mounted Encoder

ENC POWER

Note 1

C39

Connect G to Shield.

A-B 845H

Optical

Encoder

7A-50

Connector On End of Cable

none

Cable Type

Belden 8719

Connector On End of Cable Max. Cable Length

Miscellaneous 25 m (82 ft)

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C40 9/230,

9/260, and

9/290

From Module and Connector

Analog Servo Amplifier

Cable Name

Analog Servo Drive Signal

Cable

To Module and Connector

Servo Motor

Cat. No.

Prepared by Customer

Cable No.

Control

C41 9/260, and

9/290

Refer to Appendix D for A-B drives or refer to drives manual for details.

From Module and Connector

Analog Servo Module

BAT/TP (TB1)

Cable Name

Touch Probe Cable

To Module and Connector

Touch Probe

Cat. No.

Prepared by Customer

TB1

C41

Shield

Probe Common

Probe fired signal

+5 V dc probe power

Touch probe control unit

Connector On End of Cable

None

Cable Type

Belden 9502

11231-I

Connector On End of Cable Max. Cable Length

Miscellaneous 3 m (10 ft)

7A-51

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

From Module and Connector Cable Name To Module and Connector Cable No.

Control

C42

9/260, and

9/290

9/230

Analog Servo Module

ANALOG OUT (TB2)

Processor Board

ANALOG OUT (TB3)

9/440 (all) Wiring Board

ANALOG OUT (TB2 and TB3)

Analog Servo Module Drive

Signal Cable

Analog Drive Spindle Drive

Amplifier

C42

TB2

9/260 and

9/290

Shield

Signal common

+ 10V analog signal

Spindle drive

Cat. No.

Prepared by Customer

TB3

9/230

Shield

Signal common

+ 10V analog signal

Connect to PE

TB2 and

TB3

9/440

Wiring

Board

Connector On End of Cable

None

SHLD

ANLGOUT2 + 10V analog signal

RET

SHLD

ANLGOUT1

+ 10V analog signal

RET

TB3

TB2

Cable Type

Belden 9501

Connector On End of Cable Max. Cable Length

Miscellaneous 3 m (10 ft)

Refer to the drives manual provided with your Spindle Drive Amplifier for details.

7A-52

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C43 9/260 and

9/290

From Module and Connector

Optional Feedback Module

(CN24M)

Cable Name

+5V dc Encoder Power

Supply Cable

To Module and Connector

8520 3 Axis Digital Servo

Module (CN13)

Cat. No.

Included with Optional

Feedback Module

Cable No.

C44

Control

9/260 and

9/290

From Module and Connector

Optional Feedback Module

(CN14F, CN15F, CN16F)

Cable Name

Non-motor Mounted

Feedback Device Feedback

Cable

C44

To Module and Connector

Non-motor Mounted

Feedback Device

Cat. No.

Prepared by Customer

ENC_15V

Shield

SIGNAL COMM

ENC_5V

For 15V Feedback

Devices

Feedback Device

Signal Common

For 5V Feedback

Devices

Indicates twisted pairs

Connector On End of Cable Cable Type Connector On End of Cable Max. Cable Length

Honda MR-16LM (has pins)

8520-H16M

Belden 8308 5 Miscellaneous 25m (82 ft)

This cable has 22 AWG twisted pairs. Multiple lines (4) must be used to provide sufficient power to the feedback device. Instructions are provided in the connector kit.

7A-53

Section 7A

Connecting Components

Cable No.

Control

C45 9/440HR

Table 7A.A

Cable and Connector List (continued)

From Module and Connector

9/440HR System Module

Feedback Board

Cable Name

9/440HR 1326

Motor--mounted HIPERFACE

Feedback Cable

To Module and Connector

9/440HR 1326

Motor--mounted HIPERFACE

Cat. No.

Purchased with

System

(1326-CCU-xxx)

Black

White

Black

Red

Clear

Black

Blue

Clear

Black

Green

Clear

Green/Yellow

Supply Power

Supply GND

CHA_LO

CHA_HI

Wire Pair Shield

CHB_LO

CHB_HI

Wire Pair Shield

RS485_HI

RS485_LO

Wire Pair Shield

Overall Shield

Ferrite Suppressor Core

7A-54

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

C46

Control

9/230

From Module and Connector

Processor Board

TP (TB2)

9/440 (all) System Module Wiring Board

(TB5)

Cable Name

Touch Probe Cable

To Module and Connector

Touch Probe

Cat. No.

Prepared by Customer

TB5

9/440

TB2

9/230

4 3 2 1

1 4

Shield

+5 V dc probe power

Probe fired signal

+5V common

Touch probe control unit

Connector On End of Cable

None

Cable Type

Belden 9502

Connector On End of Cable Max. Cable Length

Miscellaneous 3 m (10 ft)

7A-55

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C47 9/Series

1394 Digital

From Module and Connector

9/230 Servo Connector

(J1, J2, or J3)

44- pin

D-shell

(to CNC)

16 shield chu_hi chu_lo chv_hi chv_lo chw_hi chw_lo cha_hi chb_hi chb_lo chz_hi chz_lo

return

status

/status enable gnd gnd not used

Connector On End of Cable

44--pin Miniature D-shell (has pins)

8520-MD44M

Cable Name

1394 CNC Interface Cable

To Module and Connector

1394 System Module

Cat. No.

8520-DSC

Cable Type

AB 8520-DSC

Shield wire, no connection at 1394 drive end.

10 u high u low v high v low w high w low a high a low b high b low z high z low

I ret

26- pin D-shell

Indicates twisted pair

(to 1394 System Module)

status_o status_l (gnd) axis enable request signal common signal common signal common signal common signal common gnd 24v input return

Connector On End of Cable

26 pin Miniature D-shell (has pins)

8520-MD26M

Max. Cable Length

25m (82 ft)

(8520-DSC comes

27 inches standard)

7A-56

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C48 1394 Digital

Amplifier or

9/440

Resolver-based

From Module and Connector

1394 CNC System Module

Cable Name

1394 Resolver Interface

Cable. (note this cable requires 360°shielding for

CE compliance. See page

17-9 in this manual.)

To Module and Connector

1326 Motor--mounted

Resolver

Cat. No.

Purchased with

System

(1326-CCU-xxx)

Cable No.

Control

C49 1394

Digital

Amplifier or

9/440 (all)

From Module and Connector

1394 Axis Module

Shield

4 3 2 1

C49

Ferrite Suppressor Core

Cable Name

1394 Motor Interface Cable

(note this cable requires 360° shielding for CE compliance.

See page 17-9 in this manual.)

To Module and Connector

1326 Motor

Cat. No.

Purchased with

System

(1326-CPB1xxx)

TB1

For 1326-CPB1xxx

Cabinet Ground Bar

PE1

PE2

PE3

Shield

Motor

Connector

7A-57

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C50 9/260,

9/290

44- pin

D-shell

(to CNC)

From Module and Connector

4-axis 1394/Analog Servo Module

(8520-SM4)

Cable Name

1394 CNC Interface Cable

16 shield not used not used not used not used not used not used cha_hi cha_lo chb_hi chb_lo chz_hi chz_lo

V return not used status

/status not used gnd gnd not used not used gnd

To Module and Connector

1394 System Module

Cat. No.

Customer Supplied

Shield wire, no connection at 1394 drive end.

10 u high u low v high v low w high w low a high a low

IB b high b low z high z low

26- pin D-shell

Indicates twisted pair

(to 1394 System Module)

status_o status_l (gnd) axis enable request signal common signal common signal common signal common signal common gnd 24v input return

Connector On End of Cable

44--pin Miniature D-shell (has pins)

8520-MD44M

Cable Type

Belden 9515

Connector On End of Cable

26--pin Miniature D-shell (has pins)

8520-MD26M

Max. Cable Length

25m (82 ft)

7A-58

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C51 9/260, and

9/290

From Module and Connector

4-axis 1394/Analog Servo Module

(8520-SM4)

Cable Name

Encoder and Analog Drive

Signal Cable

C51

To Module and Connector

1771-HTE Enc. Termination

Panel AXIS terminal

Term

Panel

Cat. No.

Customer Supplied

Servo

Mod.

+5_ENC

SIGNAL COMM

+5_ENC

SIGNAL COMM

DRIVE

DRIVE.RET

Shield

+5V_ENC

SIGNAL COMM

Shield*

CHA_HI

CHA_LO

Shield

CHB_HI

CHB_LO

Shield

CHZ_HI

CHZ_LO

Shield

+5V_ENC

SIGNAL COMM

+15V_ENC

SIGNAL COMM

* Use one of the unused drain wires from a twisted pair for the pin one to pin one connection.

Connector On End of Cable

44--pin D-shell (has pins)

Cable Type

Belden 8774

Connector On End of Cable Max. Cable Length

26--pin D-shell (has pins) 120 in.

+5.5 or -1.5 in.

7A-59

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C52 9/440

Resolver-based

From Module and Connector

9/440 Resolver--based System

Module Feedback Board

Use four 22 gauge twisted pair to make the power connections to pins 6 and 12. Strip 1 inch of one lead and solder into pin. Solder the three remaining leads to the exposed one inch of wire to make the equivalent of 16 gauge wire. Use the appropriate wire tape. Repeat for both pins.

Cable Name

Encoder Signal Cable

16 AWG for encoder power pins 6 and 12 (use four 22 gauge)

To Module and Connector

AB 845H Encoder

Cat. No.

Customer Supplied

AB 845H

Encoder

Connector On End of Cable

AMP 770581--1

Cable Type

Belden 8307

Connector On End of Cable Max. Cable Length

MS Type 25 m (82 ft.)

Cable No.

Control

C53 9/440 (all)

From Module and Connector

On/Off Power Control Module

On/Off Power Control Module

L1 ac

AUX ac

ON SW

COMMON

OFF SW

C53

Cable Name

115V Transformer Feed

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9409

To Module and Connector

24V Logic Transformer

(customer supplied)

Customer supplied

24V logic transformer

High

Low

Cat. No.

Prepared by Customer

To local cabinet

PE bus

Important: Make sure 24V logic power is applied before allowing 3--phase power to come up. Logic power must be applied to the system module first.

Connector On End of Cable Max. Cable Length

Miscellaneous Line Drop Limitation

7A-60

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C54 9/440 (all)

From Module and Connector

24V Logic Transformer

(customer supplied)

Cable Name

24V Logic Power

Important: Make sure 24V logic power is applied before allowing 3 phase power to come up. Logic power must be applied to the system module first.

To Module and Connector

9/440 System Module

Power Terminal Block

Cat. No.

Prepared by Customer

9/440 System Module

Power Terminal Block

Customer supplied

24V logic transformer

High

Low

Connector On End of Cable

Miscellaneous

Cable Type

Belden 9409

15 AMP

Customer Supplied

Fuses

C54

Connector On End of Cable

Clamped by terminal screws dc+

INT

COL

W1(+)

W2(--)

Max. Cable Length

Line Drop Limitation

7A-61

Section 7A

Connecting Components

Table 7A.A

Cable and Connector List (continued)

Cable No.

Control

C55 9/440 (all)

From Module and Connector

External 380/460V Three Phase

Cable Name

Drive Power

To Module and Connector

9/440 System Module

Power Terminal Block

Cat. No.

Prepared by Customer

9/440 Power Strip

Bussman FRS--R--20A (class RK-5)

600 V ac (qty. 3)

Three-phase input

380-460V ac

dc+

INT

COL

U V

Bulletin 100

Contactor Power ac Bulletin 100--A30N x 3 (surge protector required) or dc Bulletin 100--A30NZ x 3

Noise suppressor

E-Stop Status Contactor

(customer supplied or internal 9/440 TB1 status)

ATTENTION: Brake control should not be directly released by the

E-Stop status relay (or your customer supplied E-Stop control relay).

Brakes should only be released by the PAL logic when it has determined that the 9/440 is in full control of the servo motors and the control is out of E-Stop. See the description of the PAL flag

$PFLT.15 for detail on how to test drive status.

Connector On End of Cable

Miscellaneous

Cable Type

See Local Codes

(12Awg max)

Connector on End of Cable Max. Cable Length

Clamped by terminal screws Line Drop Limitation

7A-62

Section 7A

Connecting Components

Cable No.

Control

C56 9/440HR

Table 7A.A

Cable and Connector List (continued)

From Module and Connector

9/440HR System Module

Feedback Board (J9 -- J12)

Cable Name

A quad B Optional Feedback

Device

To Module and Connector

AB 845H Encoder

Cat. No.

Prepared by Customer

Shield

CHA_HI

CHA_LO

CHB_HI

CHB_LO

CHZ_HI

CHZ_LO

Cat. No. 8520--MS16F

Connector

Channel B is inverted for AB- 845H encoder

+5V_PWR

GND

+SENSE

--SENSE

AB 845H

Encoder

All 22 AWG wire

Ferrite Suppressor Core

Connector On End of Cable

Molex 43025--1600

Cable Type

Belden 830

Connector On End of Cable Max. Cable Length

MS Type 25 m (82 ft)

7A-63

Section 7A

Connecting Components

Cable No.

Control

C56 9/440HR

Table 7A.A

Cable and Connector List (continued)

From Module and Connector

9/440HR System Module

Feedback Board (J9 -- J12)

Cable Name

A quad B Optional Feedback

Device

To Module and Connector

generic AqB Feedback

Device

Cat. No.

Prepared by Customer

Cat. No. 8520--MS16F

Connector

Shield

CHA_HI

CHA_LO pair shield

CHB_HI

CHB_LO pair shield

CHZ_HI

CHZ_LO pair shield

+5V_PWR

GND

+SENSE

--SENSE

Pair Shields are optiona. l

Not used with Belden # 830

Ferrite Suppressor Core

Optional

AqB feedback device

All 22 AWG wire

Connector On End of Cable

Molex 43025--1600

Cable Type

Belden 830

Connector On End of Cable Max. Cable Length

MS Type 25 m (82 ft)

END OF SECTION

7A-64

7B.0

Section Overview

7B.1

Fiber Optic Cable

Specifications

Section

Fiber Optic Connections

Page 1B-1 begins illustrations of typical small and large system configurations and the modules that can be used. Most inter-module communication is accomplished through fiber optics.

Most I/O devices, including handwheels, the standard MTB panel, and the operator panel, are connected to the control through an “I/O ring”. Ring devices each have an optical transmitter and receiver. Optical transmitters are connected to optical receivers using fiber optic cable to form the I/O ring.

The I/O ring must be complete; each transmitter must be connected to a receiver or an I/O ring communications error will occur.

Each module using the I/O ring must be included in the I/O Assignment file. The I/O Assignment file is edited using the I/O Assignments utility of the Offline Development System (ODS).

Fiber optic cables can be damaged by excessive bend radii, excessive pulling forces, or crushing forces. If the transmissive core is scratched or nicked, transmission characteristics may deteriorate noticeably and mechanical failure (breakage) of the core will be accelerated.

The following fiber optic cable installation recommendations should be taken into account:

Avoid pulling cable over sharp edges.

Do not install cable in areas where it is likely to suffer impact damage

(from such things as dropped tools).

Avoid installing cable in areas where it will experience repeated flexing, particularly with small radii.

Support cable in long vertical runs.

7B-1

Section 7B

Fiber Optic Connections

Cable suspended in the air should be supported to withstand the load produced by its own weight.

DOP, a plasticizer, commonly used with polyvinyl chloride insulated wire (80% of wires) tends to degrade the acrylic core of fiber optic cable. If fiber optic cable is tightly bundled with wire cables and these cables are subjected to high temperature and humidity, the DOP in the wire cable’s insulation may leech into the fiber optic cable and degrade the core.

Fiber transmittivity may also be degraded if exposed to organic solvents including, but not limited to:

Common Solvents Degrading Transmittivity

acetone benzene ethyl acetate gasoline methanol methyl ethyl ketone toluene trichloroethane trichloroetholene

Fiber optic cable can be exposed to the following liquids for long terms without transmittivity being degraded:

Cable Resistant to these Solvents

NaOH (10%) at 60 ° C

NH4 (5%) at 60

C chlorinated hydrocarbon cutting oil 1

H2SO4 (10%) at 60

NaCl (5%) at 60 distilled water

° C mineral oil based dielectric fluid 1

The PVC jacket of the cable will be affected but fiber attenuation will not be affected.

Fiber optic cable can be exposed to the following liquids for short terms without transmittivity being degraded:

Cable Resistant to these Solvents for Short Term only

isopropyl alcohol sodium phosphate based flux cleaners (0.5% sodium phosphate synthetic detergent) soap suds (0.5%) at 60

Ammonium hydroxide based flux cleaners

7B-2

Section 7B

Fiber Optic Connections

Table 7B.A shows the specifications for the fiber optic cable used to connect optical transmitters to optical receivers. Table 7B.B shows the fiber optic thermal Specifications and Table 7B.C shows the cable attenuation specifications.

Table 7B.A

Fiber Optic Cable Mechanical Specifications

Fiber Optic Mechanical Specifications

Cable Length

Tensile Load During Installation

Tensile Load in Continuous Use

Bend Radius

Impact (10mm R 1/2 cyl. of 1Kg mass)

Twisting

Min

Max

Units

Kg/Cable

Kg/Cable mm cm

Twists/m

Table 7B.B

Fiber Optic Cable Thermal Specifications

Min Max Fiber Optic Thermal

Specifications

Storage Temperature

Application Temperature

-40

+85

+70

Units

° C

Table 7B.C

Fiber Optic Cable Attenuation Specifications

Fiber Optic Attenuation Specifications

30 meter (conditions: 660 nm, 25

10 meter (conditions: 660 nm, 25

Min

.21

.23

Max

.30

.34

Units

dB/meter dB/meter

7B-3

Section 7B

Fiber Optic Connections

7B.2

Fiber Optic Cable

Construction

1. Fiber Optic Cable Stripping

Before a fiber optic plug can be connected to the end of a fiber optic cable, the end of the cable must be stripped. Use a Thomas & Bettst wire stripper no. 007--8990--95 or equivalent to strip away approximately

25 mm (1 in.) of the outer jacket of the fiber optic cable. Set the stripper to strip the outer jacket without damaging the inner jacket.

Figure 7B.1

Fiber Optic Cable Stripping

Outer jacket

25.4 mm

(1.00 in)

Fiber

Inner jacket

11362-I

2. Fiber Optic Plug Assembly

Insert the stripped fiber optic cable into the fiber clamp of the fiber optic plug along the fiber clamp guide groove. Leave approximately .8 mm

(.032 in) of space between the back of the fiber clamp and the unstripped area of the outer jacket. Allow the stripped portion of the fiber optic cable to protrude several millimeters from the front of the fiber optic plug.

Figure 7B.2

Inserting the Cable into the Clamp

Fiber clamp

.8 mm

(.032 in)

Cable

Plug housing

11363-I

7B-4

Section 7B

Fiber Optic Connections

Squeeze the fiber clamp and the plug together with pliers until the fiber clamp reaches the bottom of the plug.

Important: The lower jaw of the pliers must be seated on the recessed step of the plug housing as shown in Figure 7B.3.

Figure 7B.3

Assembling the Fiber Clamp and the Plug Housing

Connector

Pliers

Fiber clamp and fiber are trimmed as pieces are clamped together

11364-I

Important: Once the plug has been clamped it cannot be reclamped or reused.

The cable clamp slides over the fiber optic plug housing to secure the fiber optic cable.

Figure 7B.4

Cable Clamp Mounting

Plug

Cable clamp

11365-I

7B-5

Section 7B

Fiber Optic Connections

3. Inserting a Fiber Optic Plug into a Receptacle

Insert the polarized positive-snap retention fiber optic plug into the color coded receptacle. The red receptacles are transmitters, the black receptacles are receivers.

Figure 7B.5

Inserting a Fiber Optic Plug into a Receptacle

Receptacle

Plug

11366-I

4. Removing a Fiber Optic Plug

To remove a fiber optic plug from a receptacle, press the quick release tab on the top of the plug and slide the plug out of the receptacle.

Figure 7B.6

Removing a Fiber Optic Plug

Quick-release tab

11369-I

END OF SECTION

7B-6

7C.0

Section Overview

7C.1

Preventing Noise

Noise Prevention

Section

This section discusses wiring guide lines and techniques that should be followed to help lower system noise susceptibly. Of these guide lines are followed, noise should not be a factor in most 9/Series system applications.

The first measures to take to protect the electrical system from electrical noise is to provide a protective ground. Proper grounding helps reduce the effects of electrical noise by isolating induced noise voltages to individual ground wires and shunting them to ground. This allows the noise to be directed to the earth instead of being transmitted through the cables. See page 3B-9 (9/230 systems), page 4D-10 (9/260 and 9/290 systems), or page 5A-42 (9/440 systems) for details on proper protective grounding.

In addition to protective grounding, the following noise prevention measures may also be used:

Signal Grounding

Mechanical Shielding

Shielded Cables and Twisted-pair Cables

Separation of Cable Routes

Noise Suppressors

To prevent noise related problems, first find the noise transmission route and then take the appropriate noise prevention measures.

Signal Grounding

Signal grounding is used to direct any electrical noise, caused by shorted or leaking high frequency electrical currents, to earth ground. Protective ground, which has a high impedance path for high frequency noise, cannot effectively lead electrical noise from high frequency current to the earth ground.

Signal grounding must be made separately from other protective electronic component grounding. Protective ground and signal ground methods differ from each other in that the type of grounding wire used is different.

Signal noise, which is caused by high frequency current, has strong skin effect and flows only on the surface layer of the grounding wire.

Therefore, the wire used for signal grounding should be as thick as possible and as short as possible to minimize resistance and inductance.

7C-1

Section 7C

Power Distribution and Wiring Guidelines

Important: When grounding more than one electronic device, do not serially connect their grounding wires. If connected in series, even low level noises can cause interference, as they accumulate additively.

Grounding must be made to a single point.

Mechanical Shielding

Radiated noise generates high frequency noise on high-impedance control inputs. For effective noise prevention, install a low-impedance grounded conductor in the radiated noise transmission route. Normally, installing the control inside a metallic cabinet and providing protective ground to this cabinet will produce satisfactory results.

Shielded Cables and Twisted-pair Cables

Shielded cables are very effective for protecting weak signals such as control signals from electrical noise.

These cables are effective for protecting the signals from full frequency band electrostatic inductive noises and radio frequency band electromagnetic noises. However, they are not as effective for low frequency magnetic inductive noises and electromagnetic inductive noise of frequencies lower than radio frequency band.

Generally, signal cables carrying signals of similar voltage or current levels are run along the same route. This sometimes causes electrostatic coupling between the signal cables. To prevent such a problem, use shielded cables to carry weak signals, drive signals, and feedback signals, for example.

Exposure of signal cables must be kept to a minimum to provide common mode noise rejection and protection. Ground the shielded cable only at one end (usually, the controller or signal source end). The other end of the shield cable should be insulated with tape or shrink tubing.

Important: If both ends of the shielded cable are connected to ground, a ground loop will be formed. This may conduct the noise current through the cabinet frame and the chassis ground, generating noise problems instead of eliminating them.

To carry NC control signals, use twisted--pair cables, as shown in

Figure 7C.1, to prevent transmission of noise to the differential input signals.

7C-2

Section 7C

Power Distribution and Wiring Guidlines

Figure 7C.1

Shielded Twisted-pair Cables

Signal source

Twisted pair

Cable shielding

C Exposure of the signal cables must be minimal

Signal destination

Differential input

Connect the cable shielding through a terminal block

DO NOT connect the cable shielding to ground at the signal destination

11237-I

When parallel wires are used for carrying control signals, if distances between the noise source and the individual cables differs, one of these two wires will be subject to stronger radiation noise than the other. However, when a twisted--pair cable is used, both wires will be subject to equal radiation noise regardless of the position of the noise source. This means that equal noise voltage is applied to both of the differential input terminals. Thus, the noise applied to the two terminals will cancel each other and reduce the drive circuit noise.

Usually, twisted-pair shielded cables as illustrated in Figure 7C.1 are used to transmit weak signals such as drive signals and feedback signals.

Separation of Cable Routes

Route cables with high power and low power levels (voltages and/or currents) separately. Run cables along opposite sides of the cabinet to minimize the influence of magnetic and electromagnetic induction noises.

Install steel sheet metal wireways between machine application cabinets.

Do not use aluminum or other non-ferrous wireways as they do not provide magnetic shielding for the cables. Do not use dissimilar metals as this may lead to noise buildup. In wireways, bundle wires loosely into groups according to similar power levels and functions.

Do not run cables carrying weak signals such as drive signals and feedback signals in parallel with the ac power cables and I/O cables. If they must be run in parallel with each other, pass the weak signal carrying cables in metallic conduit to protect them from the influence of magnetic and

7C-3

Section 7C

Power Distribution and Wiring Guidelines

AC power electromagnetic noise. If there is no electric conductivity between the metallic conduit and the frame or the cabinet, connect them using a conductor.

Important: Run cables carrying weak signals inside metallic conduit whenever possible. Do not use the metallic conduit as the grounding connection for the frame or the cabinet. Use an exclusive conductor for grounding.

Figure 7C.2

Cable Routing

Discrete I/O

AC power

Machine connections panel

Motor power

Feedback

Application power distribution panel

Customer

AC power

Machine cable conduits

Axis signals Drive command

9/230, 9/260, or

9/290 controller cabinet

Recommended steel dividers

Axis drive cabinet

11238-I

Noise Suppressors

To prevent noise in the ac power line on the power receiving side

(controller side), connect a filter or transformer as shown in Figure 7C.3.

7C-4

Section 7C

Power Distribution and Wiring Guidlines

Figure 7C.3

Non-Isolated Conductive Type Noise Suppressing

LC Filter

L L

RC Noise Suppressor

Figure 7C.4

Isolated Insulation Type Noise Suppressing

11239-I

Isolation Transformer Shielded Transformer

Noise Cutting Transformer

11240-I

These noise filters and isolation transformers have different effects depending on noise characteristics (common mode noise, normal mode noise, high frequency noise, low band width noise, high band width noise, etc.). Therefore, select the appropriate noise suppression parts meeting the noise characteristics. Install these parts as close to the controller as possible for them to be most effective.

7C-5

Section 7C

Power Distribution and Wiring Guidelines

Figure 7C.5

Location of Noise Suppressors

Noise

Filter

Noise

Source

YES

Suppressor close to source, transient current does not circulate through the cables

Noise

Source

Noise

Filter

Transient current circulates through the cables and generates interference

11241-I

Spike Voltage Noise Suppression

Spike voltage is generated when contacts in an inductive circuit open. To reduce spike voltage, connect a noise suppressor in parallel with the load.

This suppresses spike voltage as shown in Figure 7C.6. This also prevents arcing between the contacts due to spike voltage, thereby protecting both the contacts and the internal circuit of the solid state output.

Figure 7C.6

Spike Voltage Noise Suppressing

Noise Suppressor

100V ac

100 mH

Inductive

Load switch opened

141v p

Voltage waveform

4.5A p

Current waveform

11242-I

-4.5A

7C-6

Section 7C

Power Distribution and Wiring Guidlines

Inductive Load Noise Suppression

Select the noise suppressor according to load size and applied voltage.

Connect the noise suppressor as close to the load as possible.

For a small ac inductive load, such as a solenoid operated by a pushbutton switch or a limit switch, connect the RC circuit as shown in Figure 7C.7.

Figure 7C.7

Small AC Inductive Load

Small AC inductive load voltage

Load

C R

11243-I

For a large ac inductive load, such as a motor operated by a contactor, connect a varistor in parallel with the RC circuit as shown in Figure 7C.8.

Figure 7C.8

Large AC Inductive Load

Large AC inductive load voltage

Load

C R

Varistor

11244-I

7C-7

Section 7C

Power Distribution and Wiring Guidelines

For a three-phase ac inductive load, connect noise suppressors across the individual phases as shown in Figure 7C.9.

Figure 7C.9

Three-phase AC Inductive Load

C R

3-phase AC inductive load

11245-I

For a small DC inductive load, such as a miniature relay operated by a switch, connect the diode as shown in Figure 7C.10. The diode must have a peak voltage rating higher than two times that of the applied voltage.

Figure 7C.10

Small DC Inductive Load

Small DC inductive load voltage

Load

Diode

11246-I

Devices used for surge protection should be connected as close to the load device as possible. When Allen-Bradley relays, contactors, and motor starters are used, refer to Table 7C.A.

7C-8

Section 7C

Power Distribution and Wiring Guidlines

Table 7C.A

Allen-Bradley Surge Suppressors

Device

Bulletin 509 Motor Starter

Bulletin 100 Contactor

Bulletin 709 Motor Starter

Coil Voltage

120V ac

240V ac

120V ac

240V ac

120V ac

Bulletin 700 R, RM Type Relay ac coil

Bulletin 700 R Type Relay

Bulletin 700 RM Type Relay

12V dc

Bulletin 700 R Type Relay

Bulletin 700 RM Type Relay

Bulletin 700 R Type Relay

Bulletin 700 RM Type Relay

Bulletin 700 R Type Relay

Bulletin 700 RM Type Relay

Bulletin 700 R Type Relay

Bulletin 700 RM Type Relay

24V dc

48V dc

115--125V dc

230--250V dc

Bulletin 700 N, P Type Relay 150V MAX. ac

Electromagnetic device whose sealed power is limited to 35 VA.

150V max. ac or dc

700--N10

700--N13

700--N16

700--N17

700--N11

700--N14

700--N12

700--N15

700--N24

Surge Suppressor Catalog No.

599--K04

5990KA04

199--FSMA1

199--FSMA2

1401--N10

(surge suppressor not required)

700--N22

700--N28

Typical surge protection circuit examples are shown in Figure 7C.11.

Figure 7C.11

Surge Protection Circuits for Inductive Load

Inductive output device Inductive output device

Varistor

DC inductive load

RC circuit

AC inductive load

Diode Surge suppressor

11247-I

7C-9

Section 7C

Power Distribution and Wiring Guidelines

7C.2

Reducing Noise

The following sections explain different types of noise and measures to reduce them.

Electrical Noise

Electrical noise can be considered to be unwanted electrical signals, which produce undesirable effects in the circuits of the control systems in which they occur. High intensity noise can interfere with system functioning.

The following sections explain electrical noise and the measures to reduce them.

Electrical noise is transmitted in two ways. One means of transmission is through cables (conducted noise). The other is transmission through the air (radiated noise).

Figure 7C.12

Noise Transmission Routes

Radiated noise

Source Conducted noise

Wire or cable

Destination

11233-I

Conducted Noise

Conducted noise is transmitted to the control through conductors such as power source cables, signal cables, and grounding cables. Conducted noise is further divided into two modes; normal mode and common mode.

As shown in Figure 7C.13, normal mode noise reaches the control by passing through the two lines. Common mode noise reaches the control by passing through each line and the conductor that functions as the common potential for the two lines.

7C-10

Section 7C

Power Distribution and Wiring Guidlines

Figure 7C.13

Types of Line Noise

Power source

Noise source

9/Series control

Power source

9/Series control

Noise source

A. Normal mode noise B. Common mode noise

11234-I

Electrical noise varies in waveforms and magnitude over the entire frequency width. Typical examples of abnormal phenomenon and waveforms observed in the power source line are shown in Figure 7C.14.

Figure 7C.14

Abnormal Voltage Waveform

Slow voltage fluctuation Sharp voltage fluctuation

Flicker Higher harmonic

Voltage spike High frequency noise

One of the sources of electrical noise is a sharp current variation in inductive circuits, as shown in the circuit of Figure 7C.15. In this circuit, voltage V

L applied to the inductive load L (a relay coil, for example) is equivalent to the voltage applied to the circuit while the switch SW is closed. If this switch is opened, the inductive load that prevents current variation, generates a momentary high voltage called a “spike”.

7C-11

Section 7C

Power Distribution and Wiring Guidelines

Figure 7C.15

Spike Voltage 100V ac (rms) Arc Inductive Load

100V ac

(528V)

100mH

141 V peak dt = 0.7ms

0 Volts

3.71A peak

-3.71 A di = +3.71A

0 Amps

11236-I

Radiated Noise

Radiated noise reaches the control through the air. The cables and the metallic frames, of the control, function as antennas that receive electrical noise from a variety of sources such as ac power lines, welding arcs, transformers, motors, and radio wave transmission devices.

If a number of electronic components are arranged near the control, the surrounding air will be filled with radiated noise. The control must be shielded to protect it from radiated noise. Radiated noise is composed of three types of noise: electrostatic induction noise magnetic induction noise electromagnetic induction noise

END OF SECTION

7C-12

Publication 852062--RM007A--EN--P -- November 2000

Supercedes Publication 8520--6.2.7 -- August 1998

PN 176960

9/Series Hardware

TAB 8

Communications

8520-6.2.8 -- August 1998

9/290 Remote I/O Plug

PN--176441

8.0 Section Overview

8.1 RS-232 Interface

Section

Communication Interface

This section covers the connection of peripherals to the control. The following types of interfaces to connect the peripherals to the control:

RS-232 (ports A or B)

RS-422 (port B only)

For Information on:

RS-232 Interface

RS-232 Signal Description

Connection of Peripherals

RS-422 Interface

RS-422 Description

Connection of Peripherals

Protocol

RS-491 Level 1 Protocol

Peripherals

See Page

8-7

8-9

8-11

8-15

8-1

8-2

8-3

8-6

RS-232 is a common serial interface that uses a single return line for all signals. This interface is often called single ended serial communication because of the single return line and because the “True” (High) and “False”

(Low) data bits are positive and negative voltages referenced to the common return.

Control

9/230

Port A and location

----

9/260

9/290

9/440

RS-232 on the CPU Module

RS-232 bottom of system module

Port B and location

RS-232/422 on the processor board

RS-232/422 on the motherboard

RS-232/422 bottom of system module

When you select RS-232, the interface cable cannot be longer than 50 cable feet (15 meters). The length of the interface cable should be kept as short as possible and should be shielded to reduce the possibility of noise interference.

8-1

Section 8

Communication Interface

8.2 RS-232 Signal Description

RS-232 sends and receives the signal codes in Table 8.A to and from the control. The control is a data communication equipment (DCE) device.

Table 8.A

RS-232 Connector Pin Assignment Port A

Pin No.

Signal Code Signal Name Signal Type Description

DSR

Shield

Send Data

Receive Data

Request To Send

Clear To Send

Data Set Ready

Input

Output

Input

Output

Shield

This line is used to carry data sent from a peripheral device to the control.

This line is used to carry data that is sent from the control to a peripheral device.

The peripheral turns this line “ON”to request the control send it data.

The control turns this line “ON”to request the peripheral send it data

The control turns this line “ON”when power to the control is applied.

Signal Line Ground 7

Port B Only

GND Signal Ground --

Table 8.B indicates the signal conditions for control signal ON/OFF status.

Table 8.B

Control Signal Status

Signal Conditions

Control Signal

Logic

Signal Level

Mark Space

OFF

-3 to -15V +3 to +15V

8-2

Section 8

Communication Interface

8.3 Connection of Peripherals

The figures below show the wiring connections for the RS-232 interface with hardware handshake. The arrows in the following figures indicate the signal flow direction. Figure 8.1 shows the wiring connections when the

CNC is a DCE (Data Communication Equipment) device and the peripheral is a DTE (Data Terminal Equipment) device. A DTE device transmits data on pin 2, and a DCE device transmits on pin 3. Figure 8.2

shows the wiring connections when the CNC and the peripheral are both

DCE (Data Communication Equipment) devices. On the 9/230 systems all communications connections are made with port B.

Figure 8.1

RS-232 Cable Wiring with Hardware Handshake (DCE to DTE)

CNC

GND

(DCE)

Hardware

Handshake

Peripheral

5 CS

7 GND

(DTE)

Figure 8.2

RS-232 Cable Wiring with Hardware Handshake (DCE to DCE)

CNC

GND

(DCE)

Hardware

Handshake

Peripheral

2 SD

GND

(DCE)

11349-I

8-3

Section 8

Communication Interface

The figures below show the wiring connections for the RS-232 interface without hardware handshake. The arrows in the following figures indicate the signal flow direction. Figure 8.3 shows the wiring connections when the CNC is a DCE (Data Communication Equipment) device and the peripheral is a DTE (Data Terminal Equipment) device.

Without hardware handshake, if the peripheral needs RR , connect the TR

(Terminal Ready) pin to the RR (Received Line Signal Detector - carrier dated) pin on the peripheral. Figure 8.3 and Figure 8.4.

Figure 8.3

RS-232 Cable Wiring without Hardware Handshake

(DCE to DTE)

CNC

CS 5

GND

(DCE)

No Hardware

Handshake

Peripheral

2 SD

GND

(DTE)

11350-I

Figure 8.4 shows the wiring connections when the CNC and the peripheral are both DCE (Data Communication Equipment) devices.

Figure 8.4

RS-232 Cable Wiring without Hardware Handshake

(DCE to DCE)

CNC

No Hardware

Handshake

Peripheral

GND

(DCE)

GND

(DCE)

11351-I

8-4

Section 8

Communication Interface

Figure 8.5 through Figure 8.7 show cable wiring examples for the RS-232 interface between the control and Allen-Bradley T45, T47, T35 and T50 workstations.

Figure 8.5

RS-232 Cable Wiring to an Allen-Bradley T45 or T47

9/Series

15- Pin D-Shell

GND

Allen-Bradley

T45 or T47

25 Pin D-Shell

Figure 8.6

RS-232 Cable Wiring to an Allen-Bradley T35

GND

9/Series

15- Pin D-Shell

SH 1

SD 2

Allen-Bradley

T35

9 Pin D-Shell

11869-I

8-5

Section 8

Communication Interface

8.4 RS-422 Interface

Figure 8.7

RS-232 Cable Wiring to an Allen-Bradley T50

9/Series

15- Pin D-Shell

SH 1

GND

Allen-Bradley

T50

9 Pin D-Shell

RS-422 is used for serial communication between the control and peripherals. RS-422 is also known as complimentary serial I/O. It is available only on port B which is located on the motherboard (for the

9/260 and 9/290 control) and on the processor board for the 9/230 control.

This signal is able to resist noise even over long distances. When you use

RS-422, the interface cable can be as long as 4000 cable feet (1220 meters). Use shielded, twisted-pair cables to resist noise.

8-6

Section 8

Communication Interface

8.5 RS-422 Signal Description

RS-422 sends and receives the signals in Table 8.C to and from the control.

The control is a data communication equipment (DCE) device.

Pin No.

Signal

Code

SD A

RD A

RS A

CS A

DM A

TR A

SD B

RD B

Table 8.C

RS-422 Connector Pin Assignment

Signal Name

RS B

CS B

DM B

TR B

Shield

Send data A

Receive data A

Request to send A

Clear to send A

Data set ready A

Signal Ground

Data term ready A

Send Data B

Receive data B

Request to send B

Clear to send B

Data set ready B

Data terminal ready B

Signal

Type

Description

Shield

Input Data is sent from the peripheral to the control.

Output Data is transmitted from a control to a peripheral.

Input The peripheral turns “ON”when requesting to send data to the control.

Output The control turns “ON”when the control is ready to transmit or receive data.

Output The peripheral turns “ON”when it is ready to transmit or receive data.

Ground for each signal line.

Input Data is transmitted from a peripheral to the control.

Input Data is sent from the peripheral to the control.

Output The peripheral turns “ON”when requesting to send data to the control.

Input The control turns “ON”when data transmission from peripheral to the control is permitted.

Output The control turns “ON”when the control is ready to transmit or receive data.

Output The peripheral turns “ON”when it is ready to transmit or receive data.

Input Data is transmitted from a peripheral to the control.

Table 8.D indicates the signal conditions corresponding to control signal

ON/OFF status.

Table 8.D

Control Signal Status

Signal Conditions

Control Signal

Logic

Signal Level

Mark Space

OFF

A < B A > B

8-7

Section 8

Communication Interface

8.6 Connection of Peripherals

Figure 8.8 shows the cable connection for the RS-422 interface that uses a hardware handshake.

Figure 8.8

RS-422 Cable Wiring with Hardware Handshake

Receiver

Driver

CNC

Hardware

Handshake

SD A

SD B

RD A

RD B

RS A

RS B

CS A

CS B

DM A

DM B

TR A

TR B

Signal

Common

Peripheral

SD A

SD B

RD A

RD B

RS A

RS B

CS A

CS B

DM A

DM B

TR A

TR B

Signal

Common

11352-I

Figure 8.9 shows the cable connection for the RS-422 interface without a hardware handshake.

Figure 8.9

RS-422 Cable Wiring without Hardware Handshake

Driver

Receiver

No Hardware

Handshake

CNC

SD A

SD B

RD A

RD B

RS A

RS B

CS A

CS B

DM A

DM B

TR A

TR B

Signal

Common

Peripheral

SD A

SD B

RD A

RD B

RS A

RS B

CS A

CS B

DM A

DM B

TR A

TR B

Signal

Common

11353-I

8-8

Section 8

Communication Interface

8.7 Protocol

8.7.1 RS-491 Level 1 Protocol

RS-491 Level I and Level II protocol are used for data communication between the control and peripherals. They provide a structured process of communication through the RS-232 or RS-422 interface ports.

Level I protocol is used for data communication between the control and a simple peripheral, a printer for example. When communication between the control and a simple peripheral has been established, the following three signals are used to control data transmission start/stop:

RS (request to send)

CS (clear to send)

DM (data set ready) Port B only

Data Receiving Sequence

When the control receives data from a peripheral, CS and RS signals are used to control the communication, see Figure 8.10. The peripheral confirms that the control is ready for data reception by the CS (clear to send) signal before it transmits the data.

Figure 8.10

Data Reception Sequence

Signal flow

Peripheral

CNC

1 2 3 4 5 6 7 8 9

11354-I

The control receives data from the peripheral in the following sequence.

The numbers correspond to those in Figure 8.10.

8-9

Section 8

Communication Interface

8-10

1 Port B only

1 2 3

The peripheral (DTE) turns on the RS signal to notify the control

(DCE) that there is data to be transmitted.

The control turns the CS signal ON to notify the peripheral that it is ready for data reception.

The peripheral begins transmitting data to the control.

If the control buffer cannot accept the data, the control turns the CS signal OFF to notify the peripheral to stop data transmission.

The peripheral, upon recognizing that the CS signal has been turned

OFF, stops data transmission within two characters.

The control turns the CS signal ON when it can receive data again.

The peripheral, upon recognizing that the CS signal has been turned

ON, begins data transmission.

After transmitting all data to the control, the peripheral turns the RS signal OFF to notify the control that all data has been transmitted.

The control turns the CS signal OFF

Data Transmitting Sequence

When the control transmits data to a peripheral, CS and RS signals are used to control the communication, see Figure 8.11. The control confirms that the peripheral is ready for data reception by the TR signal before it transmits the data.

Figure 8.11

Data Transmitting Sequence

Signal flow

Peripheral

Pin 5

CNC

Pin 4

Pin 6

Pin 3

4 5 6 7 8 9

11355-I

Section 8

Communication Interface

8.7.2 RS-491 Level II Protocol

The control transmits data to the peripheral in the following sequence. The numbers correspond to those in Figure 8.11.

The control turns the CS and the DM signals ON to notify the peripheral that there is data to be transmitted.

The peripheral turns the RS signal ON to notify the control that it is ready to receive data.

The control begins data transmission to the peripheral.

If the peripheral buffer cannot accept the data, the peripheral turns the

RS signal OFF to notify the control to stop data transmission.

The control, upon recognizing the RS signal has been turned OFF, stops transmitting data within two characters.

The peripheral turns the RS signal ON when it can receive data again.

The control, upon recognizing the RS signal has been turned ON, begins data transmission .

After transmitting all data to the peripheral, the control turns the CS and DM signals OFF to notify the peripheral that all data has been transmitted.

The peripheral turns the RS signal OFF.

Level II protocol is used for the communication between the control and a peripheral (tape reader/puncher) or a computer. Level II protocol differs from Level I protocol in that data transmission/reception is controlled by the control codes ( DC1, DC2, DC3, DC4, EOT, DLE ). The functions of these control codes are shown in Table 8.E.

Devices where the protocol is labeled LEVEL 2* implement a slightly modified version of the protocol. This serves to better match the specific

Level 2 device. The device type GENERIC LEVEL 2 implements the full protocol as it is described here.

The 9/Series controls send and receive program data using the data format appropriated for punched tape. This means all ASCII characters have even parity in the eight bit position. EIA characters have their own parity format which is recognized by the control. Characters which do not have the proper parity are not stored in the control. In addition, lower case

ASCII data sent to the control is converted into upper case when stored.

RS-491 Level 2 control characters do not have eighth bit parity. The control characters are used for device control only.

8-11

Section 8

Communication Interface

Binary data such as AMP and PAL images do not have eighth bit parity bits attached to them. Because binary files such as AMP and PAL can contain data which correspond to RS-491 Level 2 control characters, these files cannot be output to Level 2 devices. The control characters could halt or otherwise affect the file transfer. The Level 2 tape reader interface on the 9/Series is capable of reading binary files.

A man readable file name is punched to the tape by the 9/Series at the beginning of all files. This is done for all types of devices except the

Generic Level 2 device which doesn’t output the man-readable header.

Care should be taken when transmitting files to the control which contain man-readable headers. Sometimes this part of the tape can contain Level 2 control characters which may halt or other wise affect the file transfer.

Table 8.E

Control Code Functions

Control Code

DC1

Function

Start Xmission

DC2

DC3

DC4

EOT

DLE

Restart

Stop Xmission

Ignore

End of Transmission

Data Link Escape

Description

This code is used to begin data transmission from a peripheral to the control. It is also used to restart data transmission which had been interrupted by the DC3 code output from the peripheral or the control.

This code is used to begin data transmission from the control to a peripheral.

This code is used to stop data transmission from the transmitting device. It is output from the data receiving device.

The device receiving this code ignores any received data until it receives the DC2 code after the data has been transmitted from the control to the peripheral.

This code is used to notify the completion of data transmission.

This code is used to abort the transmission.

Important: For the EOT code, M02 or M30 is usually used.

8-12

Section 8

Communication Interface

Data Receiving Sequence

Figure 8.12 shows the data receiving sequence of the control.

Figure 8.12

Data Receiving Sequence

Control codes from the control

1 2 3 4 5 6 7 8

DC1 DC1 DC1 DC3 DC1 DC3

Leader Program Data

Program Data MO2

Data transmission from a peripheral device (tape reader, etc)

11356-I

The control transmits the DC1 code in three-second intervals until the peripheral begins data transmission.

Upon reception of the DC1 code, the peripheral begins data transmission.

The control transmits the DC3 code when its buffer cannot accept the received data.

Upon reception of the DC3 code, the peripheral stops data transmission within two characters.

The control sends the DC1 code when it is ready to receive data again.

The peripheral, upon reception of the DC1 code, begins data transmission again.

The control stops data reception when it recognizes the M02 or M30 code and outputs the DC3 code.

The peripheral stops data transmission when it receives the DC3 code.

8-13

Section 8

Communication Interface

Data Transmitting Sequence

Figure 8.13 shows the data transmission sequence of the control.

Figure 8.13

Data Transmission Sequence

Data transmission from the control

1 2

3 4 5

7 8

DC2 DC2 DC2 Leader Program data Program data MO2EOT DC4

DC1

DC3

DC1 DC3

Control codes from a peripheral device (tape reader, etc)

11357-I

The control transmits the DC2 code in three--second intervals until it receives the DC1 code from the peripheral.

Upon reception of the DC1 code, the control begins data transmission.

The peripheral transmits the DC3 code when its buffer cannot accept the received data.

Upon reception of the DC3 code, the control stops data transmission within two characters.

The peripheral transmits the DC1 code when it is ready to receive data again.

The control, upon reception of the DC1 code, begins data transmission again.

The control transmits the DC4 code after it transmits the M02 or M30 code.

The peripheral transmits the DC3 code when it receives the DC4 code to end data input.

8-14

8.8 Peripherals

Section 8

Communication Interface

The following table lists the peripherals that can be connected to the

9/Series control. Communication protocol can be altered to accept peripherals other than those listed below.

Table 8.F

Peripheral List

Device

Allen-Bradley 1770-SB

Ricoh PTR240R

Facit N4000

Decitek AB 8000-XPDR

DSI SP75

Facit 4070

Facit N4000

Epson LX-810 (USA)

Epson SP-500 (JAPAN)

User Punch

User Reader

User Printer

Teach Pendant

PAL-RS232 Comm

ODS

Generic Level_2

Greco Minifile

Intelligent Device

Cartridge

Reader

Punch

Printer

User Defined

Device Type

ODS Terminal

Computer using only level 2 protocol

Intelligent Storage

Personal Computer using

Communication Software

Table 8.F lists the recommended configuration and connection of the peripherals.

8-15

Section 8

Communication Interface

1. Allen-Bradley 1770-SB Data Cartridge Recorder Connection

The recommended configuration of the Allen-Bradley 1770-SB data cartridge recorder is shown below:

Configuration

Parameter

DEVICE:

PORT TYPE:

BAUD RATE:

PROTOCOL:

PARITY:

STOP BITS:

DATA LENGTH:

TIMEOUT:

OUTPUT CODE

Setting

ALLEN--BRADLEY 1770--SB

RS232C

1200

LEVEL_2*

NONE

15 SEC

N/A

The Allen-Bradley 1770-SB data cartridge recorder is connected to the control using a standard RS-232 with hardware handshake interface cable

(see Figure 8.2).

2. Ricoh PTR240R Tape Reader Connection

The recommended configuration of the Ricoh PTR240R tape reader is shown below:

Configuration

Parameter

DEVICE:

PORT TYPE:

BAUD RATE:

PROTOCOL:

PARITY:

STOP BITS:

DATA LENGTH:

TIMEOUT:

OUTPUT CODE

Setting

RICOH PTR240R

RS232C

2400

LEVEL_2*

EVEN

15 SEC

N/A

The switch assembly on the rear of the tape reader must be set to the 2400 baud rate and to the self test mode as shown below:

______________________________

| Dip off on

1[* -] 2400/4800

| Switch

2[* -] Self Test |

|______________________________|

8-16

Section 8

Communication Interface

3. Facit N4000 Tape Reader/Punch Connection

The recommended configuration of the Facit N4000 Tape Reader/Punch is shown below:

Configuration Parameter

DEVICE:

PORT TYPE:

BAUD RATE:

PROTOCOL:

PARITY:

STOP BITS:

DATA LENGTH:

TIMEOUT:

OUTPUT CODE

Setting

FACIT N4000

RS232C

2400

LEVEL_2*

EVEN

15 SEC

ASCII

The Facit N4000 Tape Reader/Punch is connected to the control using a standard RS-232 with hardware handshake interface cable (see Figure 8.2).

4. Decitek AB 8000- XPDR Connection

The recommended configuration of the Decitek AB 8000-XPDR tape reader is shown below:

Configuration

Parameter

DEVICE:

PORT TYPE:

BAUD RATE:

PROTOCOL:

PARITY:

STOP BITS:

DATA LENGTH:

TIMEOUT:

OUTPUT CODE

Setting

DECITEK AB 8000-XPDR

RS232C

2400

LEVEL_2*

EVEN

15 SEC

N/A

8-17

Section 8

Communication Interface

The switch assemblies on the side and rear of the tape reader must be set as shown below:

SIDE VIEW

____________________

| SW3

12345678

****||||

||||****

SW2

- *

* -

- *

* -

REAR VIEW

___________________

* -

OFF

SW1

* -

- *

* -

11359-I

* Denotes switch lever location

The Decitek AB 8000-XPDR tape reader is connected to the control using a standard RS-232 with hardware handshake interface cable (see

Figure 8.2).

5. DSI SP75 Connection

The recommended configuration of the DSI SP75 tape punch is shown below:

Configuration

Parameter

DEVICE:

PORT TYPE:

BAUD RATE:

PROTOCOL:

PARITY:

STOP BITS:

DATA LENGTH:

TIMEOUT:

OUTPUT CODE

Setting

DSI SP75

RS232C

600

RAW

EVEN

15 SEC

ASCII

The DSI SP75 tape punch is connected to the control using a standard

RS-232 with hardware handshake interface cable (see Figure 8.2).

8-18

8.9 Remote I/O Modules

Section 8

Communication Interface

6. Epson LX-810 Printer Connection

The recommended configuration of the Epson LX-810 printer is shown below:

Configuration

Parameter

DEVICE:

PORT TYPE:

BAUD RATE:

PROTOCOL:

PARITY:

STOP BITS:

DATA LENGTH:

TIMEOUT:

OUTPUT CODE

Setting

Epson LX--810

RS232C

2400

LEVEL_2*

EVEN

15 SEC

N/A

The remote I/O modules allow the 9/Series control to appear as a remote

I/O rack to the I/O scanner of a PLC processor. There are two separate remote I/O modules, one for 9/260 controls, and one for 9/290 controls.

9/230 and 9/440 controls, equipped with remote I/O, have the remote I/O circuitry and connections mounted directly on the processor or wiring board respectively. Though the remote I/O link performs the same functions and is configured in the same manner for all the 9/Series controls, the installation and appearance is significantly different between processors.

Remote I/O is a feature of Allen-Bradley’s 1771 I/O and is beyond the scope of any 9/Series documentation. For details on the operation, configuration, and capabilities of a remote I/O device on the 1771 I/O network refer to documentation that came with your 1771 I/O system.

This document only discusses what is necessary to install and troubleshoot the 9/Series remote I/O modules.

Implementing Remote I/O on the 9/Series control

Important: PAL must set the $RMON flag TRUE, during the first foreground execution, to enable the remote I/O connection. Also several remote I/O operating parameters must be setup in AMP to configure the remote I/O communications for your specific network. Refer to your

9/Series AMP and PAL reference manuals for details.

When remote I/O information is sent to the control, it is transmitted as values from eight output words in the PLC processors output image table

8-19

Section 8

Communication Interface

8.9.1 9/290 Remote I/O Module

into the 9/Series remote I/O connection. These values are then stored on the control where they are assigned to the remote I/O input PAL flags

($RMI1-$RMI8).

When sending data from the control to a PLC processor, PAL must first assign values to the remote output flags ($RMO1-$RMO8). The control passes these output flag values to the PLC processor where they are loaded into eight input words in the PLC input image table.

Figure 8.14 shows the remote I/O module as it comes mounted to the component enclosure for 9/290 controls.

Figure 8.14

Remote I/O Module Mounted to the Component Enclosure

Remote I/O Module

(9/290 only)

Mounting the Remote I/O Module to the Component Enclosure

If you ordered the remote I/O module with your 9/290 control, it comes already assembled and mounted to the component enclosure. If you have ordered the remote I/O module separately, use this procedure to mount the remote I/O module to the component enclosure:

Remove the parts from the bag

8-20

Section 8

Communication Interface

Lay the metal support on a flat surface so that the brackets stand out.

Align the plastic track with the full set of brackets and slide it into the metal support. Align metal brace and assemble as shown:

Repeat step 2 with the second plastic track. The card guide assembly is complete. Slide the remote I/O module into the assembly.

Attach the assembly to the chassis as shown:

19207

Important: Refer to the information provided with your PLC processor or scanner for additional information on connecting the remote I/O module to your PLC processor or PLC scanner. Only port A may be used for remote

I/O connection to this module. Port B is not used.

9/290 Remote I/O LEDs

The 9/290 remote I/O module uses only one of its two status indicators to help you troubleshoot remote I/O communications. The second status indicator is not used. Figure 8.15 shows the location of these status indicators. Table 8.G lists these status indicators.

8-21

Section 8

Communication Interface

Figure 8.15

Location of Status Indicators in the Remote I/O Port

8-22

Table 8.G

Remote I/O Module Status Indicators

Indicator

(B is not used)

Color/State Description

green/steady active link red/steady hardware fault at processor

Probable Cause

normal operation hardware error red/blinking off communication break remote I/O port is offline

AMP is not set correctly port is not being used

Recommended Action

none required

Recycle power. Replace the processor. Refer to your processor documentation.

reset AMP parameters to communicate with scanner program bring remote I/O port on line

Section 8

Communication Interface

8.9.2 9/260 Remote I/O Module

Figure 8.16 shows the remote I/O module as it comes mounted in the component enclosure for 9/260 controls.

Figure 8.16

Remote I/O Module Mounted in the Component Enclosure

CPU

Module

Remote I/O

Communication Module

19441

Enclosure

Mounting the Remote I/O Module in the Component Enclosure

If you ordered the remote I/O module with your 9/260 control, it comes already mounted in the component enclosure. If you have ordered the remote I/O module separately, use this procedure to mount the remote I/O module in the component enclosure.

Important: You can not use the remote I/O module in a 9/260 system that contains either a 9/Series Data Highway Plus communication module or a

9/Series MMS/Ethernet communication module. A 9/260 system can contain only one Remote I/O, DH+, or MMS/Ethernet module.

ATTENTION: To prevent damage to the module, wear an ESD wristband while you unpack and install the module. Connect the wristband to the ground screw on the control’s component enclosure.

8-23

Section 8

Communication Interface

To install the remote I/O module, follow this procedure:

Turn off power to the control by pressing the <OFF> pushbutton.

OFF

Unpack the module from the box. Make sure you are wearing an

ESD wristband.

Install the module as shown in Figure 8.17.

Figure 8.17

Installing the Module

Component

Enclosure

RIO Port

LED

Can be installed in the first slot or second

Clear

Shield

Blue

Important:

Only port A is available on this module.

Status LEDs

RS232/422 port (Not Used)

Remote I/O

Communication Module

19439

8-24

Section 8

Communication Interface

9/260 Remote I/O LEDs

Assuming you have: made all necessary remote I/O communication connections on your

1771 I/O network configured your module for the network in AMP written PAL to set $RMON true and to handle input and output words you are ready to start receiving and transmitting remote I/O information.

As the remote I/O module responds to commands, you should see this LED pattern:

Figure 8.18

LED Pattern You See When You Send a Command

LED for port B is not used.

solid green - port is configured and connected to network blinking red - port is configured, but not connected to the network

FLT1

FLT2

ACT solid green - module is actively linked to

9/Series CPU

8-25

Section 8

Communication Interface

Use this table if you see a different LED pattern than shown above.

Indicator

(B is not used)

Color/State Description

green/steady active link red/steady hardware fault at processor

ACT

FLT1

FLT1 red/blinking communication break off off remote I/O port is offline green/steady active link to 9/Series

CPU remote I/O module is not communicating with

9/Series control on major hardware fault

Probable Cause

normal operation hardware error

AMP is not set correctly port is not being used normal operation remote I/O module is offline device has failed

Recommended Action

none required cycle power. Replace the processor.

Refer to your processor documentation.

reset AMP parameters to communicate with scanner program bring remote I/O port on line none required

AMP or PAL is not properly configured or your remote I/O network is not configured to communicate with the module.

if LED remains on after cycling power, contact your Allen-Bradley sales representative

8-26

8.9.3 9/230 Remote I/O

Connection

Section 8

Communication Interface

On 9/230 controls the remote I/O circuitry and plug are integral parts of the main board. No external module exists. Figure 8.19 shows the remote I/O connector and LED mounted on the 9/230 mother board.

Wire connections for the remote I/O communications are made through the

TB4 NODE ADAPT connector. Connect the wires for remote I/O as shown in the following figure. Refer to your 1771 I/O documentation for details on making remote I/O connections.

Figure 8.19

Remote I/O Module Mounted in the Component Enclosure

DS4 NA COMM ACTIVE LED for Remote I/O

Clear

Shield

Blue

TB4

NODE

ADAPT

TB1

TB2 TB3

J3 J2 J1

INPUT

115/230V

8A/5.5A

47 - 63 Hz

The analog 9/230 enclosure

9/230 Remote I/O LED

Assuming you have: made all necessary remote I/O communication connections on your

8-27

Section 8

Communication Interface

8.9.4 9/440 Remote I/O

Connection

You are ready to start receiving and transmitting remote I/O information.

As the remote I/O module responds to commands, you should see this LED pattern:

LED

DS4

NA COMM

Status

Description

Active Link to PLC. This is the normal state when the

RIO link is active.

FLASHING The remote I/O link is active but the PLC is currently in program mode.

OFF Remote I/O plug is offline. The port is not being used, not configured in AMP correctly, not turned on with

$RMON, or not attached to a 1771 device.

The remote I/O circuitry and connector are integral parts of the wiring board in the 9/440 system module. Figure 5A.11 shows the remote I/O connector mounted on the 9/440 wiring board.

Wire connections for the remote I/O communications are made through the

TB4 NODE ADAPT connector. Connect the wires for remote I/O as shown in the following figure. Refer to your 1771 I/O documentation for details on making remote I/O connections.

Figure 8.20

Remote I/O Connector in System Module

9/440 System Module

Remote I/O

Plug

TB4

Open Cover

8-28

Section 8

Communication Interface

CNC Processor Board

Serial

Port A

Front of

System Module

R--I/O

LED

Video

8.10 MMS Ethernet

Communications

9/440 Remote I/O LED

Assuming you have: made all necessary remote I/O communication connections on your

You are ready to start receiving and transmitting remote I/O information.

An LED is provided on the 9/440 CNC processor board and is visible from the bottom of the system module. As remote I/O responds to commands, you should see this LED pattern:

LED

Green

R- I/O LED

Status Description

ON Active Link to PLC. This is the normal state when the

RIO link is active.

FLASHING The remote I/O link is active but the PLC is currently in program mode.

OFF Remote I/O link is offline. The port is not being used, not configured in AMP correctly, not turned on with

$RMON, or not attached to a 1771 device.

The 9/260 and 9/290 CNCs have an MMS Etherent communications module available that provide MMS Ethernet services. With this module, the software is pre--installed with a set of default communication settings

(modifications to these defaults is performed with Allen-Bradley Station

Manager software).

A wide range of services are supported that allow you access to PAL and control variables, part program management, CNC status, etc... Details on the MMS Ethernet communications module are provided in a separate

9/Series MMS/Ethernet Communication Module Users Manual (Catalog number 8520-ENETM). Refer to this publication for further details.

8-29

Section 8

Communication Interface

8.11 DH+ Communications

The 9/260 and 9/290 CNCs have a DH+ (Data Highway Plus) communications module available that provide DH+ communications.

With this module, the 9/Series can communicate to pass/receive data over

DH+ with other Allen--Bradley DH+ compatible devices.

A wide range of services are supported that allow you access to PAL and part program variables, part program management, CNC status, etc...

Details on the DH+ communications module are provided in a separate

9/Series Data Highway Plus Communication Module Users Manual

(Catalog number 8520-DHM). Refer to this publication for further details.

END OF SECTION

8-30

Publication 8520-6.2.8 -- August 1998

I--2

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.8 -- August 1998

PN176441

9/Series Hardware

TAB 9

Operator Interface

852061--RM009A--EN--P -- November 2000 PN--176959

Operator Interface

Section

9A.0

Section Overview

9A.1

Operator Panel Overview

This section covers the integration of the components that make up the

Operator Interface for the 9/Series CNCs. A section is devoted to each of the following components:

Operator Panel (Display device and keyboard -- 3 versions)

- Mounted Monochrome operator panel

- Mounted Color panel (CRT and Flat panel)

- Removable operator panel

MTB Panel (selector switches and pushbuttons -- 3 versions)

- Standard MTB panel with fiber optic connection

- LED type Lamp panel with fiber optic connection

- LED type Lamp panel with Direct 24 V I/O connection

HPG (Hand pulse generator for manual jogging)

These components work together to enable the machine tool operator to interface with the control. Data entered through the operator panel keyboard, the MTB panel push buttons and switches, and the HPG handwheel is input to the control via the system I/O ring. How the specific components connect and interact with other modules of the control is explained in the following sections.

The operator can edit programs, view system data, perform machine functions, and many other tasks through the operator panel. The operator panel allows an interface to/from the control through:

5 softkeys and 2 page keys a keyboard with 51 alphanumeric, control, and shift keys the display (CRT or TFT)

The display terminal can be either a 9--inch monochrome CRT, a 12--inch color CRT, or the 10.4 inch color flat screen TFT. The system installer must set an AMP parameter to select between the color and monochrome displays (the removable operator panel is always a monochrome display, the flat panel is always configured as a color display). The color displays will use all white characters if the AMP parameter is set incorrectly to

“monochrome”. A monochrome display will not display any RED characters if AMP is configured for a color panel. This includes ALL of the system emergency messages.

9A-1

Section 9A

Operator Interface

The monochrome and the color operator panels are powered by the operator panel power supply. It supplies:

+12V dc power to the monochrome or color flat panel displays

+12 V dc power to the MTB panel I/O module

+5V dc power to the keyboard I/O ring interface

+5V dc power to the HPGs

The operator panel power supply receives power directly from the controls main power supply.

The keyboard and softkeys on the operator panel are interfaced into the

9/Series I/O ring through the keyboard I/O interface. Fiber optic cables connect the optical receiver (black) and optical transmitter (red) on the operator panel keyboard I/O ring interface to the I/O ring. For more information on fiber optic cables and connectors refer to page 7B-1.

Figure 9A.1 shows the different operator panels.

9A-2

Figure 9A.1

Operator Panels

Section 9A

Operator Interface

9/SERIES

Monochrome Operator Panel

Removable Operator Panel Color Operator Panels

(CRT and Flat Panel)

9A-3

Section 9A

Operator Interface

9A.2

Mounted Operator Panel

Installation

The mounted operator panels are typically mounted directly in a cabinet and are fixed in their location. It is directly linked to the 9/Series fiber optic ring, and contains its own power supply. The video signal is connected directly through a cable from the main processor to the CRT.

Figure 9A.2 shows the connectors and terminal blocks of the monochrome operator panel.

Figure 9A.2

Monochrome Operator Panel Connectors and Terminal Blocks

Front

Operator

Panel

Optical in

OP04

Optical out

OP03

BT02

GND

12V

GND

To HPG

To MTB Panel

I/O Module

Rear

CN19M

9A-4

Section 9A

Operator Interface

Figure 9A.3 shows the connectors and terminal blocks of the CRT color operator panel.

Figure 9A.3

Color CRT Operator Panel Connectors and Terminal Blocks

CN19M

Back of Panel

Optical in

OP04

Optical out

OP03

9A-5

Section 9A

Operator Interface

Figure 9A.4 shows the connectors and terminal blocks of the color flat panel operator panel.

Figure 9A.4

Color Flat Panel Operator Panel Connectors and Terminal Blocks

Optical in

OP04

Optical out

OP03

Operator Panel Power Supply

BT02

HPG

GND

HPG

GND

HPG

GND

MTB

12V

GND

Video Connection

Fiber Optic Connection

9A.2.1

Mounted Operator Panel

Video Connector

Table 9A.A shows the mounted operator panel video signal connector

CN19M.

Table 9A.A

Operator Panel Video Signal Connection

Connector On

Operator Panel

CN19M

Connected To

Component

Motherboard/System Processor

Cable

Connector Number

Video C09

Remark

Video

Signal

Video connector CN19M is the connector that connects the video monitor with the motherboard (9/260 and 9/290) or processor board (9/230 and

9/440). Figure 9A.5 shows video connector CN19M.

9A-6

Section 9A

Operator Interface

9A.2.2

Mounted Operator Panel

Power Supply

Figure 9A.5 shows the pin assignments of video connector CN19M.

Figure 9A.5

Video Connector CN19M 15 Pin Male D-Shell Connector (has pins)

Pin Assignment

Pin No.

Signal Name Pin No.

Signal Name

GND (SHIELD)

RED (H)

GREEN (H)

BLUE (H)

CLOCK (H)

H-SYNC (H)

V-SYNC (H)

RED (L)

GREEN (L)

BLUE (L)

CLOCK (L)

H-SYNC (L)

V-SYNC (L)

The monochrome, color, and color flat panel operator panels use the operator panel power supply. It supplies power to the monochrome and color flat panel displays (+12 V dc), the keyboard I/O ring interface (+5 V dc), the HPGs, and the MTB panel I/O module (note the color CRT uses

115V from the main power supply). The operator panel power supply receives power from the main power supply.

Figure 9A.6 shows the operator panel power supply.

Figure 9A.6

Operator Panel Power Supply

BT02

GND

12V

GND

To HPG

To MTB panel

I/O module

9A-7

Section 9A

Operator Interface

Table 9A.B shows the input and output power connections for the operator panel power supply.

Table 9A.B

Operator Panel Power Supply Connection

Connector On

Operator Panel

BT02

AC-L1

AC-L2

CN1

CN2

+5V dc

GND

+5 V dc

GND

+5 V dc

GND

+12V dc

GND

Connected To

Component Connector

Main Power Supply BT04 AUX-H

AC-L

HPG (1)

Cabinet Chassis

Ground

BT23

HPG (2) BT23

HPG (3) BT23

MTB Panel

I/O Module

MTB

I/O

GND

+12V

GND

Keyboard I/O Ring

Interface

CN23

Monochrome and Flat Panel Circuit Board

+5V

GND

+5V

GND

+5V

Cable

Number

C03

C29

C28

Remark

Input

Earth

GND

Output

GND

Output

GND

Output

GND

Output

GND

+5V dc

+12V dc

Table 9A.C shows the output specifications of the operator panel power supply. For input specifications and fuse specifications refer to page 4D-5.

Outputs

Table 9A.C

Operator Panel Power Supply Output Specifications

Item Specifications

5 V dc (3 terminals) 0.4 A/channel

12 V dc (1 terminal) 1.5 A

5 V dc

12 V dc

Remark

For 3 HPGs

For MTB Panel I/O Module

For Keyboard I/O Module

For Monochrome and

Flat Panel

Protection Function Overcurrent protection

Connection Terminal Block

9A-8

Section 9A

Operator Interface

9A.2.3

Mounted Operator Panel

Fiber Optic Connection

Important: The color CRT operator panel has an additional internal power supply that is used to power the color CRT. The ac power supply cable, cable C03, provides ac power to the sub power supply terminal on the rear of the color operator panel as shown in Figure 9A.3. The ac power supply is jumpered internally to the color CRT power supply from operator panel power supply.

Fiber optic connection is made through the operator panel I/O interface card mounted on the back of the operator panel. Table 9A.F shows the connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the

I/O ring. Refer to page 7B-1 for additional information on fiber optic cables and connectors. Figure 9A.2, Figure 9A.3, and Figure 9A.4 shows the location of these connectors.

Table 9A.D

Operator Panel I/O Connectors

Connector

RED

BLACK

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output (OP03)

Input (OP04)

9A-9

Section 9A

Operator Interface

9A.2.4

Mounted Operator Panel

Node Address Setting

Each operator panel must have a unique node address on the I/O ring. The node address corresponds to a unique address assigned to each operator panel in the I/O assignment file. The node address is selected by cutting the jumpers located on the operator panel. Figure 9A.7 shows the location of the jumpers on the operator panel.

Figure 9A.7

Operator Panel Jumper Location

Front

Operator

Panel

JP1

JP2

Rear

BT02

GND

12V

GND

To HPG

To MTB panel

I/O module

The preceding figure shows the jumpers located on the keyboard I/O ring interface board of the the monochrome operator panel. This board is also used by the color and color flat panel operator panels. Locate this board by the fiber optic connections.

9A-10

Section 9A

Operator Interface

Set the node address by cutting the wire jumper(s) according to Table 9A.E

shown below.

Table 9A.E

Operator and Removable Operator Panel Node Address Setting

Node Address Jumper

Hexidecimal Binary JP1

00 00 Short

Open

Short

Open

JP2

Short

Open

The node address may be any number between 00 and 03. You may have a total of 4 interface assemblies on the I/O ring (if the removable operator panel interface is used a separate power supply is required if you use more than 2 assemblies). The same node address can be used for different types of modules, but may not be used more than once for a specific type of module.

9A.2.5 Flat Panel Horizontal

Adjustment

The flat screen operator panel has a set of dip switches used to adjust the screens horizontal centering. Screen centering on the flat panel must be adjusted for different connecting control types. Figure 9A.8 illustrates the location and use of these dip switches.

Figure 9A.8

Flat Operator Panel Horizontal Adjustment Dip Switches

HOR PHASE

7 56 4 23 1

For this control type: Sw

On Off On Off Off Off Off Off 9/230, 9/260, and

9/290 CNCs

9/440 CNCs

(factory default)

On On On On Off Off Off Off

Video Connection

Fiber Optic Connection

9A-11

Section 9A

Operator Interface

9A.2.6

Keyboard Interface

Jumper JP3

Jumper JP3 on the operator panel keyboard interface is used to determine if the keyboard interface module is attached to a monochrome or color operator panel (note these keyboard configurations are different). This jumper comes preset from the factory in the correct position for your operator panel. Adjustment of this jumper should only be made when replacing the operator panel keyboard interface module.

Set the color or monochrome operator panel jumper (JP3) to match the type of operator panel you have. The following table illustrates proper setting of JP3.

Jumper JP3 Setting

MOP

For this Operator Panel:

Color and Flat Panel Operator Panels

COP

MOP

JP3

Monochrome Operator Panel

COP

JP3

JP3 shown configured for color operator panel.

JP3

JP1

JP2

9A.2.7

Adjusting Monitor Intensity

Monitor intensity is controlled by adjusting the contrast on monochrome and color CRT systems. No intensity adjustments are available for the flat operator panels.

Monitor intensity adjustment is typically not required on the operator panels as they are adjusted to an acceptable level before shipping from the factory. In the event that you think you must alter the monitor intensity use the following procedure:

9A-12

Section 9A

Operator Interface

Color CRTs

Remove power from the operator panel.

Remove the plastic cover from the back of the operator panel. The cover is attached with three plastic snap pins at the bottom of the cover. Pull these pins until they snap free of the operator panel.

Using a small screw driver, adjust the contrast or sub contrast pot as shown below. Note these pots are labeled on the printed circuit board:

Monochrome CRTs

Use Sub--Contrast Pot found at far right of video connector

(Color CRT only)

Use Contrast Pot found behind video connector

(Monochrome CRT only)

Important: We do not recommend adjusting any of the “Brightness” pots located on either CRT types. The brightness controls are preset at the factory for optimum monitor performance and reliability.

Re--attach the plastic cover to the back of the operator panel.

Re--establish power to the operator panel.

Repeat steps 1 thru 5 until the desired monitor intensity is reached.

9A-13

Section 9A

Operator Interface

9A.3

Removable Operator Panel

Installation

Use the removable operator panel on controls installed in locations where operator/machine interface is not needed often and it is practical for one operator panel to be transported from control to control when necessary.

The 9/Series removable operator panel allows the connection and disconnection of the operator panel from the control while the control is running. This connection/disconnection takes place without any interruption to control operation and requires no reconfiguration of the control.

This functionality is made available through the installation of a separate operator panel interface assembly installed in the 9/Series I/O ring. This interface assembly allows the removable operator panel to be attached or detached from the 9/Series I/O ring without physically breaking the I/O ring. You must install an interface assembly in the 9/Series I/O ring wherever you intend to attach a removable operator panel.

All connections between the 9/Series controller and the removable operator panel are made through a single cable. This cable provides all necessary communications to the 9/Series control (I/O ring interface for the keyboard, video signal, and power).

9A-14

Section 9A

Operator Interface

9A.3.1

Installing the Removable

Operator Panel Interface

Assembly

The operator panel interface assembly is used to makes all connections between the 9/Series control and the removable operator panel. Install an interface assembly in the 9/Series fiber optic I/O ring at any location you intend to connect a removable operator panel.

Figure 9A.9

Placing Operator Panel Interface Assemblies

Operator panel interface assembly

Fiber optics to/from other

9/Series I/O devices

9A-15

Section 9A

Operator Interface

Assigning a Module Address

Each interface assembly must have a unique node address on the I/O ring.

The node address corresponds to a unique address assigned as independent operator panels in the I/O assignment file found in ODS (see your PAL reference manual). The node address is selected by cutting the jumpers located on the interface assembly(s). Figure 9A.10 shows the location of the jumpers on the interface module.

Important: You must remove the cover from the removable operator panel interface assembly to access the node address jumpers. Turn off power to the interface assembly before removing the cover. Make sure to follow proper ESD grounding procedures when working on any 9/Series equipment.

Figure 9A.10

Removable Operator Panel Interface Assembly JP1 and JP2

Jumper Locations

JP2

JP1

Jumpers

Fiber Optic

Connections

Remove cover

(2 screws each side)

Set the node address by cutting the wire jumper(s) according to

Table 9A.E.

The node address may be any number between 00 and 03. You may have a total of 4 interface assemblies in the 9/Series fiber optic I/O ring. The same node address can be used for other types of modules however, each removable operator panel interface assembly must have its own unique address.

9A-16

Section 9A

Operator Interface

Reinstall the cover on the interface assembly when you have finished setting your address jumpers.

Connecting the Interface Assembly to the Fiber Optic Ring

Fiber optic connection to the keyboard on the removable front panel is made through the interface assembly. Table 9A.F shows the connectors used to make the fiber optic connections to the I/O ring. Each interface assembly connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the

I/O ring. Refer to page 7B-1 for additional information on fiber optic cables and connectors.

Figure 9A.11

Removable Operator Panel Interface Module Fiber Optic Connections

JP2

JP1

Jumpers

Fiber Optic

Connections

Table 9A.F

Operator Panel I/O Connectors

Connector

RED

BLACK

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output

Input

You must connect both the input and output connectors of all devices on the I/O ring. You can not leave an open connector on any module.

9A-17

Section 9A

Operator Interface

Interface Assembly Video Connection CN19M

Table 9A.G shows the interface assembly video signal connector.

Table 9A.G

Interface Assembly Video Signal Connection

Connector On

Motherboard/System

Processor

15 pin D--shell

To Connector On

Removable Front Panel

Interface Assembly

CN19M

15 pin D--shell

Cable

Number

(page 7A-24)

C09

Remark

Video

Signal

Video connector CN19M is the connector that connects the removable operator panel interface module to the motherboard (9/260 and 9/290) or processor board (9/230).

Figure 9A.12 shows the pin assignments of the video connector CN19M.

Figure 9A.12

Video Connector CN19M 15 Pin Male D-shell Connector and Pin

Assignment

Pin No.

Signal Name Pin No.

Signal Name

GND (SHIELD)

GREEN (H)

H-SYNC (H)

V-SYNC (H)

GREEN (L)

H-SYNC (L)

V-SYNC (L)

9A-18

Section 9A

Operator Interface

Figure 9A.13

Removable Operator Panel Interface Module Video Connections

Interface Assembly

Video In CN19M

Connect Video Cable C09

9/230 Processor Board

Connect Video Cable C09

(connector J8)

Removable Operator Panel Interface Assembly Power Supply

Power for the removable operator panel is provided by the interface assembly power supply. The interface assembly also supplies power for

HPGs and an MTB panel I/O module. The interface assembly power supply receives power from the main power supply. Connect the ac-H and ac-L terminals on the BT02 terminal strip to the main 9/230 control power supply connector BT04 terminals AUX--H and AUX--L.

9A-19

Section 9A

Operator Interface

Figure 9A.6 shows the removable operator panel interface assembly power supply.

Figure 9A.14

Operator Panel Power Supply

Video In CN19M

T o M T B p a n e l

T o H P G

A C

Table 9A.H shows the input and output power connections for the interface assembly power supply.

Table 9A.H

Interface Assembly Power Supply Connection

Connector On

Interface Assembly

BT02 ac-L1 ac-L2

+5V dc

GND

+5 V dc

GND

+5 V dc

GND

+12V dc

GND

Connected To

Component Connector

Main Power Supply BT04 Aux-H

Aux-L

HPG (1)

Cabinet Chassis

Ground

BT23

HPG (2)

HPG (3)

MTB Panel

I/O Module

BT23

MTB

I/O

+5V

GND

+5V

GND

+5V

GND

+12V

GND

Cable

Number

C03

C29

C28

Remark

Input

Earth

GND

Output

GND

Output

GND

Output

GND

Output

GND

9A-20

Section 9A

Operator Interface

9A.3.2

Connecting/Disconnecting the Removable Operator

Panel

Table 9A.I shows the output specifications of the removable operator panel interface power supply. For input specifications and fuse specifications refer to page 4D-5.

Table 9A.I

Interface Assembly Power Supply Output Specifications

Outputs

Item Specifications

5 V dc (3 terminals) 0.4 A/channel

12 V dc (1 terminal) 1.5 A

5 V dc

12 V dc

Protection Function Overcurrent protection

Connection Terminal Block

Remark

For HPGs

For MTB Panel I/O Module

For Keyboard I/O Module

For Monochrome CRT

Your removable operator panel connects to the 9/Series control through the removable operator panel interface assembly you installed as discussed on page 9A-15. The connection between removable operator panel and interface assembly is made via a 10 ft (max length) cable. This cable is provided with your removable operator panel.

Attach the removable operator panel cable between the interface assembly connector CN5 and the 37--pin D--shell connector on the front of your removable operator panel. You can attach or detach the operator panel at any time. We do not recommend, however, disconnecting this panel while in the middle of editing online or Patch AMP or while editing a part program.

9A-21

Section 9A

Operator Interface

Removable Operator Panel

Connect Interface Assembly

(37---pin D---Shell has pins)

Interface Assembly

Video In CN19M

Connect Operator Panel

(37---pin D---Shell has sockets)

Removable Operator Panel Interface Cable

The removable operator panel interface assembly cable has a 37 pin D shell connector at both ends of the cable. The female end of the cable (has sockets) connects to the removable operator panel. The male end of the cable (has pins) connects to the removable operator panel interface assembly. The pin out connections for this cable are as follows:

9A-22

Section 9A

Operator Interface

Pin number:

Description:

Shld. Chassis Ground

Keyboard Data

Pin number:

Description:

Ground

Video Hi

Video Lo

H -- Sync Hi

H -- Sync Lo

V -- Sync Hi

V -- Sync Lo

Ground

12 Vdc

Ground

No Connection

9A.3.3

Multiple Removable

Operator Panel Assemblies

If your machine layout calls for more than one location to plug in your removable operator panel, read this section. Multiple operator panel locations typically require a separate removable operator panel interface assembly at each location. A maximum of four interface modules can exist in the 9/Series fiber optic I/O ring.

The interface assembly provides power to the CRT as well as a keyboard interface to the fiber optic ring.

Important: It is possible to place a mounted fixed location operator panel on the ring with a removable operator interface assembly at some other location. Call your Allen Bradley support group for details on installing this type of system.

For systems with two removable operator panel interface assemblies:

Wire the power supplies for both interface assemblies

Connect the KBI interface to the fiber optic ring for both assemblies

9A-23

Section 9A

Operator Interface

Connect the video signal cable to only one interface assembly.

Construct the cable shown in Figure 9A.15 to jumper the video signal to the second interface assembly.

ATTENTION: Use PAL to select which keyboard is the active keyboard ($KYB_SEL) in conjunction with some external device hardware. PAL should allow an operator to connect his keyboard, and lock out other keyboards from access to the I/O ring. Other keyboards can than be connected to the ring for monitoring but their keyboard inputs will be ignored. Failing to do this check will allow the connection of more than one functioning operator panel at one time which, in some applications, can be dangerous to equipment or personnel.

Use the following procedure to connect multiple removable operator panel interface assemblies.

Connect the video signal to both interface assemblies. This is accomplished by connecting the video signal from the processor to one interface assembly and jumping the video signal out of CN4 on the interface assembly to the video connection on the second interface assembly. The total video signal cable length must be less than 100 feet (including from processor to interface assembly, between interface assemblies, and to portable operator panel).

Figure 9A.15

Connecting Multiple Removable Operator Panel Interface Assemblies

Connect Video Cable C09 from 9/Series Processor

Construct this cable to connect video signal between two interface assemblies. We recommend using Belden 9503 for lengths less than 50 ft.. One end of cable will have a

37 pin D shell with sockets, the other end will have a 15 pin D shell with sockets.

Connect Second Interface

Assembly Video

(37 pin D Shell has pins)

Indicates twisted pairs

N.C.

Interface Assembly 1

Interface Assembly 2

9A-24

Section 9A

Operator Interface

Connect AC power from the main power supply to the interface assemblies. Daisy chain the power between the two assemblies. The standard 9/Series power supply can supply power for two interface assemblies. If your system requires more than two interface assemblies in the same ring you must supply your own external power to the interface assemblies. All interface assemblies in the I/O ring must be powered when the system is running.

To 9/Series Main

Power Supply

Connect the 9/Series Fiber optic ring. Other devices can be in the ring at any location but are not shown here for clarity.

9A-25

Section 9A

Operator Interface

9A.4

MTB Panels

There are three versions of the Pushbutton MTB panel available for use with the 9/Series controls.

Standard MTB panel -- fiber optic (MTB2)

MTB Panel with LED Lamps -- fiber optic (MTBL)

MTB with LED lamps-- direct inputs /outputs (MTB24)

The first two of these panels are identical except for the type of illumination in the push buttons. They both are a combination of machine tool builders (MTB) pushbutton panel and a fiber optic I/O module. This combination provides the push-button MTB panel with direct fiber optic communication to the control.

The third type of MTB panel does not have the fiber optic interface module, but provides connection from the panel using direct 24 V DC inputs and outputs. An external Fiber Optic interface device is required to provide an interface to the control. This panel uses LEDs for the

Pushbutton lamps. This version of the MTB panel is used where complex switching of the signals between several CNCs is required.

9A-26

Section 9A

Operator Interface

The push-button MTB panels are used to provide the user with manual control over various system functions. These system functions are selected using the various switches and push buttons on the push-button

MTB panel. The selected functions are then interfaced to the control via a fiber optic I/O module.

Important: A PAL module that provides the PAL logic necessary to decode the push-button MTB panel functions is available on Motion

Control Bulletin Board. Refer to the 9/Series CNC PAL Reference

Manual, publication 8520-4.3, for more information.

Figure 9A.16 shows a front view of all of the push-button MTB panels.

Figure 9A.16

Push-Button MTB panel

MODE SELECT

AUTO MDI MAN

CYCLE

START

SINGLE

BLOCK

CYCLE

STOP

JOG SELECT

INCR CONT

HAND HOME

AXIS

+4 --X

+Y TRVRS --Y

+Z --4 --Z

SPEED/MULTIPLY

LOW

MEDL

X10

MED

X100

MEDH

X1000

HIGH

X10000

FUNCTION

F1 F2

F3 F4

F5 F6

SPINDLE SPEED

OVERRIDE

SPINDLE

CCW CW

50 120

OFF

FEEDRATE

OVERRIDE

100

RAPID FEEDRATE

OVERRIDE

F1 25

ESTOP

RESET

150

50 100

OFF

19930

Only the three push-button MTB panels are covered in these sections. The system installer may develop custom MTB panels for specific applications.

Refer to the system installer’s literature for any information on custom

MTB panels.

If a custom MTB panel is to be used, the MTB I/O module can be purchased separately to interface a custom MTB panel with the system I/O ring. To use a custom panel with the I/O module, you must set JPR3 to the

Custom Panel position.

9A-27

Section 9A

Operator Interface

9A.4.1

MTB Panel Connectors and Pin Assignments

(fiber- optic versions)

To Main Power

Supply (BT04)

To CNC

Processor Board

(TB1)

PWR

COM

PWR

OFF

ESTOP

COM

RESET

Figure 9A.17 shows the terminal blocks and connectors used to connect both versions Fiber--Optic push-button MTB panels (incandescent and

LED lamps).

The MTB panel I/O module is interfaced with the system I/O ring using fiber optic cables that are connected to the optical receiver and transmitter on the I/O module. Refer to page 7B-1 for additional information on fiber optic cables and connectors.

The MTB I/O module interfaces the push-button MTB panel with the control. It provides 44 inputs and 18 outputs to the system I/O ring. These inputs and outputs provide communication between the push-button MTB panel and the control.

Figure 9A.17

Push-Button MTB Panel Terminal Block and Connectors

+12V DC

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

CN52

I/O ring fault indicator

BT20

Table 9A.J shows the terminal connector used to connect the push-button

MTB panel to the power supply and the CNC processssor.

Table 9A.J

Push-Button MTB Panel Terminal Connector BT-20

Connector On

Push-Button MTB Panel

BT-20

PWR ON

PWR COM

PWR OFF

E-STOP

E--STOP

COM

RESET

Connected To

Component

Power Supply

Motherboard/System Processor

Connector

BT04

BT01

COM

E-STOP

COM

RESET

Cable

Number

C01

C06

9A-28

Section 9A

Operator Interface

Table 9A.K shows additional connectors of the push-button MTB panel.

Table 9A.K

Push-Button MTB Panel Connectors

Connector On

Push-Button MTB Panel

+12V

GND

Input Interface Ribbon Cable

Output Interface Ribbon Cable

CN56F

Connected To

Component

Operator Panel

Power Supply

Standard MTB

Panel I/O Module

Motherboard/System Processor

Connector

BT03

CN51

CN52

CN16F

+12V

GND

Cable

Number

C28

C26

C27

C07

Remark

Input

Output

Port B

Input Interface Ribbon Cable

Input signals from the push-button MTB panel are sent through input interface ribbon cable to connector CN51 on the push-button MTB panel

I/O module. These signals are then sent to the motherboard via the fiber optic I/O ring. Table 9A.L shows the pin assignments and functions for input interface ribbon cable on the push-button MTB panel.

PAL expects the push-button MTB panel input signals, which are shown below, to be sent through the push-button MTB panel I/O module on the corresponding pin numbers. If the input signals differ from those listed in

Table 9A.L, the PAL I/O assignments file must be altered. Refer to the

9/Series CNC 9/230,9/260, and 9/290 PAL Reference Manual, publication

8520-4.3, for more information.

The default settings at power-up for the push-button MTB panel are:

Selection Default

Mode Select

Jog Select

Speed/Multiply

Spindle

MAN

CONT

OFF

Rapid Feedrate Override F1

Output Interface Ribbon Cable

Output signals from connector CN52 on the push-button MTB panel I/O module are sent to the push-button MTB panel via the output interface ribbon cable. Table 9A.M shows the pin assignments and functions for output interface ribbon cable on the push-button MTB panel. PAL outputs signals to the push-button MTB panel through the push-button MTB panel

I/O module on the corresponding pin numbers. If the output signals differ from those listed in Table 9A.M, the PAL I/O assignments file must be altered. Refer to the 9/Series CNC 9/230, 9/260, and 9/290 PAL Reference

Manual, publication 8520-4.3, for more information.

9A-29

Section 9A

Operator Interface

Pin No.

Function

F 1

-Y

-Z

-4

TRVRS

-X

Cycle Stop

Cycle Start

Single Block

F 2

F 3

F 4

Feedrate Override “a”

Feedrate Override “b”

Feedrate Override “c”

Feedrate Override “d”

Not Used

Power Off

Power Common

Power On

E-stop

E-stop Common

Table 9A.L

Push-Button MTB Panel Input Interface Ribbon Cable Pin Assignments

Gray Code Pin No.

Function Gray Code

N/A d

N/A a b c

PAL

Device

Name

CN51-17

CN51-19

CN51-21

CN51-23

CN51-25

CN51-27

CN51-29

CN51-1

CN51-3

CN51-5

CN51-7

CN51-9

CN51-11

CN51-13

CN51-15

CN51-31

CN51-33

CN51-35

CN51-37

CN51-39

CN51-41

CN51-43

N/A

MANUAL

INCR

CONT

HAND

HOME

X10

+12V

AUTO

MDI

X100

X1000

X10000

Rapid Override F1

Rapid Override 25

Spindle Speed Override “d”

Spindle Speed Override “c”

Spindle Speed Override “b”

Spindle Speed Override “a”

Rapid Override 50

Rapid Override 100

CCW

OFF

Reset

N/A a b c b a a b d a b c a b a b

PAL

Device

Name

N/A

CN51-34

CN51-32

CN51-30

CN51-28

CN51-40

CN51-38

CN51-36

CN51-45

CN51-47

CN51-42

CN51-44

CN51-46

CN51-48

CN51-49

CN51-50

N/A

9A-30

Section 9A

Operator Interface

Table 9A.M

Push-Button MTB Panel Output Interface Ribbon Cable Pin Assignments

Pin No.

Function Pin No.

Function

Not Used

X10

X100

X1000

X10000

Ground

Cycle Stop

Cycle Start

Single Block

-Z

-4

-X

-Y

Trvrs

Jog Retract

Ground

PAL

Device

Name

CN52-1

CN52-3

CN52-5

CN52-7

CN52-9

CN52-11

CN52-13

CN52-15

CN52-17

CN52-19

CN52-21

CN52-23

CN52-25

N/A

Ground

F 4

F 3

F 2

F 1

AUTO

MDI

MANUAL

Rapid Override F1

Rapid Override 25

Rapid Override 50

Rapid Override 100

CCW

OFF

INCR

CONT

HAND

HOME

Ground

PAL

Device

Name

N/A

CN52-18

CN52-20

CN52-22

CN52-24

CN52-26

N/A

9A-31

Section 9A

Operator Interface

Serial Interface Connector CN56F

The push-button MTB panel has an optional serial interface connector

(CN56F). This connector provides an external interface port for a peripheral’s RS 232 or RS 422 interface cable. It is interfaced with Port B

(connector J7) on the motherboard/system processor boards by cable C07.

Refer to page 7A-22 for additional information on cable C07.

Connector CN56F (8520-D25FS) is a 25 pin D-shell connector that is connected to one end of cable C07. This connector is then mounted on the left side of push-button MTB panel under the connector cover.

Figure 9A.18 shows the location and mounting instructions for connector

CN56F.

Figure 9A.18

Push-Button MTB Panel Optional Connector CN56F

Push-Button

MTB Panel

Spacer alignment ridge

Screw

D-sub connector

Toothed washer

Spacer

Spacer alignment ridge

11268-I

Important: The two screws with their corresponding spacers and the serial port cover are included with the push-button MTB panel.

9A-32

Section 9A

Operator Interface

9A.4.1.1

MTB I/O Module

Specifications

Power Supply Specifications

Table 9A.N lists the power requirements for the MTB I/O module.

Table 9A.N

MTB I/O Module Power Requirements

Item Specifications

Rated Input Voltage 12V dc

Power Source Voltage Range 11.5-13.2V dc

Power Consumption 1.3 A typical, 2.6 A maximum

Input Specifications

Table 9A.O lists the input specifications for the circuit that receives the signals from the pushbuttons and the selector switches on the push-button

MTB panel.

Item

Table 9A.O

MTB I/O Module Input Specifications

Specifications

Number of Input Points

Modal Group

Discrete I/O

Rotary Input

Interconnect Group

Unused

A-B MTB Panel

Custom MTB Panel

All MTB Panels

Operating Voltage

OFF

Allowable Voltage Drop

Input Impedance

Input Current at ON

Leakage Current at OFF

Response

11.5 to 13.2 V dc

0-2V dc

Less than .5V dc

2.25 K ohms

5mA

Less than 1mA

1-22 msec. Includes Digital Filter Time

Number of Common Points 6 (per 44 inputs)

Fuse 3A

Isolation

Connection

Non-Isolated type

60 Pin flat cable connector (CN51)

Remark

Total input signals from all switch groups

For External Device

With 12V dc Input

OFF ® ON, ON ® OFF

Internally connected to Power Supply

Protects 12V Power Supply

Max. Length 1m

9A-33

Section 9A

Operator Interface

Figure 9A.19 shows the input circuit diagram for the MTB I/O module.

Figure 9A.19

MTB I/O Module Input Circuit Diagram

Push-Button MTB Panel Push-Button MTB Panel I/O Module

Switch Common

CMOS

Input

Converted to

Optic Signal

Operator Panel

DC power supply

Common

3A AMP fuse

+12V

Common

Fiber optics

11269-I

Output Specifications

Table 9A.P lists the output specifications for the circuit that outputs the operation status to the push-button MTB panel.

Table 9A.P

MTB I/O Module Output Specifications

Item Specifications

A-B MTB Panel

Number of Output Points

Modal Group Outputs

Discrete Outputs

Output Type

Sink/Source

Output Voltage Range

Output Current at ON

9.3-13.2V dc

Less than 125mA

Output Voltage Drop at ON Less than 1 V DC

Number of Common Points 22

Custom MTB Panel

Isolation

Connection

Non-Isolated type

60 Pin Flat Cable Connector (CN52)

Remark

Non--I/O Outputs

I/O Outputs

Totem Pole Driver Output

Per Each Output

Internally Connected to Power

Supply

Max. Length 1m

9A-34

Section 9A

Operator Interface

Fiber optics

Figure 9A.20 shows the output circuit diagram for the MTB I/O module.

Figure 9A.20

MTB I/O Module Output Circuit Diagram

Push-Button MTB Panel I/O Module

Push-Button MTB Panel

Output

Common

Load

Converted from optical to electrical signal

+12V

Common

Operator Panel

DC power supply

11860-I

9A.4.1.2

MTB Panel I/O Module Fiber

Optic Connection

Table 9A.Q shows the connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring.

Table 9A.Q

MTB I/O Module Fiber Optic Connectors

Connector On

Motherboard

OP11 (RED)

OP12 (BLACK)

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output

Input

9A-35

Section 9A

Operator Interface

9A.4.1.3

MTB I/O Module Mode

Setting

If you are using a custom MTB panel you need to set a jumper so that the

I/O module can interface with the MTB panel. If you have an

Allen-Bradley MTB panel, you don’t need to set this jumper because it is preset. Set the jumper as shown:

+12V DC

GND

CN51

OP12

(in)

OP11

(out)

JPR1

JPR2

MTB Panel Type Pins to cover with the shorting post

Custom

Allen-Bradley

3 and 2

1 and 2

CN52

PANEL

JPR3

CUSTOM

3 2 1

A-B

9A.4.1.4

MTB I/O Module Node

Address Setting

Each push-button MTB panel must have a unique node address on the I/O ring. The node address corresponds to a unique address assigned to each push-button MTB panel I/O module in the I/O assignment file. The node address is selected by cutting the jumpers located on the push-button MTB panel I/O module. Figure 9A.21 shows the location of the jumpers.

Figure 9A.21

MTB I/O Module Jumper Positions

+12V DC

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

CN52

I/O ring fault indicator

9A-36

Section 9A

Operator Interface

9A.4.2

MTB Panel Connectors and Pin Assignments

(Direct I/O version)

Set the node address by cutting the wire jumper(s) on the push-button

MTB panel I/O module, according to Table 9A.R shown below.

Table 9A.R

MTB I/O Module Node Address Setting

Node Address

Hexidecimal Binary

00 00

JP1

Jumper

JP2

Short Short

Short

Open

Short

Open

The node address may be any number between 00 and 03. You may have a total of 4 MTB panels on the Fiber Optic I/O ring. The same node address can be used for different types of modules, but may not be used more than once for a specific type of module.

Figure 9A.22 shows the connectors used to connect the Direct I/O push-button MTB panel to your I/O system.

The Direct I/O version of the MTB Panel provides for 51 inputs to and 38 outputs from the I/O system. These inputs and outputs provide machine control functions for the operator to affect the Machine logic (PAL) program. A separate I/O ring device must be used to interface this panel to the 9/Series control.

9A-37

Section 9A

Operator Interface

Figure 9A.22

Direct I/O MTB Panel Connectors

Control ON lamp operation selection

Input conector CN1

Pin 1

Output conector CN2

Pin 1

1 2 3

CN 1

CN 2

Direct I/O MTB panel integration

1) Note the locations of pin number one (#1) of CN1 and CN2 .

Although the pin #1 locations are the same with respect to the connector keying, the connectors are oriented differently.

2) The P1 jumper is used to set the operation of the “control on” Lamp.

In the 1--2 position (MTBD) the lamp is controlled by the I/O system (on when 24V is applied to pin CN2--32). In the 2--3 position (MTBI) the lamp is on whenever 24V is applied to the panel.

Input Interface Connector

Input signals from the direct I/O MTB panel are sent through input connector CN 1 . These signals are available for use by the I/O system by pins supplied with this panel. Table 9A.S shows the pin assignments and functions for input interface ribbon cable on the push-button MTB panel.

9A-38

Section 9A

Operator Interface

Pin No.

Table 9A.S

Direct I/O MTB Panel Input connector ( CN 1 ) Pin Assignments

Function

MDI

MANUAL

INCR

CONT

HAND

HOME

X10

+24 V

AUTO

X100

X1000

X10000

Rapid Override F1

Rapid Override 25

Spindle Speed Override “d”

Spindle Speed Override “c”

Spindle Speed Override “b”

Spindle Speed Override “a”

Rapid Override 50

Rapid Override 100

CCW

OFF

Reset

Pin No.

Function

-X

-Y

--Z

-4

TRVRS

F 1

Cycle Stop

Cycle Start

Single Block

F 2

F 3

F 4

Feedrate Override “a”

Feedrate Override “b”

Feedrate Override “c”

Feedrate Override “d”

Not Used

Power Off

On / Off Pushbutton Common

Power On

E-stop

E-stop PB Common

Output Interface connector

Output signals from the I/O system are sent to the Lamps on the Direct

MTB panel via the output interface connector CN 2. Table 9A.T shows the pin assignments and functions for this connector.

9A-39

Section 9A

Operator Interface

Pin No.

Table 9A.T

Direct I/O MTB Panel Output connector ( CN 2 ) Pin Assignments

Function

F 4

F 3

F 2

F 1

Gnd

Ground

Gnd

CCW

OFF

INCR

CONT

HAND

HOME

GND

F 6

AUTO

MDI

MANUAL

Rapid override F1

Rapid Override 25

Rapid Override 50

Rapid Override 100

Pin No.

Function

-- Y

-- Z

-- 4

Trvrs

+ Y

+ Z

+ 4

-- X

Cycle Stop

Cycle Start

Single Block

+ X

X 1

X 10

X 100

X 1000

X 10 000

GND

Not Used

MANUAL

Contro On (if P1 is set to 1--2)

Not Used

9A-40

Section 9A

Operator Interface

9A.5

HPG (Hand Pulse Generator)

The Hand Pulse Generator (HPG) is a hand wheel used for manual operation of the the control’s axes. The HPGs are generally used to jog axes into position. The operator panel power supply provides power for three Hand Pulse Generators.

The HPG is composed of two parts, the HPG itself and the HPG interface board. The HPG interface board is used to interface the HPG with the fiber optic I/O ring. Fiber optic cables are connected to the optical receiver

(black) and transmitter (red) on the HPG interface board. The fiber optic cables and connectors are supplied by the system installer. For more information on fiber optics refer to page 7B-1.

Figure 9A.23 shows the HPG (Hand Pulse Generator).

Figure 9A.23

HPG (Hand Pulse Generator)

Front

Side

Bottom

Common terminal

I/O Ring Fault Indicator

DIP switch

11271-I

9A-41

Section 9A

Operator Interface

9A.5.1

HPG Connectors

Figure 9A.24 shows the connectors and terminal block used to make connections to the HPG interface board.

Figure 9A.24

HPG Interface Board Connectors and Terminal Block

Rear

+5V dc GND

OP14

(IN)

OP13

(OUT)

Optical connectors

From Operator Panel power supply

Table 9A.U shows the power supply connections to the HPG interface board.

HPG

Connector Terminal

BT23 +5V

GND

Table 9A.U

HPG Power Supply Connectors

Connected To

Operator Panel

Power Supply

Mating

Connector

BT03 5V dc

GND

Cable

Number

C28

Remark

Input

Output

Table 9A.V shows the connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to page 7B-1 for additional information on fiber optic cables and connectors.

9A-42

Section 9A

Operator Interface

Table 9A.V

HPG Fiber Optic Connectors

Connector On

Motherboard

OP13 (RED)

OP14 (BLACK)

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output

Input

9A.5.2

HPG Power Requirements

The HPGs require a +5V dc power supply. This is supplied from connector BT03 on the operator panel power supply. If the control uses more than three HPGs the system installer will have to provide an external power supply. Table 9A.W lists the power requirements for the HPG.

Table 9A.W

HPG Power Requirements

Item Specifications

Rated Input Voltage 5V dc

Power Source Voltage Range 4.75-5.25V dc

Power Consumption

Connection

Less than 0.4A

2-M3 Terminals

Distance from Power Supply Less than 5 meters

9A.5.3

HPG Node Address Setting

Each HPG must have a unique node address on the I/O ring. The node address corresponds to a unique address assigned to each HPG in the I/O assignment file. Select the node address using the switch assembly shown in Figure 9A.25. Table 9A.X lists the required switch assembly settings for each possible node address.

Figure 9A.25

HPG Interface Board Switch Assembly Location

Bottom of HPG

Back of HPG

11273-I

9A-43

Section 9A

Operator Interface

Table 9A.X

HPG Node Address Settings

Node Address

Hexadecimal Binary

00 000

001

010

011

100

101

110

111

Switch Assembly Position

OFF

The node address may be any number between 00 and N, with N being the total number of modules allowed for a specific type of module. The same node address may be used for different types of modules, but may not be used more than once for a specific type of module.

END OF SECTION

9A-44

Section

Integrating Your Teach Pendant

9B.0

Section Overview

9B.1

Connecting the Teach

Pendant

This section describes how to connect and program your teach pendant.

For information on how to program PAL to receive messages from the teach pendant, refer to your PAL reference manual.

You connect the teach pendant to port B on the control. Once you have connected the pendant, you have to select it as the active device with the

Device Setup Screen:

Press SYSTEM SUPORT.

(softkey level 1)

PRGRAM

MANAGE

OFFSET MACRO

PARAM

PRGRAM

CHECK

SYSTEM

SUPORT

FRONT

PANEL

ERROR

MESAGE

PASS-

WORD

SWITCH

LANG

Press the DEVICE SETUP softkey:

(softkey level 2)

PRGRAM

PARAM

AMP

DEVICE

SETUP

MONI-

TOR

TIME

PARTS

PTOM

SI/OEM

SYSTEM

TIMING

Cursor to the SERIAL PORT field. Press the right cursor key until

PORT B appears.

Cursor to the DEVICE field. Use the left or right cursor key to select

TEACH PENDANT. The teach pendant interface software is an option. If you have not purchased it, it does not appear as a device.

9B-1

Chapter 9B

Integrating Your Teach Pendant

9B.2

Using DF1 Protocol

The teach pendant needs to communicate in DF1 protocol. DF1 is a communication protocol developed by Allen-Bradley that is used by the

Data Highway networks. For more information on DF1 protocol, refer to the Data Highway/Data Highway Plus Protocol and Command Set Manual, publication 1770-6.5.16.

9B.3

Programming the Teach

Pendant to Send and

Receive Messages

Field

All requests and information are sent in DF1 packets. The packets are structured like this:

DLE STX CMD SD1 SD2 SD3 TNS TNS DATA DLE ETX BCC

Description

DLE STX

CMD

Start of Message

Command field. Determined by CNC or the teach pendant.

SD1, SD2, SD3 Special Data 1, 2, and 3. Use for command modifiers or to include data for

CMD.

TNS TNS Transaction Number chosen by DF1 driver.

PAL cannot access this data for packets its sends or receives.

Two packets sent or received in sequence cannot have the same number.

If the CNC detects duplicate numbers, it eliminates the packet(s) after the first instance of the number.

This field resets to 0 when you turn on power to the CNC.

Size in Bytes

You need to program your teach pendant to perform checks for duplicate numbers, and to fill this field to satisfy the CNC.

DATA

DLE ETX

BCC

Some commands will have a field that contains additional command data.

The same type of data that can be put into the special data fields, including commands, can be programmed here as well.

End of Message

Block Checksum

0 -- 14

Four types of commands can be sent or received with the teach pendant interface. Some are pre-defined by the teach interface software. Others are defined by the teach pendant and/or PAL programmer.

9B-2

Chapter 9B

Integrating Your Teach Pendant

These are the 4 command types used by the teach pendant interface:

Teach Pendant

PAL

This type of command is defined by the teach pendant programmer.

The PAL programmer should refer to the PAL reference manual for information on sending and receiving these types of commands.

Teach Pendant

Interface on CNC

Teach Pendant

Application

PAL

This type of command is pre-defined by the teach interface software.

Teach Pendant

Interface on CNC

· Teach Pendant Õ Unsolicited Application Command

G01

Application Software

This type of command is sent only by the

CNC. It includes watchdog and error messages.

G01

Application Software

Teach Pendant

Interface on CNC

Illegal Command Received from Teach Pendant

This type of command is sent only by the

CNC when the teach pendant attempts to send an illegal command.

Teach Pendant

Interface on CNC

9B-3

Chapter 9B

Integrating Your Teach Pendant

9B.4

Sending Commands to PAL

(CMD=60 hex)

PAL

To send a command that the PAL program can receive, you send a packet with 60 hex in the command (CMD) field. The teach pendant and PAL programmers define the values in the special data (SD) and DATA fields and map those values to a teach pendant function.

You can use the SD1, SD2, and SD3 fields for requests that require minimal data. The SD1 field is seen as an integer in PAL, but when it is received from PAL, it contains only the least significant byte of the PAL flag. SD2 and SD3 are stored as a single integer to PAL, with SD2 being the most significant byte and SD3 the least significant byte. You can send a maximum of 7 integers to PAL in the DATA field.

For example, let’s say that the programmer has defined the SD fields as:

Field

SD1

SD2

SD3

Definition

Request Type: Jog (1), Home (2), or Data (3)

Axis Number: 1 through 9

Motion Type: Absolute (1) or Incremental (2)

A keystroke combination defining Incremental Jog for Axis 6 would then send this command to PAL when pressed:

CMD SD1 SD2 SD3 TNS TNS DATA

DLE STX 60 01 06 02 05 02

[position]

DLE ETX BCC

When the CNC receives the message, the teach interface software acknowledges the message by sending a DLE ACK (DF1 protocol) to the pendant. The interface software checks PAL’s message input buffers to see if they are clear.

If they are clear, the interface software moves the message into the buffers and sets the PAL flag $TPRECV. PAL must decode the message to jog axis

6 incrementally according to the position information in the DATA field.

The PAL programmer decides if PAL responds with a message back to the teach pendant.

If the buffers are not clear, the interface software sets the Input Buffer

Overflow flag, $TPOFLOW, but does not send a message back to the teach pendant. PAL would have to notify the teach pendant of the overflow by initiating a transmission if the pendant needs to take action.

9B-4

Chapter 9B

Integrating Your Teach Pendant

9B.5

Sending Commands to the

Application Software

(CMD=61 hex)

G01

You use this type of command to take advantage of functions supplied in the teach interface software. For this type of command, SD1 and SD2 have specific definitions:

Field

SD1

SD2

Definition

Type of Request

Sub-process. For single process systems, you can use any value for this field. For multi-process systems, set at 1 for sub-process 1, and set at 2 for sub-process 2.

Sending to a Process

If you’re sending to a multi-process system, use the SD2 field to indicate the process. For example, if you send a request for the current block to process 2

CMD SD1 SD2 SD3 TNS TNS

DLE STX 61 01 02 00 03 00 DLE ETX BCC and the application software responds with this message packet:

CMD SD1 SD2 SD3 TNS TNS DATA

DLE STX 61 01 02 00 04 02 N00001G71 NULL DLE ETX BCC

ASCII

You don’t have to indicate the process for requests to display error messages or requests that end the display of error messages on the teach pendant.

Requesting the Current Block: SD1=01

To request the current block, send a message with CMD=61 (hex) and

SD1=01. For example:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 61 01 00 00 00 01 DLE ETX BCC the application software responds with this message packet:

CMD SD1 SD2 SD3 TNS TNS DATA

DLE STX 61 01 00 00 00 03 N00001G71 NULL DLE ETX BCC

ASCII

The current block information is an ASCII string of up to 128 characters ending with a NULL. If there is no block active, no active program, or no active MDI block, then the application software returns a NULL.

9B-5

Chapter 9B

Integrating Your Teach Pendant

Requesting the Active Program Name: SD1=02

To request the active program name, send a message with CMD=61 (hex) and SD1=02. For example:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 61 02 00 00 04 01 DLE ETX BCC the application software responds with:

CMD SD1 SD2 SD3 TNS TNS DATA

DLE STX 61 02 00 00 00 03 PROGRAM1 NULL DLE ETX BCC

ASCII

The active program is an ASCII string of 8 characters (maximum) ending with a NULL. If there is no active program, a NULL is returned.

Requesting the Block Number: SD1=03

To request the block number, or the last N word that was executed, send a message with CMD=61 (hex) and SD1=03. For example:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 61 03 00 00 01 02 DLE ETX BCC the application software responds with:

CMD SD1 SD2 SD3 TNS TNS DATA

DLE STX 61 03 00 00 02 01 N12345 NULL DLE ETX BCC

ASCII

The block number is an ASCII string of 5 characters (maximum, with leading zeros suppressed) ending with a NULL. This value is the same value that’s displayed on the operator panel’s CRT. If no value is displayed, the software returns a NULL.

Transmit Error Messages to the Teach Pendant: SD1=04

To have the system error messages transmitted to the pendant, send a message with CMD=61 (hex) and SD1=04. For example:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 61 04 00 00 00 06 DLE ETX BCC

The application software responds by sending error messages as they occur.

9B-6

Chapter 9B

Integrating Your Teach Pendant

Suspend Transmission of Error Messages to the Teach Pendant:

SD1=05

To stop sending error messages to the teach pendant, send a message with

CMD=61 (hex) and SD1=05. For example:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 61 05 00 00 00 06 DLE ETX BCC

The application software responds by ending the transmission of error messages to the teach pendant.

This request is useful if alternating error messages are being displayed on the CRT. The teach pendant is sent a message every time the message toggles on the CRT. This operation uses much of the serial band width.

This is the default at power turn-on.

9B.6

Receiving Unsolicited

Messages from the Control

(CMD=62 hex)

G01

The control can be commanded to send error messages. It always sends watchdog signals to the teach pendant. Since these messages are not individually requested by the teach pendant, they are called unsolicited messages. These messages send specific data in the DF1 command fields:

Field

CMD

SD1

Description for Unsolicited Messages

62 hex indicates an unsolicited message identifies the message as watchdog signal or error message

Receiving Watchdog Signals

The control sends this watchdog signal to the teach pendant according to the time interval specified in PAL flag $TPWDFQ:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 62 01 00 00 00 02 DLE ETX BCC

The teach pendant must respond to the message before the next one is sent or the watchdog timeout PAL flag is set to true. Here is a recommended response:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 62 01 00 00 00 01 DLE ETX BCC

9B-7

Chapter 9B

Integrating Your Teach Pendant

If the teach pendant does not respond, a watchdog timeout occurs and:

$TPTO is set an error message is displayed on the operator panel CRT

PAL can control the activities in response to the timeout system continues to send watchdog signals to try and reestablish communication. When the system receives a correct response packet, the control sets $TPTO to false.

A watchdog timeout can also occur if 3 ENQs are sent to the teach pendant in response to NAKs.

Receiving Error Messages

If requested by the teach pendant with a CMD 61 (hex) and SD1=04, when the control displays an error message, it also sends the message in ASCII to the teach pendant:

CMD SD1 SD2 SD3 TNS TNS DATA

DLE STX 62 02 00 00 00 04

PAL DOES NOT EXIST NULL

DLE ETX BCC

ASCII

The teach pendant does not have to respond to the message. It only has to send an ACK or a NAK.

9B.7

Receiving the Illegal

Request Message from the

CNC

(CMD=63 hex)

If you send an illegal request from the teach pendant to the control, the control sends a message back telling you about the illegal request. In the message from the control the SD2 and SD3 fields contain the information that identifies the illegal request:

This Field Contains this Information about the Illegal Request

SD2

SD3

CMD value received

SD1 value received

For example, if the teach pendant sends this illegal request:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 71 02 00 00 00 41 DLE ETX BCC

The teach interface software responds with:

CMD SD1 SD2 SD3 TNS TNS

DLE STX 63 00 71 02 00 21 DLE ETX BCC

To the teach interface software, an illegal request is any request that does not match those defined in this section.

END OF SECTION

9B-8

--1

--2

Publication 852062--RM009A--EN--P -- November 2000

Supercedes Publication 8520--6.2.9 -- August 1997

PN 176959

9/Series Hardware

TAB 10

I/O Interface

8520--6.2.10 -- February 1997

1746 I/O Adapter

PN--176041

10A.0

Section Overview

Section

10A

I/O Interface

This section covers the devices that provide an I/O interface with the control. I/O devices transmit inputs from external switches, sensors, etc. to the executing PAL program for processing. Outputs originating from the

PAL program are transmitted through the I/O devices to external lamps, relays, valves, etc.

The I/O devices are connected either directly to the control or through a fiber optic I/O ring that provides serial communication with the control.

The devices on the I/O ring convert electrical signals to optical signals for transmission through the I/O ring. These optical signals are converted back to electrical signals at the CPU board for use by the PAL program.

This entire process is reversed for outputs originating from the PAL program.

The following I/O devices can be installed on the I/O ring:

Push-Button MTB Panel I/O Module

Digital I/O

High--density I/O Module

Analog I/O

1746 I/O Ring Adapter

1771 I/O Ring Adapter

HPG

Operator Panel

1394 Digital Drive

In addition, the following I/O devices can be connected directly to the motherboard (it does not transmit through the fiber optic ring):

Fast I/O (9/260 and 9/290 only)

Remote I/O Port

The size of the I/O ring is limited in how many I/O devices it can support.

This limitation is imposed to make sure that the I/O data used by PAL is updated within the time period allotted for PAL foreground execution.

Refer to the 9/Series CNC 9/230,9/260, and 9/290 PAL Reference Manual, publication 8520-4.3, for more information.

10A-1

Section 10A

I/O Interface

10A-2

ATTENTION: When the control faults or loses power, all I/O devices remain in their last state. I/O devices do not automatically reset to an off state. It is the system installers responsibility to make sure that all I/O is in a safe state when a control shut down occurs. 1771 I/O devices have a dip switch on the backplane that determines the shutdown state for I/O in that 1771 I/O chassis when used with a PLC-5 processor. This dip switch does not have any effect when 1771 I/O devices are used with a 9/Series control.

Each I/O device requires a specific amount of update time regardless of the number of inputs and outputs actually connected to the device. This is because devices on the I/O ring use Asynchronous Serial Ring Network circuits (referred to as ASRN “chips”) for input and output transmission.

These chips are constantly scanned through the fiber optic ring by the control. Table 10A.A lists the number of ASRN “chips” per device and the number of I/O points per device.

I/O Ring Modules

Important: The total number of ASRN chips allowed on the fiber optic ring is dependent on your processor as shown in Table 10A.B. Exceeding this number creates an E-STOP condition. Since your system scan time is configurable in AMP it is possible to set the system scan time so low that the control will not complete the I/O scan of all the ASRNs in your ring.

When this occurs old data may be made available to PAL. On systems with large I/O rings and low system scan times, the PAL flag $RNGS should be used to test if the system has completed the I/O scan and made all the necessary ring I/O updates.

Table 10A.A

I/O Ring Modules Connectors

Number of ASRN Chips Number of I/O Points

Operator Panel (standard non-portable)

Portable Operator Panel Interface Assembly

HPG

Pushbutton MTB Panel I/O Module

Digital I/O

High--density I/O Module

Analog I/O

1394 Digital Drive

1746 24V dc Digital I/O Assembly (S24)

1746 110V ac Digital I/O Assembly (S115)

1746 Analog I/O Assembly (SANL)

Other 1746 or 1771 I/O Chassis

6 see page 10B-10

1 8-bit Input

1 6-bit Input

44 Digital Inputs; 18 Digital Outputs

20 Digital Inputs; 12 Digital Outputs

66 Digital Inputs; 33 Digital Outputs

1 12-bit Analog Input; 1 12-bit Analog Output

21 Digital Inputs (see appendix H for addressing)

32 inputs, 16 outputs

32 Inputs, 16 Outputs

2 analog input channels, 2 analog output channels

Depends upon modules used

Section 10A

I/O Interface

Table 10A.B

Max Number of ASRN Chips

9/Series Control

9/230

9/260

9/290

9/440

ASRN

ASRN Chip Used by 1746 or 1771 I/O Chassis

The number of ASRN chips used by a 1746 or 1771 I/O chassis will vary depending on the chassis size and the number and type of digital/analog

I/O cards installed in the chassis. Refer to page 10B-10 for information on calculating the number of ASRN chips used by one of these racks.

The number of ASRN “chips” used by the 1746 or 1771 I/O chassis must be added to the total number of ASRN “chips” used by all the I/O devices on the current I/O ring.

10A-3

Section 10A

I/O Interface

10A.1

Fiber Optics

I/O devices are connected either directly to the control or through a fiber optic I/O ring that provides serial communication with the control. The

I/O devices on the I/O ring convert electrical signals to optical signals for transmission through the I/O ring. These optical signals are converted back to electrical signals at the sub processor board for use by the PAL program. This entire process is reversed for outputs originating from the

PAL program.

Each I/O device connected to the I/O ring has an transmitter and receiver.

Fiber optic cables connect transmitters to receivers to form the I/O ring. A typical ring layout is shown below.

Figure 10A.1

Typical Layout of a Multiple Device Fiber Optic I/O Ring

Operator’s Panel

HPG

MTB Panel

9/290 Processor

Digital I/O

High--density I/O

1746 I/O Rack

11386-I

10A-4

Section 10A

I/O Interface

The devices on the fiber optic I/O ring convert electrical signals to optical signals for transmission through the I/O ring. These optical signals are converted back to electrical signals at the sub processor board for use by the PAL program. An example of the input process is shown in

Figure 10A.2.

Figure 10A.2

PAL Fiber Optic Input Process

Executing PAL checks for %HOM_SW1 input to be true prior to setting $HMSW.00 true

I/O signals converted from optical to electrical

Other

I/O ring devices

1746 I/O Rack

I/O name %HOM_SW1 assigned to input labeled

A08 on I/O device

I/O signals converted from electrical to optical

Home Switch

(typical I/O input element)

Customer supplied I/O power source

11387-I

10A-5

Section 10A

I/O Interface

This entire process is reversed for outputs originating from the PAL program. An example of the output process is shown in Figure 10A.3.

PAL signals converted from electrical to optical

Figure 10A.3

PAL Fiber Optic Output Process

Executing PAL checks $ESTOP

(from the control) and sets %ES_ALARM true

Other I/O ring devices

1746 I/O Rack

E-Stop Warning Alarm

(typical I/O output element)

Customer supplied I/O power source

I/O name %ES_ALARM assigned to output labeled

B12 on I/O device

PAL signals converted from optical to electrical

All I/O devices on the I/O ring must be assigned a position that corresponds to the physical location of that device on the I/O ring. Their corresponding input and output terminals must be assigned variable names.

These assignments are listed in the I/O Assignment file.

10A-6

Section 10A

I/O Interface

10A.1.1

Fiber Optic Ring Device

Fault Indicators

Color Operator Panel

Rear

Each I/O interface device connected to the I/O ring has a fault indicator

(LED) located on it. Some examples of these indicators are shown in the following figure. The fault indicators on the I/O devices will be lit whenever there is a ring communication error.

Figure 10A.4

Fiber Optic Interface Device Fault Indicators

Monochrome Operator

Panel

Rear HPG

1771 I/O

Ring Adapter acTIVE

ADAPTER

FAULT

I/O RING

FAULT

I/O RING

ADAPTER

ALLEN-BRADLEY

Push-button MTB I/O Panel

Keyboard I/O

Ring Interface

8500-1746I

Digital (or Analog) I/O

A01 A02 A03 A04 A05 A06 A07 A08 A09 A10

B01 B02 B03 B04 B05 B06 B07 B08 B09 B10

A11 A12 A13 A14 A15 A16 B11 B12 B13 B14 B15 B16

High--density I/O

11389-I

10A-7

Section 10A

I/O Interface

10A.2

Push-Button MTB Panel I/O

Module

The push-button MTB panel I/O module is included with the push-button

MTB panel. It can also be purchased separately to interface a custom

MTB panel to the control. This module provides 44 inputs and 18 outputs to the I/O ring.

The push-button MTB panel I/O module is interfaced with the system I/O ring through fiber optic cables, which are connected to the optical receiver and transmitter on this module. Refer to Appendix A for additional information on fiber optic cables and connectors.

Figure 10A.5 shows the external appearance of the push-button MTB panel

I/O module.

Figure 10A.5

Push-Button MTB Panel I/O Module External Appearance

+12V dc

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

CN52

I/O ring fault indicator

10A.2.1

Push-Button MTB Panel I/O

Module Pin Assignments

Connector On

MTB I/O Module

+12V

GND

CN51M

CN52M

Table 10A.C lists the connectors used to connect the push-button MTB panel I/O module to the operator panel power supply and a custom MTB panel.

Table 10A.C

Push-Button MTB Panel I/O Module Connectors

Remark

Module

Connected To

Connector

Operator Panel Power Supply

(or External Power Supply)

+12V

BT03

GND

Custom MTB Panel

Cable

Number

C28

Input

Output

Input Interface Ribbon Cable

MTB panel data is sent to the push-button MTB panel I/O module via the input interface ribbon cable. It is then sent to the control via the fiber optic

I/O ring. Table 10A.D lists the pin assignments for the input interface ribbon cable for a custom MTB panel. If you are using an Allen-Bradley

MTB panel refer to page 9A-30 for the pinouts of this cable.

10A-8

Section 10A

I/O Interface

Pin No.

Pin Assignments for Use with Custom MTB Panels

The connector pins that are reserved for supplying power to the push-button MTB panel I/O module are indicated. Any pins that are not reserved can be assigned to custom MTB panel functions or an external I/O device. Use the blank space beside each pin number to indicate any pin assignments that are made. The pin assignments will have to correspond to the pin assignments of the push-button MTB panel I/O module in the PAL

I/O Assignment file. The I/O assignment file will have to be edited if the pin assignments do not correspond. Refer to the 9/Series CNC

9/230,9/260, and 9/290 PAL Reference Manual, publication 8520-4.3, for more information.

Table 10A.D

Input Interface Cable Pin Assignments for Custom MTB Panels

(Connector CN51)

MTB Input Functions Pin No.

Power Off

Power Common

Power On

E-Stop

E-Stop Common

MTB Input Functions

+12V

52 Reserved for use with A-B MTB Panels

Reset

10A-9

Section 10A

I/O Interface

Output Interface Ribbon Cable

The data from the push-button MTB panel I/O module is sent to the MTB panel via the output interface ribbon cable. Table 10A.E lists the pin assignments for output interface ribbon cable. If you are using an

Allen-Bradley MTB panel refer to page 9A-31 for the pinouts of this cable.

Pin Assignments for Use with Custom MTB Panels

The connector pins that are reserved for grounding are indicated. Any pins that are not reserved can be assigned to a custom MTB panel function or an external I/O device. Use the blank space beside each pin number to indicate any pin assignments that are made.The pin assignments will have to correspond to the pin assignments of the push-button MTB panel I/O module in the PAL I/O Assignment file. The I/O assignment file will have to be edited if the pin assignments do not correspond. Refer to the 9/Series

CNC 9/230,9/260, and 9/290 PAL Reference Manual, publication

8520-4.3, for more information.

10A-10

Section 10A

I/O Interface

Table 10A.E

Output Interface Ribbon Cable Pin Assignments (Connects to CN52)

10A-11

Section 10A

I/O Interface

10A.2.2

Push-Button MTB Panel I/O

Module Specifications

Power Source Specifications

Table 10A.F lists the power requirements for the push-button MTB panel

I/O module.

Table 10A.F

MTB Panel I/O Module Power Requirements

Item

Rated Input Voltage

Input Voltage Range

Power Consumption

External Connection

Specifications

12 V dc

11.5 - 13.2 V dc

1.3A Typ., 2.6A Max.

Terminal Block

Input Specifications

Table 10A.G lists the input specifications for the circuits that receive the signals from the pushbuttons and the selector switches on the push-button

MTB panel.

Item

Table 10A.G

Push-Button MTB Panel I/O Module Input Specifications

Specifications

Number of Input Points

Modal Group

Discrete I/O

Rotary Input

Interconnect Group

Unused

A-B MTB Panel

Custom MTB Panel

All MTB Panels

Operating Voltage

OFF

Allowable Voltage Drop

Input Impedance

Input Current at ON

Leakage Current at OFF

Response

11.5 to 13.2 V dc

0-2V dc

Less than .5V dc

2.25 K ohms

5mA

Less than 1mA

1-22 msec. Includes Digital Filter Time

Number of Common Points 6 (per 44 inputs)

Fuse 3A

Isolation

Connection

Non-Isolated type

60 Pin flat cable connector (CN51)

With 12V dc Input

OFF ® ON, ON ® OFF

Internally connected to Power Supply

Protects 12V Power Supply

Max. Length 1m

Remark

Total input signals from all switch groups

For External Device

10A-12

Section 10A

I/O Interface

Figure 10A.6 shows a typical input circuit diagram for the push-button

MTB panel I/O module.

Figure 10A.6

Push-Button MTB Panel I/O Module Input Circuit Diagram

Push-Button MTB Panel Push-Button MTB Panel I/O Module

Switch Common

CMOS

Input

Converted to

Optic Signal

Operator Panel

-dc power supply

Common

3A AMP fuse

+12V

Fiber optics

The MTB I/O module inputs can be energized by a number of different switching devices, provided that the input specifications listed in

Table 10A.G are met. Figure 10A.7 shows some typical input device options.

11269-I

Figure 10A.7

Input Device Options for the Rotary MTB Panel I/O Module

MTB Panel MTB Panel

Switch or relay contact

Conductive rubber

(resistance) switch

MTB Panel MTB Panel

Semi-conductor switch

External supply

8.5 to 13.2 V dc

11312-I

10A-13

Section 10A

I/O Interface

Output Specifications

Table 10A.H lists the output specifications of the MTB I/O module.

Item

Number of Output Points

Modal Group Outputs

Discrete Outputs

Output Type

Output Voltage Range

Output Current at ON

Output Voltage Drop at ON

Number of Common Points

Isolation

Connection

Table 10A.H

Push-Button MTB Panel I/O Module Output Specifications

Specifications

A-B MTB Panel Custom MTB Panel

Sink/Source

9.3-13.2V dc

Less than 125mA

Less than 1 V dc

Non-Isolated type

60 Pin Flat Cable Connector (CN52)

Per Each Output

Remark

Non--I/O Outputs

I/O Outputs

Totem Pole Driver Output

Internally Connected to Power Supply

Max. Length 1m

Figure 10A.8 through Figure 10A.9 show typical output circuit diagrams for the push-button MTB panel I/O module.

Fiber optics

Figure 10A.8

Push-Button MTB Panel I/O Module Output Circuit Diagram

Push-Button MTB Panel I/O Module

Push-Button MTB Panel

Converted from optical to electrical signal

Output

Common

Load

+12V

Common

Operator Panel dc power supply

Important: A protection resistor is not required with this module.

10A-14

Section 10A

I/O Interface

Fiber optics

Converted from optical to electrical signal

Important: When an inductive load (a relay, for example) is directly connected to the output circuit, connect a noise suppressor in the circuit, parallel with the load.

Figure 10A.9

Output Device Requiring a Noise Suppressor

Noise suppressor

MTB Panel

Output

Common

Load

MTB Panel I/O Module

+12V

Operator Panel

Common dc power supply

11315-I

10A.2.3

Push-Button MTB Panel I/O

Module Fiber Optic

Connection

Table 10A.I lists the connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to Appendix A for additional information on fiber optic cables and connectors.

Table 10A.I

Push-Button MTB Panel I/O Module Fiber Optic Connectors

Connected To Connector on Rotary MTB

Panel I/O Module

OP11 (RED)

OP12 (BLacK)

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output

Input

10A-15

Section 10A

I/O Interface

10A.2.4

Push-Button MTB Panel I/O

Module Node Address

Setting

Each push-button MTB panel I/O module must have a unique node address on the I/O ring. The node address corresponds to a unique address assigned to each push-button MTB panel I/O module in the I/O assignment file. The node address is selected by cutting the jumpers located on the push-button MTB panel I/O module.

Figure 10A.10 shows the location of the node address jumpers on the MTB

I/O module.

Figure 10A.10

Push-Button MTB Panel I/O Module Jumper Positions

+12V dc

GND

CN51

OP12

(in)

OP11

(out)

JPR1

JPR2

CN52

I/O ring fault indicator

Set the node address by cutting the jumper(s) on the push-button MTB panel I/O module according to Table 10A.J.

Table 10A.J

Push-Button MTB Panel I/O Module Node Address Setting

Node Address

Hexadecimal Binary

JP1

Jumper

JP2

Short

Open

Short

Open

The node address may be any number between 00 and 03. You may have a total of 4 modules with the MTB panel. The same node address can be used for different types of modules, but may not be used more than once for a specific type of module.

10A-16

Section 10A

I/O Interface

10A.2.5

Setting the Push-Button

MTB Panel I/O Module for a

Custom MTB Panel

If you are using the push-button MTB panel I/O module with custom MTB panel, you need to set some jumpers. Figure 10A.11 locates and defines the jumpers.

Figure 10A.11

Setting the Jumpers on the Push-Button MTB I/O Panel for a Custom MTB Panel

+12V dc

GND

OP12

(in)

OP11

(out)

JPR1

JPR2

CN51

CN52

MTB Panel Type Pins to cover with shorting post

Custom

Allen-Bradley

3 and 2

1 and 2

PANEL

JPR3

CUSTOM

3 2 1

A-B

10A-17

Section 10A

I/O Interface

10A.3

Digital I/O

The Digital I/O provides for an additional 20 inputs and 12 outputs to the system I/O ring. The digital I/O interface circuits are designed to interface this I/O device with the fiber optic I/O ring. These circuits use a fiber optic transmitter and receiver to provide communication with the fiber optic I/O ring.

The digital I/O receives input signals from external devices assigned to its input terminals. These signals are sent to PAL, through the I/O ring, to be used in the ladder logic process. PAL generates signals that are then sent through the I/O ring to the digital I/O. The digital I/O outputs these signals to external devices assigned to its output terminals.

This section covers the specifications, connection and the settings for the digital I/O. Figure 10A.12 shows the digital I/O.

Fuse

Figure 10A.12

Digital I/O

Color code location

Optical connector

OUT (OP21)

Optical connector

IN (OP22)

There are four types of digital I/O. The four types have different combinations of power supply and I/O specifications.

11317-I

10A-18

Section 10A

I/O Interface

10A.3.1

Digital I/O Connection

Table 10A.K list the four types of digital I/O that can be selected according to individual machine applications.

Table 10A.K

Digital I/O Types

Type Power

Required

Input Points

115/230 V ac 20@ 100/115 V ac

50-60HZ

Output Points

E151

E152 115/230 V ac 20@ 200/230 V ac

50-60 Hz

2 10 Triacs: 85-265V ac

2 Relays: 10-250 V ac/

10-125V dc

2 10 Triacs: 85-265V ac

2 Relays: 10-250 V ac/

10-125V dc

E153

E154

115/230 V ac

24 V dc

20@ 24V dc

12 Relays: 10-250 V ac/

10-125V dc

10 Transistors: 10-50 V dc

2 Relays: 10-250 V ac/

10-125V dc

The color code appears in the upper right corner on the front of the unit.

10 Triac Outputs of sufficient capacity to energize size 0 - 3 contactors.

Two Isolated Relay Outputs.

3 Refer to table 10. M

4 Refer to table 10.N

5 Refer to tables 10.O-10.S

Color Code

RED

BLacK

BLUE

GREEN

Power Connection

Figure 10A.13 and Figure 10A.14 show the power connection diagram for the digital I/O.

Figure 10A.13

Power Connection (E151, E152, E153)

115V ac

L H

To frame

230V ac

To frame

Terminal

Block

230V ac

NEUT

CHASSIS

GND

115V ac

NEUT

NOT

USED

115/230

V ac

Label

Terminal

Block

230V ac

NEUT

CHASSIS

GND

115V ac

NEUT

NOT

USED

115/230

V ac

Label

11318-I

10A-19

Section 10A

I/O Interface

Figure 10A.14

Power Connection (E154)

24 V dc

To frame

Terminal

Block

NOT

USED

CHASSIS

GND

24V dc

NEUT

NOT

USED

+24

V dc

Label

11319-I

ATTENTION: Incorrect wiring can cause damage to the digital

I/O power supply. Do not jumper the 115V ac NEUT and the

230 V ac NEUT together. Do not jumper the 115V ac NEUT or the unused 230V ac to the Chassis GND terminal.

Input Device Connection

Table 10A.L lists the terminals of the digital I/O input terminal strips. You can assign an input device to each terminal. Use the blank space beside each terminal number to indicate any terminal assignments that are made.

The terminal assignments will have to correspond to the terminal assignments of the digital I/O in the PAL I/O Assignment file. The I/O assignment file will have to be edited if the terminal assignments do not correspond. Refer to the 9/Series CNC 9/230, 9/260, and 9/290 PAL

Reference Manual, publication 8520-4.3, for more information.

10A-20

Section 10A

I/O Interface

Table 10A.L

Digital I/O Input Terminals

Terminal No.

A05

A06

A07

A08

A01

A02

A03

A04

A09

A10

Digital Input Functions Terminal No.

B05

B06

B07

B08

B01

B02

B03

B04

B09

B10

Digital Input Functions

Figure 10A.15 and Figure 10A.16 show the input device connection diagrams for the digital I/O.

Figure 10A.15

ac Input Device Connection (E151, E152)

Proximity switch

L1 (H)

Customer supplied ac voltage

L2 (L)

LS1

PB2

Terminal

Block

COM COM

A01 A02 A03 A04 A05 A06 A07 A08 A09 A10

B01 B02 B03 B04 B05 B06 B07 B08 B09 B10

COM

All six COM terminals are connected internally

Label

11320-I

10A-21

Section 10A

I/O Interface

10A-22

Figure 10A.16

dc Input Device Connection (E153, E154)

Customer supplied dc voltage

Proximity switch

LS1

PB2

Terminal

Block

COM COM

A01 A02 A03 A04 A05 A06 A07 A08 A09 A10

B01 B02 B03 B04 B05 B06 B07 B08 B09 B10

COM

All six COM terminals are connected internally

Label

11321-I

Output Device Connection

Table 10A.M lists the terminal of the digital I/O output terminal strip.

Each terminal may have an output device connected to it. Use the blank space beside each terminal number to indicate any terminal assignments that are made.

Table 10A.M

Digital I/O Output Terminals

Terminal No.

Digital Output

Functions

A11

A12

A13

A14

A15

A16

Terminal No.

B11

B12

B13

B14

B15

B16

Digital Output

Functions

Refer to the 9/Series CNC 9/230, 9/260, and 9/290 PAL Reference

Manual, publication 8520-4.3, for more information.

Section 10A

I/O Interface

Figure 10A.17 shows a triac output connection diagram.

Figure 10A.17

Triac Output Connection (E151, E152)

Relay type output

A11

Relay type output

Triac output - Group 1

V ac Common

V ac A12 A13 A14 A15 A16

NOT

USED

B11

Triac output - Group 2

V ac Common

V ac B12 B13 B14 B15 B16

NOT

USED

Solenoid

Noise suppressor dc dc +

Customer supplied dc L1 (H)

Noise suppressor

115 V ac

Customer supplied

L2 (L) L1 (H)

Noise suppressor

230 V ac

Customer supplied

L2 (L)

11322-I

Important: Triac outputs are isolated by means of a photocoupler. They are also protected from transient current by a varistor.

To reduce leakage current, it may be necessary to connect a load resistor or additional noise suppressor. When a triac output is connected with a hard contact to control an inductive load, it is recommended that a varistor be used. Do not use suppressors having RC networks, since damage to triacs could occur.

Important: A noise suppressor is not incorporated in the relay type output circuit (terminals A11, B11).

Connection of an external surge suppressor is recommended to protect the relay contact from a transient voltage spike, which occurs when an inductive device is turned off.

10A-23

Section 10A

I/O Interface

Figure 10A.18 shows a relay type output connection diagram.

Figure 10A.18

Relay Type Output Connection (E153)

Relay type output Relay type output

A11

Relay output - Group 1

V ac/V dc Common

V ac

V dc

A12 A13 A14 A15 A16

NOT

USED

B11

Relay output - Group 2

V ac/V dc Common

V ac

V dc

B12 B13 B14 B15 B16

NOT

USED

M M

Solenoid

Noise suppressor dc dc +

Customer supplied dc L1 (H)

Noise suppressor or load resistor

115 V ac

Customer supplied

L2 (L)

Incorporated noise suppressor

Noise suppressor or load resistor

230 V ac

L1 (H)

Customer supplied

L2 (L)

11323-I

Important: The relay type output circuits of Group 1 (A12 - A16) and

Group 2 (B12 - B16) incorporate a noise suppressor.

Important: Surge suppression reduces arcing of an output contact and is recommended for most applications, particularly when switching an inductive load off.

Relay contacts A11 and B11 do not have built-in suppression and may exhibit 50% of the relay life of contacts A12-A16 and B12-B16.

The contact life of relays used in the output circuits of the E153 module can be significantly reduced if surge suppression is not connected across the load. Performance testing indicates that contact life may be reduced by as much as 30% without surge suppression across the load.

10A-24

Section 10A

I/O Interface

The relay life of output contacts used in the E153 depends on the load being controlled. The following shows contact performance for a load that has surge suppression applied across it:

Load

Allen-Bradley Bulletin 500 Size 1 ac Contactor

Switching Voltage

120V ac

Relay Life

2,500,000 (operations)

Figure 10A.19 showing the output device connection diagram, shows a transistor output connection.

Relay type output

Figure 10A.19

Transistor Output Connection (E154)

Relay type output

A11

Transistor output - Group 1

V ac/V dc Common

V dc1 A12 A13 A14 A15 A16

COM

B11

Transistor output - Group 2

V ac/V dc Common

V dc2 B12 B13 B14 B15 B16

COM

Solenoid Solenoid

Noise suppressor

115 V ac

L1 (H)

Customer supplied

Noise suppressor

24 V dc

L2 (L) dc (+)

Customer supplied dc (-)

Noise suppressor

48 V dc dc (+)

Customer supplied dc (-)

11324-I

Important: Transistor output is a source type output, which is isolated by means of a photocoupler. An external surge suppressor should be connected to protect transistors from a transient voltage spike, which occurs when an inductive device is turned off.

Important: A noise suppressor is not incorporated in the relay type output circuits (terminals A11 and B11). Connection of an external surge suppressor is recommended to protect the relay contact from a transient voltage spike, which occurs when an inductive device is turned off.

10A-25

Section 10A

I/O Interface

10A.3.2

Digital I/O Specifications

Table 10A.N lists the power requirements for the 4 types of digital I/O.

Table 10A.N

Digital I/O Power Requirements

Item

Rated Input Voltage

Input Voltage Range

Power Consumption

Fuse Rating

Fuse Type

Power ON Indicating LED

Connection

E151, E152, E153

Digital I/O Types

E154

115/230 V ac 50/60 Hz

85-132/170-265 V ac 47-63 Hz

24 V dc

10-30 V dc

Less than 15 VA

315mA/250V

Less than 9 VA

1.6A/250V

Glass-tube-filled ( f

6.35

31.8 mm)

Lights up when +5V is supplied to the internal circuit

Terminal Block

Table 10A.O lists the input specifications for the 4 types of digital I/O. All input circuits include optical isolation as well as filtering to guard against high voltage transients from external input devices.

Table 10A.O

Digital I/O Input Specifications

Item Digital I/O Types

Number of Inputs

Rated Input Voltage

Operating Voltage

Input Current

OFF

Leakage Current at OFF

E151 E152

20 Input Terminals (pins: A01-A10, B01-B10)

85-132 V ac 50/60 Hz 170-265 V ac 50/60 Hz 10-30 V dc

85-132 V ac 170-265 V ac 10-30 V dc

Less than 30 V ac

Less than 2mA

Less than 50 V ac

E153

Less than 4 V dc

Less than 1mA

E154

Approximately 8mA Approx. 4mA at 12 V dc

Approx. 8mA at 24 V dc

Maximum Inrush Current

Response ON to OFF

Less than 0.8A

3-13 msec 1

Operation Indication

Connection

OFF to ON 9-18 msec 1

Number of Common Points

LED ON when power is ON

Terminal Block

6 points per 20 input points

Dielectric Strength Higher than 1500V 3

Excluding digital filter time.

All common lines are internally connected to each other.

Across input terminal - control logic circuit.

4-8 msec

10A-26

Section 10A

I/O Interface

Figure 10A.20 and Figure 10A.21 show the digital I/O input circuit diagrams for ac and dc applications.

Figure 10A.20

Digital I/O ac Input Circuit Diagram (E151, E152)

Signal source Digital I/O Module

L1 ac power supply

Com.

Photocoupler

11325-I

Signal source

Figure 10A.21

Digital I/O dc Input Circuit Diagram (E153, E154)

Digital I/O Module dc power supply

Photocoupler

Com.

11326-I

Table 10A.P through Table 10A.T list the output specifications for the 4 types of digital I/O. It is recommended that some type of surge suppressor be used when switching inductive load devices with hard contact outputs.

10A-27

Section 10A

I/O Interface

Table 10A.P

Digital I/O Output Specifications

Item

Number of Output Points

Output Type

E151 E152

Triac type: 10 points

Relay Type: 2 points

Digital I/O Types

E153

E154

Relay Type: 12 points Transistor Type: 10 points

Relay Type: 2 points

1440 VA/total output

Terminal Block

Maximum Output Capacity

Connection

E151, E152:

Triac Output: A12 - A16, B12 - B16

Relay Type Output: A11, B11 (without RC circuit)

E153:

Relay Type Output: A12 - A16, B12 - B16 (with RC circuit)

A11, B11 (without RC circuit)

E154:

Transistor Output: A12 - A16, B12 - B16

Relay Type Output: A11, B11 (without RC circuit)

Table 10A.Q

Triac Output Specifications

Item Rating Remark

Triac Type

Output Voltage Range

Non-Zero Cross Type With Snubber Circuit

85 - 265 V ac

Continuous Output Current per Circuit

1.0A at 30

0.5A at 60

Continuous Output Current Per Chassis

10.0A at 30

Surge Current

5A at 60

10A/25 msec

1 surge/sec (30

1 surge/2 sec (60 ° C)

Minimum Load Current

Maximum OFF State Leakage Current

OFF to ON Response Time

Zero-Cross Turn-On Timing Accuracy

10mA

2mA

0.1 msec (max.) Non-Zero Cross

Saturation Voltage Drop

Electrical-Optical Isolation

500 microseconds

1.5 V at 1.0A

1500 V

Recommended Output Fusing San-O: SOC ST4-3A

Bussman: MSL-2A

Between Output Voltage and Control Logic

Or Equivalent

10A-28

Section 10A

I/O Interface

Specifications for hard contact relay outputs are shown below. It is recommended that some type of noise suppressor be used when switching inductive load devices with hard contact outputs.

Table 10A.R

Relay Type Output Specifications

Item

Voltage Range

Contact Resistance

Electrical-optical Isolation

Rating

10-125 V dc

50/60 Hz

20 milliohms

2000 V

Remark

Between Output Contacts and Control Logic

Digital I/O types E151, E152, and E154 have 2 hard contact relay outputs, at terminals A11 and B11. These outputs do not have internal arc suppression circuitry.

Digital I/O type E153 has 12 hard contact relay outputs. Relay outputs at terminals A12 through A16 and B12 through B16 have internal arc suppression circuitry. Relay outputs at terminals A11 and B11 do not have internal arc suppression circuitry.

Table 10A.S

Contact Ratings

Volts Amperes Amperes

Make Break Continuous

240 V ac 7.5A

0.75A 2.5A

120 V ac 15A

125 V dc

1.5A

0.22A

24 V dc 1.2A

1.0A

2.5A

Voltamperes

Make Break

1800

180 VA

28 VA

10A-29

Section 10A

I/O Interface

Table 10A.T

Transistor Output Specifications

Item Rating Remark

Output Voltage Range

Continuous Output Current per Circuit

10 - 50 V dc

1.0A at 30 ° C

0.5A at 60

Continuous Output Current Per Chassis

10.0A at 30 ° C

Surge Current

Minimum Load Current

Maximum OFF State Leakage Current

OFF to ON Response Time

Maximum ON State Voltage Drop

Electrical-Optical Isolation

Recommended Output Fusing

5A at 60 ° C

3.0A/20 msec

1 surge/sec (30

1 surge/2 sec (60

1.0mA

0.1mA

100 microseconds

1.5 V at 1.0A

0.8 V at 0.5A

1500 V Between Output Voltage and Control Logic

San-O: SOC ST4-2A Or Equivalent

Figure 10A.22 through Figure 10A.23 show the digital I/O output circuit diagrams. In Figure 10A.23 consider that the relay type outputs, A11 and

B11 terminals of E151, E152, E153, and E154 are not provided with a noise suppressor.

Digital I/O Module

Photocoupler

Figure 10A.22

Digital I/O Triac Output Circuit Diagram (E151, E152)

Signal destination

V ac ac power supply

Load

Noise suppressor

11327-I

10A-30

Section 10A

I/O Interface

Figure 10A.23

Digital I/O Relay Output Circuit Diagram (E151, E152, E153, E154)

Digital I.O Module

V ac or

V dc

Signal destination ac or dc power supply

Load

Noise suppressor

11328-I

Figure 10A.24

Digital I/O Transistor Output Circuit Diagram (E154)

Digital I/O Module Signal destination

V dc

Photocoupler

Load dc power supply

Com.

Noise suppressor

11329-I

10A-31

Section 10A

I/O Interface

10A.3.3

Digital I/O Fiber Optic

Connections

10A.3.4

Digital I/O Node Address

Setting

Table 10A.U lists the connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to Appendix A for additional information on fiber optic cables and connectors.

Table 10A.U

Digital I/O Fiber Optic Connectors

Connector on Digital I/O

OP21 (RED)

OP22 (BLacK)

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output

Input

Different types of I/O devices can have the same node address, but devices of the same type must each have a unique node address. Each digital I/O is assigned a unique node address in the I/O assignment file of ODS. This address corresponds to a switch setting on the device itself.

Figure 10A.25 shows the location of the node address switch assembly on the digital I/O.

Figure 10A.25

Digital I/O Switch Assembly Location

11330-I

Set the switch assembly to correspond to the node address as shown in

Table 10A.V.

10A-32

Section 10A

I/O Interface

10A.4

High- density I/O Module

Table 10A.V

Digital I/O Node Address Setting

Node Address Switch Assembly Position

Hexadecimal Binary

00 00 0000

OFF

01 00 0001 OFF OFF OFF OFF OFF ON

00 0010 OFF OFF OFF OFF

11 1101 ON

11 1110 ON

11 1111 ON

OFF

The high--density I/O module provides for an additional 66 inputs and 36 outputs to the system I/O ring.

The high--density I/O module receives input signals from external devices assigned to its input terminals. These signals are sent to PAL, through the

I/O ring, to be used in the ladder logic process. PAL generates signals that are then sent through the I/O ring to the high--density I/O module. The high--density I/O module outputs these signals to external devices assigned to its output terminals.

This section covers the specifications, connection and the settings of the high--density I/O module (cat. nos. 8500-HDM).

10A-33

Section 10A

I/O Interface

Fuse

DIP switch

Figure 10A.26 shows the high--density I/O module.

Figure 10A.26

High- density I/O Module

8500-HDM1

CN61M

I/O Inputs

10A.4.1

High Density I/O Module

Connection

I/O ring fault indicator

CN62M

BT33

CN63F

I/O Inputs

I/O Outputs

Optical connector

OP23 (OUT)

Optical connector

OP24 (IN)

Figure 10A.27 shows the power connections for the high--density I/O module.

Figure 10A.27

High- density I/O Module Power Connection

Module and

Input Device power

Frame

Ground

BT33

Power for output devices

TB1 TB2

24V dc

Com

+ 24V dc

24V dc

Com

+ 24V dc

Important: The + 24V dc power for the high--density I/O module and its output devices may originate from the same power source. However, power sources with excessive noise or poor voltage regulation should not be used to power the high--density I/O module.

10A-34

Section 10A

I/O Interface

Figure 10A.28 shows typical input device connections to connectors

CN61M or CN62M of the high--density I/O module.

Figure 10A.28

High- density I/O Module Input Device Connection

PROXIMITY SWITCH

LS1

PB2

1 8 13 19

20 25 30 37

+24V

Table 10A.W and Table 10A.X show the relationship between the input data and the pins of connectors CN61M and CN62M.

Table 10A.W

Relationship of Input Data to Connector CN61M Pins

Connector CN61M

Input Data Connector Pin No.

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

D27

D28

D29

D30

D31

D32

D33

Important: Pins 34, 35, 36, and 37 are a fused +24 volt power used for input device circuits. If you chose to use an external power source to power input device circuits, do not make connections to these four pins.

Additionally any external power supply used for input devices must have its common tied to the same potential as the common at TB1.

10A-35

Section 10A

I/O Interface

Table 10A.X

Relationship of Input Data to Connector CN62M Pins

Connector CN26M

Input Data Connector Pin No.

D38

D39

D40

D41

D34

D35

D36

D37

D42

D43

D44

D45

D46

D47

D48

D49

D50

D51

D52

D53

D54

D55

D56

D57

D58

D59

D60

D61

D62

D63

D64

D65

D66

Additionally any external power supply used for input devices must have its common tied to the same potential as the common at TB1.

Figure 10A.29 shows typical output device connections to connector

CN63F.

Figure 10A.29

High- density I/O Module Output Device Connection

Solenoid

19 13 8 1

Not Used

To output device power supply

GND on high--density I/O module

25 20

11334-I

Important: When a lamp is directly connected to an output circuit, connect a protection resistor to reduce inrush current.

Important: A noise suppressor is incorporated in the output circuits.

10A-36

Section 10A

I/O Interface

Table 10A.Y lists the relationship between the output data and the sockets of connector CN63F.

Table 10A.Y

Relationship of Output Data to Connector CN63F Sockets

Output

Data

D13

D14

D15

D16

D10

D11

D12

D17

D18

Connector CN63M

Connector

Pin No.

Output

Data

D31

D32

D33

D34

D27

D28

D29

D30

D35

D36

D23

D24

D25

D26

D19

D20

D21

D22

Connector

Pin No.

Important: Pin 37 is not used.

10A-37

Section 10A

I/O Interface

10A.4.2

High Density I/O Module

Specifications

Power Supply Specifications

Table 10A.Z lists the power requirements for the high--density I/O module.

Table 10A.Z

High- density I/O Module Power Requirements

Item

Rated Input Voltage

Input Voltage Range

Current Consumption

Connection

Specifications

24 V dc

18-30 V dc

Less than 1.2A (Excluding Output Power)

Phoenix Connector or Terminal Block

Important: The power requirements listed above are for the logic power of the high--density I/O module only.

Important: Power supplies with excessive noise or poor voltage regulation should not be used to power the high--density I/O.

Input Specifications

Table 10A.AA lists the input specifications for the high--density I/O module.

Table 10A.AA

High- density I/O Module Input Specifications

Item

Number of Input Points

Operating Voltage ON

OFF

10-30 V dc

0-5 V dc

Max. 6 V dc

Specifications Remark

Pin Number

Allowable Voltage Drop

Input Impedance

Input Current ON

OFF

3 K ohms

Approx. 4.0mA

Approx. 8.0mA

Less than 1mA

For external device

With 12 V dc Inputs

With 24 V dc Inputs

Leakage Current

Response

Number of Common Points

Fuse

Isolation

0.1-23msec Including Digital Filter Time OFF to ON, ON to OFF

4 per each 33 inputs All common points are internally connected to each other

1.25 A

Non-Isolated type

1 for all inputs*

Input Connection 2 37-Pin, D-Shell Connectors Male type

* Fuse is used only for inputs using 24V module power from pins 34, 35, 36, and 37 of CN61 or CN62

10A-38

Section 10A

I/O Interface

The input circuit diagram for the high--density I/O module is shown in

Figure 10A.30.

Figure 10A.30

High- density I/O Module Input Circuit Diagram

Machine High--density I/O

Input signal

+24V Input

Power

CN61/CN62

1.25A

fuse dc power supply

TB1

+24V

Reference voltage generation circuit

Ground terminal

GND

BT33

TB1

Output Specifications

The output specifications for the high--density I/O module are listed in

Table 10A.AB.

Table 10A.AB

High- density I/O Module Output Specifications

11335-I

Item

Number of Outputs

Output Type

Rated Output Voltage

Specifications

Open Collector Output

24 V dc

Remark

PNP Transistor

Source Type

Output Voltage Range

Output Current at ON

18-30 V dc

Less than 250mA

Maximum Output Capacity 9A

Voltage Drop at ON Less than 1.5 V

Leakage Current at OFF

Number of Ground Points

Isolated

Output Connection

Less than 0.1mA

Non--Isolated Type

37- Pin D-Shell Connector

Per each output

All outputs “ON”

+24 V dc (COM), GND

10A-39

Section 10A

I/O Interface

Figure 10A.31 shows the output circuit diagram for the high--density I/O module.

Figure 10A.31

High- density I/O Module Output Circuit Diagram

10A.4.3

High- density I/O Module

Fiber Optic Connection

High--density I/O Module Signal destination

+24V

BT33

TB2

Customer--supplied dc power supply

Load

CN63F

BT33

TB2

Com.

Connector on Digital I/O

OP23 (RED)

OP24 (BLACK)

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

11336-I

Table 10A.AC lists the connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to Appendix A for additional information on fiber optic cables and connectors.

Table 10A.AC

High- density I/O Module Fiber Optic Connectors

Remark

Output

Input

10A-40

Section 10A

I/O Interface

10A.4.4

High Density I/O Module

Node Address Setting

Fuse

CN61M

I/O Inputs

DIP switch

Different types of I/O devices can have the same node address, but devices of the same type must each have a unique node address. Each high--density I/O module is assigned a unique node address in the I/O assignment file of ODS. This address corresponds to a switch setting on the high--density I/O module.

Figure 10A.32 shows the location of the node address switch assembly on the high--density I/O.

Figure 10A.32

High- density I/O Module Switch Assembly Location

1 2

3 4

5 6

I/O Ring

Fault Indicator

CN62M

BT33

CN63F

I/O Inputs

I/O Outputs

Optical connector

OP23 (OUT)

Optical connector

OP24 (IN)

Set the switch assembly to correspond to the node address as shown in

Table 10A.AD.

Table 10A.AD

High- density I/O Module Node Address Setting

Node Address

Hexadecimal

Binary 1

Switch Assembly Position

2 3 4 5 6

00 0000 OFF OFF OFF OFF OFF OFF

00 0001

00 0010

OFF

11 1101

11 1110

11 1111

OFF

10A-41

Section 10A

I/O Interface

10A.5

E - Series Analog I/O

Fuse

This section only discusses the use of the E--Series analog I/O module. If you are using a 1746 analog I/O device, refer to page 10B-10 for installation and operation details. The Analog I/O provides analog input and output to the control through the system I/O ring. It converts analog inputs to digital inputs and digital outputs to analog outputs for transmission to and from the control via the I/O ring. Each analog I/O provides 1 input channel and 1 output channel.

Figure 10A.33

E- Series Analog I/O External Appearance

Optical connector

11338-I

10A-42

10A.5.1

E- Series Analog I/O

Specifications

Section 10A

I/O Interface

Table 10A.AE lists the power requirements for the analog I/O.

Table 10A.AE

E- Series Analog I/O Power Requirements

Item

Rated Input Voltage

Input Voltage Range

Power Consumption

Fuse Rating

Power ON Indicator

Connection

Specifications

115/230 V ac 50/60 Hz

85-132 V ac, 170-265 V ac, 47 Hz-63Hz

Less than 15 VA

315mA/250V

Lights up when +5V and supplied to internal circuit

± 15V are

Terminal Block

Figure 10A.34 shows the terminals of analog I/O terminal block used for power source connection.

Figure 10A.34

E- Series Analog I/O Power Source Connection

115V ac

230V ac

L H L H

To frame

Terminal

Block

Terminal

Block

CHASSIS

GND

230V ac

NEUT

115V ac

NEUT

NOT

USED

115/230

V ac

Label

CHASSIS

GND

230V ac

NEUT

115V ac

NEUT

NOT

USED

115/230

V ac

Label

11339-I

ATTENTION: Incorrect wiring can cause damage to the analog I/O power supply. Do not jumper the 115V ac NEUT and the 230 V ac NEUT together. Do not jumper the 115V ac

NEUT or the unused 230V ac to the Chassis GND terminal.

10A-43

Section 10A

I/O Interface

Table 10A.AF lists the input specifications for the analog I/O.

Table 10A.AF

E- Series Analog I/O Input Specifications

Remark Item

Number of Input Points

Input Voltage Range

Resolution

Input Impedance

Conversion Rate

Maximum Input Voltage

Common Mode Rejection

Connection

PAL Variable Values

Specifications

Bipolar: -10 to +10 V dc

Unipolar: 0 to +10V dc

12 bit binary

More than 100 Kohms

Interval: Less than 100

Time: Less than 30 m sec m sec

25 V dc

More than 70dB

Terminal Block

Bipolar:

0 -- 2047 (0 to +10V dc)

2048 -- 4096 (--10 to 0 V dc)

Unipolar:

0 -- 4096 (0 to +10V dc)

Range selected by switch next to the node address switch on the analog I/O

-10V to +10V

Approx. 64

Approx. 20 m sec m sec

From dc to 60 Hz

The PAL variable name is determined in your I/O configuration using ODS.

Figure 10A.35 shows a typical analog I/O input device connection.

Figure 10A.35

E- Series Analog I/O Input Device Connection

From analog device e

2 e

1 e=e

-e

Single

Input

Differential

Input

Shielded cable Shielded cable

Terminal

Block

NOT

USED

CHASSIS

GND

CHASSIS

GND

INPUT

( - )

COM

CHASSIS

GND

INPUT

( + )

CHASSIS

GND

CHASSIS

GND

CHASSIS

GND

NOT

USED

Label

NOT

USED

CHASSIS

GND

CHASSIS

GND

INPUT

( - )

CHASSIS

GND

COM

CHASSIS

GND

INPUT

( + )

CHASSIS

GND

CHASSIS

GND

NOT

USED

11340-I

10A-44

Section 10A

I/O Interface

Table 10A.AG lists the output specifications for the analog I/O.

Table 10A.AG

E- Series Analog I/O Output Specifications

Item Specifications

Number of Output Points 1

Operating Voltage Bipolar: -10 to +10 V dc

Unipolar: 0 to +10V dc

Resolution

Load Drive Capability

Response Rate

Connection

PAL Variable Values

Remark

Range selected by switch next to the node address switch on the analog I/O

12 bit binary

Maximum 10 mA

Maximum 1 m

Maximum m F

Less than 200 m sec

Terminal Block

Bipolar:

0 -- 2047 (0 to +10V dc)

2048 -- 4096 (--10 to 0 V dc)

Unipolar:

0 -- 4096 (0 to +10V dc)

No Sustained Oscillation

The PAL variable name is determined in your I/O configuration using ODS.

Figure 10A.36 shows a typical analog I/O output device connection.

10A-45

Section 10A

I/O Interface

Figure 10A.36

E- Series Analog I/O Output Device Connection

To analog device

Shielded cable

10A.5.3

E- Series Analog I/O Fiber

Optic Connection

Terminal

Block

NOT

CHASSIS

USED

GND

CHASSIS

GND

COM

CHASSIS

GND

OUTPUT

CHASSIS

GND

CHASSIS

GND

NOT

USED

NOT

USED

NOT

USED

Label

11341-I

Table 10A.AH lists the analog I/O connectors used to make the fiber optic connections to the I/O ring. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to Appendix A for additional information on fiber optic cables and connectors.

Table 10A.AH

E- Series Analog I/O Fiber Optic Connectors

Connector on Digital I/O

OP25 (RED)

OP26 (BLacK)

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

Remark

Output

Input

10A.5.4

E- Series Analog I/O Node

Address Setting

Different types of I/O devices can have the same node address, but devices of the same type must each have a unique node address. Each analog I/O is assigned a unique node address in the I/O assignment file of ODS. This address corresponds to a switch setting on the analog I/O device.

Figure 10A.37 shows the location of the node address switch assembly on the analog I/O.

10A-46

Section 10A

I/O Interface

Figure 10A.37

E- Series Analog I/O Node Address Switch Assembly Location

This cover unsnaps and folds down to expose switches

11342-I

Set the node address switch assembly to correspond to the node address as shown in Table 10A.AI.

Table 10A.AI

E- Series Analog I/O Node Address Setting

Node Address

Hexadecimal Binary

0000

0001

0010

1101

1110

1111

Switch Assembly Position

2 3 4

OFF OFF OFF OFF

OFF OFF OFF ON

OFF OFF

OFF

10A-47

Section 10A

I/O Interface

10A.5.5

E- Series Analog I/O

Bipolar/Unipolar

Configuration

The E--Series analog I/O module allows you to select between bipolar operation (--10V to +10V dc) and unipolar operation (0V to +10V dc).

Select this using a dip switch located next to the node address switch (see

Figure 10A.38). Bipolar or unipolar can be selected independently for the input and output channels.

Figure 10A.38

E Series Analog I/O Node Address Switch Assembly Location

Bipolar/Unipolar switches

INPUT

OUTPUT

This cover unsnaps and folds down to expose switches

Switch positions are as follows:

Unipolar (0 V dc to +10 V dc)

Bipolar (--10 V dc to +10 V dc)

11342-I

10A-48

10A.6

1746 I/O

Section 10A

I/O Interface

You can place several 1746I modules with 1746 I/O chassis in the 9/Series fiber-optic ring. Each 1746 I/O chassis must contain its own 1746I module

(daisy chaining racks together using one 1746I module is not allowed).

The number of I/O points/chassis is limited to the number of ASRN chips supported by the 9/Series fiber--optic ring. Use page 10B-10 to calculate how many ASRN chips are required for each I/O chassis. A maximum of

16 chassis are allowed on the 9/Series fiber-optic I/O ring.

1746 Series B I/O Chassis

1746I adapter module

Three different fully equipped 1746 I/O chassis are available for the

9/Series I/O ring. These chassis contain the following I/O devices:

(1) 1746-A4

(1) 1746-P1

(1) 8500-1746I

(2) 1746-IA16

(1) 1746-OA16

(1) set fiber optic connectors

Total I/O

Catalog Number

8500-S115

4 Slot Chassis

115/230V ac Power Supply

I/O Ring Interface Adapter

Module

16 point 115V ac Input

Module

16 point 115V ac Output

Module for connection to I/O ring

32 115V ac Inputs

16 115V ac Outputs

3 ASRN chips

Table 10A.AJ

Standard 9/Series 1746 I/O Catalogs

(1) 1746-A4

(1) 1746-P1

(1) 8500-1746I

(2) 1746-IB16

Catalog Number

8500-S24

4 Slot Chassis

115/230V ac Power Supply

(1) 1746-A4

(1) 1746-P1

I/O Ring Interface Adapter

Module

(1) 8500-1746I

16 point 24V dc Input Module (1) 1746-NIO4V

Catalog Number

8500-SANL

4 Slot Chassis

115/230V ac Power Supply

I/O Ring Interface Adapter

Module

Analog Input Module

(1) 1746-OW16 (1) 1746-N2 2 Empty Slot Covers

(1) set fiber optic connectors

Total I/O

16 point 24V dc Output

Module for connection to I/O ring

32 24V dc Inputs

16 24V dc Outputs

3 ASRN chips

(1) set fiber optic connectors

Total I/O

For connection to I/O ring

2 analog input chnls.

2 analog output chnls

6 ASRN chips

10A-49

Section 10A

I/O Interface

10A.6.1

Removing/Installing

1746 Modules

The following procedure covers how to remove modules from your 1746

I/O chassis. In some cases it is necessary to remove a module to set or check dip switch settings.

ATTENTION: Never install, remove, or wire modules with power applied to the chassis.

Removing a Module

1. Label and remove any wiring or removable terminal blocks.

2. Gently press in on both the top and bottom latches of the module to be removed.

3. Slide the module out of the rack.

Installing a Module

1. Align the circuit board of the module with the card guide in the chassis.

Important: You must install the 1746I module in the first slot of the chassis (slot immediately next to the power supply). The 1746I module takes the place of a CPU module or a ASB adapter module in this slot. Other modules should be returned to the same slot they were removed from.

Gently slide the module in until both top and bottom latches are latched.

Reconnect wires or removable terminal blocks.

Cover all unused slots with a Card Slot Filler, Catalog Number 1746-N2.

10A.6.2

1746I I/O Ring Adapter Node

Address Setting

To install the 1746I module in the 9/Series I/O ring you must first assign the module an address on the 9/Series I/O ring. If the module is already installed in your 1746 I/O chassis, you must remove the module to set the module address. Remove the module by pressing in on the locking tabs on the top and bottom of the 1746I module and sliding the module out of the chassis.

Assign an address to the module using the dip switch S1 found on the side of the 1746I module. Figure 10B.4 shows the location of the node address switch assembly on the 1746I module.

10A-50

Section 10A

I/O Interface

Figure 10A.39

1746 I/O Ring Adapter Switch Assembly Locations

1 2 3 4 5 6

Other 9/Series I/O devices (such as an HPG or MTB panel) on the 9/Series fiber-optic ring can have the same node address as the 1746I module.

However, devices of the same type (multiple 1746I modules) must each have a unique node address. Each 1746 I/O ring adapter is assigned a unique node address in the I/O assignment file of ODS (refer to your PAL reference manual). This address corresponds to switch assembly S1 on the

1746I module.

Set switch assembly S1 to correspond to the node address as shown in

Table 10A.AK.

10A-51

Section 10A

I/O Interface

10A.6.3

1746P1 Power Supply

Table 10A.AK

1746I I/O Ring Adapter Node Address Setting

Node Address

Hexadecimal Binary

00 0000

01 0001

0010

1111

Switch Assembly Position

1 2 3 4

OFF OFF OFF OFF

OFF OFF OFF ON

OFF OFF

OFF

Important: Switch 5 and 6 of S1 must remain in the OFF position for normal operation.

The following are the specifications and wiring instructions for the 1746

P1 power supply.

Set the Input Voltage Jumper

Locate the input voltage jumper. If necessary, remove and reinstall the jumper to match the external voltage available.

ATTENTION: Set the input jumper before applying power.

Hazardous voltage is present on exposed pins when power is applied: contact with the pins may cause injury to personnel.

100/120 V

200/240 V push latch up from underneath to open the door

10A-52

Section 10A

I/O Interface

Wire the power supply terminals as shown below. These terminals accept two #14AWG wires.

PWR OUT +24 V dc

PWR OUT COM

L1 — 120/240 V

L2 — V ac NEUTRAL

— PE

ATTENTION:

Turn off power lines before connecting power; failure to do so could cause injury to personnel and/or equipment.

Table 10A.AL

1746 P1 Power Supply Specifications

Description:

Line Voltage

Typical Line Power Requirement

Internal Current Capacity

User Current Capacity

Fuse Protection

Ambient Operating Temperature Rating

Humidity Rating

Wiring

20151

Specification:

85--132/170--265 V ac

50/60 Hz

135 VA

2 AMP at 5 V dc

0.46 AMP at 24 V dc

24 V dc -- 0.2 AMP

3 AMPs

0 to +55°C

(Current capacity derated by 5% at +60°C)

5 -- 95% (noncondensing)

#14 AWG

10A-53

Section 10A

I/O Interface

10A.6.4

1746 I/O Ring Adapter Fiber

Optic Connection

The connectors used to make the fiber optic connections to the I/O ring are listed in Table 10A.AM. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to Appendix A for additional information on fiber optic cables and connectors.

The fiber-optic connectors are located under the front door of the 1746I module for easy access. Run the fiber-optic cables out the bottom of the

1746I module to allow the front door of the module to close after the cables have been installed.

Table 10A.AM

1746 I/O Ring Adapter Fiber Optic Connectors

Connector on Digital I/O

I/O (RED)

I/O (BLACK)

Remark

Output

Input

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

10A.7

1746 Discrete I/O Racks

The following tables give input and output specifications for the standard

1746 I/O modules available for the 9/Series fiber-optic I/O ring. Contact your Allen-Bradley sales representative for details on any modules not listed here. See page 10B-8 for details on other 9/Series compatible 1746

I/O modules.

General 1746 Discrete I/O Module Specifications

Noise Immunity

Description:

Shock (operating)

Isolation

Environmental conditions

Operating temperature

Storage temperature

Humidity rating

Certification

Hazardous Environment Classification

Specification

NEMA-Standard ICS 2-230

Displacement -- .015 inch peak to peak at 5 - 57 Hz

Acceleration -- 2.5 G at 57 - 2000 Hz

30 G

1500 V

0 to +60

C (+32

° to +140

-40

° to +85

C (--40

° to +185

5 to 95% (noncondensing)

UL listed, CSA approved

Class I, Division 2 Hazardous Environment.

Some modules are excluded from this certification. Refer to the following tables for a complete listing.

10A-54

Section 10A

I/O Interface

Catalog

Number

1746-IA16

(RTB)

1746-IB16

(RTB)

Voltage

Category

100/120 V ac

24 V dc

0 V ac

1746-IA16

Off--State

Operating

Voltage

Number of

Inputs

85-132

10-30

Discrete Input Module Specifications

Points Per

Common

Backplane

Current Draw

5V 24V

0.085

Signal

Delay

(ms. max)

on=35

Off=45

On=8

Off=8

Off-State

Current

(max)

2 mA

1 mA

30 V ac

Input State Not Guaranteed

85 V ac

Off-State

Voltage

(max)

30 V ac

5.0 V dc

Nominal

Input

Current

12 mA at 120 V ac

8 mA at 24 V dc

On--State

0 V dc

1746-IB16

5 V dc 10 V dc

Measure voltage between common terminal and input terminal.

Inrush

Current

(max)

0.8 A n/a

132 V ac

30 V dc

Discrete Output Module Specifications

Catalog

Number

Voltage

Category

Operating

Voltage

1746-OA16

(RTB)

1746-OW16

(RTB)

120/240

V ac

V ac/V dc

Relay

85-265

5-265 V ac

5-125 V dc

1746-OA16

0 V ac

Operation Not Guaranteed

85 V ac

Number of

Outputs

0 V dc

0 V ac

1746-OW16

5 V dc

5 V ac

Points per

Common

Backplane Current

Draw

5v 24V

0.370

0.170

0.180

Signal Delay

(ms. max)

On=0.10

Off=11.0

On=10.0

Off=10.0

Off State

Leakage

(max)

2 mA

0 mA

Recommended Operating Range

Load

Current at 5

V dc (min.)

10 mA

Continuous

Current per

Point (max.)

0.50 A at 30

0.25 at 60

See contact rating chart below.

Continuous

Current per

Module (max.)

8 A at 30

4 A at 60

16.0 A ac

8.0 A/ common

If you measure the voltage at an output terminal that is not connected to a load or is connected to a high-impedance load, you may measure as much as 100 V ac even though the output is off.

265 V ac

125 V dc

265 V ac

1746-OW16 Relay Contact Rating Chart

Type

Maximum

Volts

Relay Contact Ratings for

1746-OW16

240 V ac

120 V ac

125 V dc

24 V dc

Ampere

Make

7.5 A

15.0 A

0.22 A Á

1.2 A

Break

0.75 A

1.50 A

Amperes

Continuous

2.5 A

1.0 A

2.0 A

Voltamperes

Make Break

1800 VA 180 VA

28 VA

10A-55

Section 10A

I/O Interface

10A.7.1

Wiring 1746 Discrete I/O

100/120

V ac

1746-IA16

IN 0

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

IN 8

IN 9

IN 10

IN 11

IN 12

IN 13

IN 14

IN 15 ac COM ac COM

All modules are UL 508 listed and CSA 22.2 142 approved. These modules meet requirements for Class I division 2 hazardous location requirements of both Underwriter’s Laboratory and the Canadian

Standards Association.

+dc

---dc

V dc

1746-IB16

IN 0

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

IN 8

IN 9

IN 10

IN 11

IN 12

IN 13

IN 14

IN 15 ac COM ac COM

COMMONS CONNECTED INTERNALLY COMMONS CONNECTED INTERNALLY

100/240

V ac

1746-OA16

V ac 1

OUT 1

OUT 0

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

V ac 2

OUT 9

OUT 8

OUT 11

OUT 10

OUT 13

OUT 12

OUT 15

OUT 14

+dc or L1 dc COM or

V dc

V ac

100/240

V ac

1746-OW16

V dc or

V ac 1 OUT 0

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

OUT 9

V dc or

V ac 2

OUT 8

OUT 11

OUT 10

OUT 13

OUT 12

OUT 15

OUT 14

+dc or L1

V dc

V ac dc COM or

10A-56

10A.8

1746 Analog I/O

Section 10A

I/O Interface

Selecting Voltage or Current Mode

The NIO4V analog module has a user selectable DIP switch setting which allows you to configure the input channels as either current or voltage inputs. The switches are located on the analog module board.

ATTENTION: Care should be taken to avoid connecting a voltage source to a channel configured for current input.

Improper module operation or damage to the module can occur.

Switch 1 = Input Channel 0

Switch 2 = Input Channel 1

On -- Current Mode

Off -- Voltage Mode

The module has two individual switches labeled 1 and 2. These switches control the input mode of input channel 0 and 1. A switch in the ON position configures the channel for current input. A switch in the OFF position configures the channel for voltage input.

Output channels are always voltage mode and can not be configured.

Wiring 1746 Analog I/O

Belden cable #8761 is recommended when wiring analog modules. Use the following guidelines in planning the system wiring for the analog modules: all analog common terminals (ANL COM) are electrically connected inside the modules. ANL COM is not connected to earth ground inside the module.

10A-57

Section 10A

I/O Interface voltages on IN+ and IN-- terminals terminals must remain within ±20

Volts with respect to ANL COM for proper input channel operation.

This is true for current and voltage input channel operation.

voltage outputs (OUT 0 and OUT 1) are referenced to ANL COM.

Load resistance (R1) for a voltage output channel must be equal to or greater than 1K ohms.

current output channels (OUT 0 and OUT 1) source current that returns to ANL COM. Load resistance (R1) for a current output channel must remain between 0 and 500 ohms.

input connections for single-ended or differential inputs are the same.

ATTENTION: Before wiring any analog module, disconnect power from the chassis and from any other source to the analog module.

Grounding Your Cable

Belden cable #8761 has two signal wires (black and clear), one drain wire and a foil shield. The drain wire and foil shield must be grounded at one end of the cable. Do not earth ground the drain wire and foil shield at both ends of the cable.

Input Channel -- Ground the drain wire and foil shield near the sourcing device.

Output Channel -- Use a rack mounting tab as a ground for the drain wire and foil shield.

Important: If you cannot ground the input channel at the sourcing device, ground the drain wire and foil shield at the rack mounting tab. Do not connect the foil shield or drain wire to the analog terminal block. They must be connected to an earth ground, which is not provided at the analog module.

10A-58

Section 10A

I/O Interface

Analog Module NIO4V

OUTPUT INPUT

POWER

ANALOG

(0) IN 0+

(1) IN 0--

(2) ANL COM

(3) IN 1+

(4) IN 1--

(5) ANL COM

(6) NOT USED

(7) OUT 0

(8) ANL COM

(9) NOT USED

(10) OUT 1

(11)ANL COM

1746- NIO4V

(0) IN 0+

(1) IN 0--

(2) ANL COM

(3) IN 1+

(4) IN 1--

(5) ANL COM

(6) NOT USED

(7) OUT 0

(8) ANL COM

(9) NOT USED

(10) OUT 1

(11)ANL COM

Jumper unusedinputs

Do not jumper unused outputs

Analog source

Analog Load

Reading/Writing Analog Data

The analog I/O module passes values to PAL through the I/O ring. The variable used to read/write the analog I/O module data is assigned using the PAL I/O assigner (refer to your 9/Series PAL Reference Manual for details). The following table shows the values of these PAL variables:

Voltage/Current Range

-- 10V to + 10V (1LSB)

0V to 10 V (1LSB)

0V to 5V

1V to 5V

--20mA to +20mA

0 to +20mA

4 to +20 mA

Table 10A.AN

Analog Input Decimal Values (to PAL)

Decimal Representation

--32,768 to + 32,767

0 to 32,767

0 to 16,384

3,277 to 16,384

--16,384 to +16,384

0 to 16,384

3,277 to 16,384

Number of Significant Bits

16 bits

15 bits

14 bits

13.67 bits

15 bits

14 bits

13.67 bits

Resolution per LSB

10A-59

Section 10A

I/O Interface

To determine an approximate voltage that an input value represents, use one of the following equations:

10 V

32,768

(input value) = input voltage (V) or for current

20 mA

16,384

( input value) = input voltage (V)

For example, if an input value of --16,021 is in the input image, the calculated input voltage is:

10 V

32,768

(--16,021) = --4.889221 V

This is the calculated value. The actual value may vary within the accuracy limitations of the module.

Voltage/Current Range

-- 10V to + 10V (1 LSB)

0V to 10 V (1 LSB)

0V to 5V

1V to 5V

0 to +21mA

0 to +20mA

4 to +20 mA

Table 10A.AO

Analog Output Decimal Values (from PAL)

Decimal Representation

--32,768 to + 32,767

0 to 32,767

0 to 16,384

3,277 to 16,384

0 to +32,764

0 to 31,208

6,242 to 31,208

Number of Significant Bits

14 bits

13 bits

12 bits

11.67 bits

13 bits

12.92 bits

12.6 bits

Resolution per LSB

To determine a value for the PAL variable of an analog output to produce a desired output, use one of the following equations:

32,768

10 V dc

(desired voltage output V) = output decimal value or for current

32,768

21 mA

( desired current output mA) = output decimal value

For example, if an output voltage of +1 V dc is desired, the value to be put in the corresponding PAL variable would be:

32,768

10V dc

(+1V dc) = 3277

10A-60

Section 10A

I/O Interface

10A.8.1

Analog I/O Specifications

(1746-NIO4V)

Features

High resolution -- 16 bit input and 14 bit output converters provide accurate control capabilities.

Backplane powered -- No external power supply required, reducing system cost.

User selectable inputs -- Configurable per channel for current or voltage inputs.

Input channel filtering -- Rejects high frequency noise that couples into an analog input signal.

Image maps directly into the 1746I adapter.

Isolation -- All analog modules are isolated from each other and from the backplane.

Description

Input Channels per Module

Output Channels per Module

Backplane Current Draw

Communication Format

Field Wiring to Backplane Isolation

Conversion Time

Current/Voltage Ranges

NIO4V

Step Response

Input

Output

Maximum Wire Size

Terminal Block

Noise Immunity

Environmental Conditions

Operating temperature

Storage temperature

Humidity rating

Recommended Cable

Certification

Hazardous Environment Classification

Specification

2 differential, voltage or current selectable per channel

2 voltage outputs, not individually isolated

55mA at 5V dc

115mA at 24 V dc

16 bit Two’s Complement Binary

500 V dc

512ms for all channels in parallel

±10 V dc or ±20 mA (input)

±10 V dc (output)

60 ms at 95%

2.5 ms at 95%

14 AWG

Removable

NEMA Standard ICS 2-230

0 to +60

C (+32

° to +140

--40

C to +85

C (--40

° to +185

5 to 95% (noncondensing)

Belden #8761

UL 508 listed, CSA 22.2 142 approved

Class I, Division 2 Hazardous Environment

10A-61

Section 10A

I/O Interface

10A.9

1746 I/O Fault Status

10A.9.1

Troubleshooting the 1746I

Communication Module

If the 9/Series fiber optic I/O ring should fault or any other fault should occur within the 1746 I/O rack, the 1746I module will attempt to maintain all of its I/O in the same state condition. This holds all output devices in the chassis to their present state. (Outputs already ON remain ON, outputs already OFF remain OFF, and analog modules maintain their present output voltage).

Wire your I/O devices accordingly considering all safety issues.

This section provides diagnostic information for troubleshooting your 1746

I/O chassis using the LED’s on the front of the 1746I module. Also in this section is information on using test modes to diagnose any problems with the fiber-optic connections.

OFF

This LED Status

Flashing

Run LED On

Indicates this possible cause:

Rack LED On

Rack LED Flashing

·The I/O ring and the 1746 I/O rack are communicating properly and the rack is functioning.

·RAM or ROM failure at power turn on.

·Device in rack failed or is not seated properly.

·Internal error in the 1746I adapter.

·A card type was found in the rack at power turn on that is not supported by the 1746I module.

Ring LED On

Ring LED Flashing

·Connection or device has failed in the I/O ring for a device before the 1746I in the ring.

·Power turned off at the CNC.

·Transmitter and receiver cables are reversed.

·Connection or device has failed in the I/O ring for a device after the 1746I in the ring.

All LEDs Off

·Power turned off at the CNC while the ring was up and running.

·Connection of I/O ring broken before this 1746I module while the ring was up and running.

10A-62

10A.10

Fast I/O

(9/260 and 9/290 only)

Section 10A

I/O Interface

The Fast I/O feature provides 4 inputs to and 4 outputs from the control.

This feature is used to make changes in PAL that will take effect the next iteration of the PAL program. Using the fast I/O feature, the operator can input values to the PAL program using the PAL flag $HSIN and output values using the PAL flag $HSOUT.

The fast I/O connector on the motherboard provides an interface port for fast input and output to and from the control. This connector interfaces with cable C11. Refer to page 7A-26 for additional information on cable

C11. Figure 10A.40 and Table 10A.AP show the connector and its pin assignments.

Figure 10A.40

Fast I/O Connector (has pins)

10A-63

Section 10A

I/O Interface

Table 10A.AP

Pin Assignments for the Fast I/O Connector (P3)

(Not available on the 9/230 and 9/440 control)

Pin No.

Signal Name Pin No.

Signal Name

FAST_I1

COM

FAST_I2

COM

FAST_I3

COM

FAST_I4

COM

FAST_O1

COM

FAST_O2

COM

FAST_O3

COM

FAST_O4

COM

Allen-Bradley recommends that you use the terminal blocks shown in

Figure 10A.41 to simplify the wiring between your control and the fast

I/O. The fast I/O cable connects to the connector on the block. Use the pin assignments in Table 10A.AP to wire the terminal connections.

Figure 10A.41

Recommended Terminal Blocks for Fast I/O Wiring

Weidmueller RI-16 Idc R (rail-mounted)

Cat. No. 914892

Weidmueller RI-16 Idc P (panel-mounted)

Cat. No. 914903

19203

Phoenix FLKM 16

Order No. 22 81 02 1

19204

10A-64

Section 10A

I/O Interface

Figure 10A.42 shows the fast I/O circuit.

Figure 10A.42

Fast I/O Circuit

(Not available on the 9/230 control)

+5 V

F38 Fast I/O Output

+5 V

1.8K

Fast I/O Input

Table 10A.AQ lists the input specifications for the fast I/O.

Table 10A.AQ

Fast I/O Input Specifications

Item

Maximum Input Current - Low

Maximum Input Voltage - Low

Specification

= 6mA/input

= 0.45V/input

Remark

Source

Table 10A.AR lists the output specifications for the fast I/O.

Table 10A.AR

Fast I/O Output Specifications

Not available on the 9/230 control

Item

Minimum Output Voltage - High

Minimum Output Current - High

Maximum Output Voltage - Low

Maximum Output Current - Low

Specification Remark

= 4.25V/output --

= 300 m

A/output

Source

= 0.5V/output

= 13mA/output

Sink

10A-65

Section 10A

I/O Interface

10A.11

Wiring I/O Safely

Customer supplied brake relay

Many safety issues present themselves to the machine tool builder when wiring I/O devices. Typically, 9/Series I/O devices attempt to maintain their current status in the event of a system failure, I/O ring fault, or

E-STOP condition. Make sure that this is a safe state for your machine by following these guidelines.

Make sure I/O is wired so power failure places the device in a safe condition. For example if an output point controls an axis brake, you would typically want the brake applied when the I/O device fails or loses power.

Make sure I/O is wired so E-STOP condition places the device in a safe condition. Remember E-STOP conditions do not reset I/O devices. I/O devices attempt to maintain their last state when E-STOP occurred. For example if an output point controls an axis brake, you would typically want the brake applied when the E-STOP condition occurs.

Brake Circuit

When R1-1 is closed brake is released.

R1--1

L1 (H)

If E-STOP string is broken, brake is engaged.

R2--1

L2 (L)

Energizes Brake Relay

PB2

Terminal

Block

COM COM

A01 A02 A03 A04 A05 A06 A07 A08 A09 A10

B01 B02 B03 B04 B05 B06 B07 B08 B09 B10

COM

Label

E-STOP String

Important: Notice in the above figure the E-STOP string only kills power to the terminal blocks of the I/O module which in turn de-energizes the brake relay. The actual I/O module on the I/O ring remains powered.

Killing power to the I/O device itself while the fiber optic ring is still running can cause I/O ring fault errors.

END OF SECTION

10A-66

10B.0

Section Overview

Section

10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

This section discusses using I/O adapter modules for the 9/Series I/O ring.

These adapter modules allow you to use Allen-Bradley’s 1746 I/O or 1771

I/O modules in the 9/Series I/O ring. This is accomplished by placing an adapter module in the I/O chassis that will interface to the 9/Series fiber optic I/O ring. These modules always reside in the first slot of the I/O chassis and replace the logic controller CPU or ASB adapter module that would typically reside in the first slot.

1771 Series B I/O Chassis

1746 Series B I/O Chassis

10B.1

1771 I/O Ring Adapter

Module

1771 XIOC adapter module

1746I adapter module

Use the 1771 I/O Ring Adapter Module to interface an Allen-Bradley 1771 series B I/O chassis with the control. The 1771 I/O ring adapter module provides the system installer with the option of using a 1771 series B I/O chassis for discrete inputs and discrete outputs to the control (only discrete

I/O cards are compatible with the 1771 adapter module). Use page 10B-10 to calculate how many ASRN chips are required for each I/O chassis.

The adapter module must be placed in the first slot of the 1771 series B I/O chassis. The 1771 series B I/O chassis is then interfaced with the fiber-optic I/O ring of the control using the fiber optic connectors on the adapter module. Refer to the Allen-Bradley 1771 I/O Ring Adapter

Module Product Data Sheet, publication 8500-4.5.1, for additional information on this module. No more than 16 1771 I/O adapter modules can exist on the 9/Series I/O ring.

10B-1

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Figure 10B.1 shows the 1771 I/O ring adapter module.

Figure 10B.1

1771 I/O Ring Adapter

ACTIVE

ADAPTER

FAULT

I/O RING

FAULT

I/O RING

ADAPTER

ALLEN-BRADLEY

RECEIVER

TRANSMITTER

REMOTE

RESET

10B.1.1

1771 I/O Ring Adapter Fiber

Optic Connection

11086-I

The connectors used to make the fiber optic connections to the I/O ring are listed in Table 10B.A. Each module connected to the system I/O ring has an optical transmitter and receiver. Fiber optic cables connect transmitters to receivers to form the I/O ring. Refer to Appendix A for additional information on fiber optic cables and connectors.

Table 10B.A

1771 I/O Ring Adapter Fiber Optic Connectors

Connector on Digital I/O

I/O (RED)

I/O (BLACK)

Remark

Output

Input

Connected To

Receiver on next module in I/O ring

Transmitter on previous module in I/O ring

10B-2

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

10B.1.2

1771 I/O Ring Adapter Node

Address Setting

Different types of I/O devices can have the same node address, but devices of the same type must each have a unique node address. Each 1771 I/O ring adapter is assigned a unique node address in the I/O assignment file of

ODS. This address corresponds to a switch setting on the device itself. Up to 16 addresses are available. Figure 10B.2 shows the location of the node address switch assembly on the 1771 I/O ring module.

Figure 10B.2

1771 I/O Ring Adapter Switch Assembly Locations

S1 S2

OFF ON

11343-I

Important: Switch assemblies S1 and S2 indicate which slots in the I/O chassis have modules installed and operating. Refer to the Allen-Bradley

1771 I/O Ring Adapter Module Product Data Sheet, publication

8500-4.5.1, for additional information on this module.

Set switch assembly S3 to correspond to the node address as shown in

Table 10B.B.

Important: Switch numbers 7 and 8 of switch assembly S3 are not used.

Their position should not be altered.

10B-3

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Table 10B.B

1771 I/O Ring Adapter Node Address Setting

Node Address Switch Assembly Position

Hexadecimal Binary

00 00 0000

OFF

01 00 0001 OFF OFF OFF OFF OFF ON

00 0010 OFF OFF OFF OFF

00 1111 OFF OFF

OFF

Important: The 3D, 3E, and 3F node addresses are used for diagnostics purposes only.

10B-4

10B.2

1746 I/O Ring

Adapter Module

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Use the 1746 I/O Ring Adapter Module to interface Allen-Bradley 1746

I/O devices with your 9/Series control. The 1746 I/O ring adapter module provides the system installer with the option of using 1746 I/O devices in the 9/Series fiber--optic I/O ring.

The adapter module must be placed in the first slot (slot 0) of the 1746 series B I/O chassis. The 1746 I/O ring adapter module provides the interface between the 1746 I/O chassis and the fiber-optic I/O ring of the control using the fiber--optic connectors on the adapter module.

Figure 10B.3

1746I I/O Ring Adapter

You can place several 1746I modules with 1746 I/O chassis in the 9/Series fiber-optic ring. Each 1746 I/O chassis must contain its own 1746I module

(daisy chaining racks together using one 1746I module is not allowed).

16 chassis are allowed on the 9/Series fiber-optic I/O ring.

10B.2.1

1746I I/O Ring Adapter Node

Address Setting

10B-5

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Assign an address to the module using the dip switch S1 found on the side of the 1746I module. Figure 10B.4 shows the location of the node address switch assembly on the 1746I module.

Figure 10B.4

1746 I/O Ring Adapter Switch Assembly Locations

10B-6

1 2 3 4 5 6

Other 9/Series I/O devices (such as an HPG or MTB panel) on the 9/Series fiber-optic ring can have the same node address as the 1746I module.

1746I module.

Set switch assembly S1 to correspond to the node address as shown in

Table 10B.C.

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Table 10B.C

1746I I/O Ring Adapter Node Address Setting

Node Address

Hexadecimal Binary

00 0000

01 0001

0010

1111

Switch Assembly Position

1 2 3 4

OFF OFF OFF OFF

OFF OFF OFF ON

OFF OFF

OFF

Important: Switch 5 and 6 of S1 must remain in the OFF position for normal operation.

10B.2.2

1746 I/O Fault Status

Wire your I/O devices accordingly considering all safety issues.

10B.2.3

9/Series 1746 I/O Catalogs

(1) 1746-A4

(1) 1746-P1

(1) 8500-1746I

(2) 1746-IA16

(1) 1746-OA16

(1) set fiber optic connectors

Total I/O

Catalog Number

8500-S115

4 Slot Chassis

115/230V ac Power Supply

I/O Ring Interface Adapter

Module

16 point 115V ac Input

Module

16 point 115V ac Output

Module

For connection to I/O ring.

32 115V ac Inputs

16 115V ac Outputs

3 ASRN chips

Three different fully equipped 1746 I/O chassis are available for the

9/Series I/O ring. See page 10A-49 for details on these I/O devices.

(1) 1746-A4

(1) 1746-P1

(1) 8500-1746I

(2) 1746-IB16

Catalog Number

8500-S24

4 Slot Chassis

115/230V ac Power Supply

(1) 1746-A4

(1) 1746-P1

I/O Ring Interface Adapter

Module

(1) 8500-1746I

16 point 24V dc Input Module (1) 1746-NIO4V

Catalog Number

8500-SANL

4 Slot Chassis

115/230V ac Power Supply

I/O Ring Interface Adapter

Module

Analog Module

(1) 1746-OW16

(1) set fiber optic connectors

Total I/O

16 point 24V dc Output

Module

For connection to I/O ring.

32 24V dc Inputs

16 24V dc Outputs

3 ASRN chips

(1) 1746-N2

(1) set fiber optic connectors

Total I/O

2 Empty Slot Covers

For connection to I/O ring.

2 analog input chnls.

2 analog output chnls

6 ASRN chips

10B-7

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

10B.2.4

Other Compatible 1746 I/O

Modules

The following 1746 chassis and I/O modules are compatible when used with a 1746I module on the 9/Series fiber-optic I/O ring. Other modules not listed here may also be compatible. Call your Allen-Bradley sales office for details on compatibility with any 1746 I/O modules not listed here.

Catalog Number: Description:

1746--A4

1746--A7

1746--A10

1746--A13

Chassis

4--Slot Chassis

7--Slot Chassis

10--Slot Chassis

13--Slot Chassis

1746--P1

1746--P2

1746--P3

Power Supplies

Power Supply (120/240V ac)(2amp @ 5V dc)(.46amp @ 24V dc)

Power Supply (120/240V ac)(5amp @ 5V dc)(.96amp @ 24V dc)

Power Supply (24V dc)(3.6amp @ 5V dc)(.87amp @ 24V dc)

120V ac Input Modules

1746--IA4 120V ac 4 Input Module

1746--IA8

1746--IA16

120V ac 8 Input Module

120V ac 16 Input Module

240V ac Input Modules

1746--IM4 240V ac 4 Input Module

1746--IM8

1746--IM16

240V ac 8 Input Module

240V ac 16 Input Module

24V dc Input Modules

1746--IB8 24V dc 8 Input module (sink)

1746--IB16

1746--IB32

1746--IV8

24V dc 16 Input Module (sink)

24V dc 32 Input Module (sink)

24V dc 8 Input Module (source)

1746--IV16

1746--IV32

24V dc 16 Input Module (source)

24V dc 32 Input Module (source)

120V ac Output Modules

1746--OA8 120V ac 8 Output Module

1746--OAP12

1746--OA16

120V ac 12 Output Module

120V ac 16 Output Module

24V dc Output Modules

1746--OB8 24V dc 8 Output Module (source)

1746--OB16

1746--OB32

1746--OV8

24V dc 16 Output Module (source)

24V dc 32 Output Module (source)

24V dc 8 Output (sink)

10B-8

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Catalog Number: Description:

1746--OV16

1746--OV32

24V dc 16 Output Module (sink)

24V dc 32 Output Module (sink)

V ac/V dc Relay Output Modules

1746--OW4 V ac/V dc Relay 4 Output Module

1746--OW8

1746--OW16

V ac/V dc Relay 8 Output Module

V ac/V dc Relay 16 Output Module

1746--IO4

1746--IO8

120V ac 2 Inputs & ac/dc Relay 2 Outputs

120V ac 4 Inputs & ac/dc Relay 4 Outputs

1746--IO12

1746--NIO4I

1746--NIO4V

120V ac 6 Inputs & ac/dc Relay 6 Outputs

1746--NI4

Analog I/O Modules

Analog 4 Input Module (--20ma to +20ma) or (--10V dc to +10V dc)

Analog 2 Inputs (--20ma to +20ma) or (--10V dc to +10V dc) & 2 Outputs (0 to 20ma)

1746--NO4I

1746--NO4V

Analog 2 Inputs (--20ma to +20ma) or (--10V dc to +10V dc) & 2 Outputs

(--10V dc to + 10V dc)

Analog 4 Output Module (0 to 20ma)

Analog 4 Output Module (--10V dc to +10V dc)

Specialty I/O Modules

1746--IG16 5V dc/TTL 16 Input Module (source)

1746--OG16

1746--OBP16

1746--IN16

1746--OX8

5V dc/TTL 16 Output Module (sink)

24V dc 16 Output Module (enhanced source)

24V ac/V dc 16 Input Module (source) ac/dc Isolated Relay 8 Output Module

Important: To configure a 12--bit I/O module using the I/O assignments application, you must select a 16--bit device, while only assigning the first

12 I/O points.

10B-9

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

10B.2.5

Troubleshooting the 1746I

Communication Module

This section provides diagnostic information for troubleshooting your 1746

I/O chassis using the LEDs on the front of the 1746I module. Also in this section is information on using test modes to diagnose any problems with the fiber-optic connections.

OFF

This LED Status

Flashing

Run LED On

Indicates this possible cause:

Rack LED On

Rack LED Flashing

·The I/O ring and the 1746 I/O rack are communicating properly and the rack is functioning.

·RAM or ROM failure at power turn on.

·Device in rack failed or is not seated properly.

·Internal error in the 1746I adapter.

·A card type was found in the rack at power turn on that is not supported by the 1746I module.

Ring LED On

Ring LED Flashing

·Connection or device has failed in the I/O ring for a device before the 1746I in the ring.

·Power turned off at the CNC.

·Transmitter and receiver cables are reversed.

·Connection or device has failed in the I/O ring for a device after the 1746I in the ring.

All LEDs Off

·Power turned off at the CNC while the ring was up and running.

·Connection of I/O ring broken before this 1746I module while the ring was up and running.

10B.3

1771 and 1746 I/O adapter

ASRN Use

Use this section to calculate the number of ASRN chips used by the 1771 or 1746 I/O chassis in your system. Each chassis uses a different number of ASRN chips depending on the size of the chassis and the number and types of I/O devices in the chassis.

Each different 9/Series control supports a limited number of ASRN chips on its I/O ring. Refer to Table 10A.B for the number of ASRN chips supported on the ring for your specific 9/Series processor.

10B-10

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

The following section describes how to calculate how many ASRN chips are used by either the 1771 or 1746 I/O devices. Refer to page 10A-2 for information on the number of ASRN chips used by other 9/Series I/O ring devices.

ASRN Chip Used by 1771 and 1746 I/O Chassis

The number of ASRN chips used by a 1746 or 1771 I/O chassis will vary depending on the chassis size and the number and type of I/O cards installed in the chassis. Different size chassis have a minimum number of

ASRN chips required (regardless of the number of I/O points) and different

I/O devices in the chassis require different numbers of ASRN.

To determine the number of ASRN “chips” used by the I/O chassis in a specific I/O ring application, use the following procedure:

Determine “A”, the minimum chassis ASRN requirements:

Chassis Size:

1746 I/O Chassis

4 slot (1746-B4)

7 slot (1746-B7)

10 slot (1746-B10)

13 slot (1746-B13)

Minimum number of ASRN chips:

A = 3

A = 4

A = 6

A = 7

4 slot

8 slot

12 slot

16 slot

1771 I/O Chassis

Chassis Size: Minimum number of ASRN chips:

A = 3

A = 5

A = 7

A = 8

Calculate “B” chassis input requirements:

(discrete inputs) + (16)(number of analog input channels)

=B (round up)

Calculate “C” chassis output requirements:

(discrete outputs) + (16)(number of analog output channels)

=C (round up)

10B-11

Section 10B

9/Series Adapter Modules for

1771 and 1746 I/O Devices

Important: Each analog channel on an analog module must be counted.

Even if the channel is not used or jumpered out it must be counted as a channel on the ring.

The largest of A, B, or C determines the total number of ASRN “chips” for the 1746 and 1771 I/O configuration.

Example: A 1746 4-slot chassis, one 16-point input card, one 8-point output card, and an analog module with two input and two output channels

(1746-NIO4V).

A = 4 slot chassis = (3 ASRN)

B =

(16) + (16)(2)

= 4.36 (5 ASRN)

C =

(8) + (16)(2)

= 6.66 (7 ASRN)

The 1746 chassis in this example will use 7 ASRN “chips” (the largest value of A, B, or C).

The number of ASRN “chips” used by the chassis must be added to the total number of ASRN “chips” used by all the I/O devices on the current

I/O ring. Refer to page 10A-2 for information on the number of ASRN chips used by other 9/Series I/O ring devices.

Important: The total number of ASRN chips allowed on the fiber optic ring is shown in Table 10A.B for each processor type. Exceeding this number creates an E-STOP condition. Since your system scan time is configurable in AMP it is possible to set the system scan time so low that the control will not complete the I/O scan of all the ASRNs in your ring.

END OF SECTION

10B-12

--1

Publication 8520--6.2.10 -- February 1997

--2

Publication 8520--6.2.10 -- February 1997

PN 176041

9/Series Hardware

TAB 11

1394 Digital Drive Systems

8520-6.2.11 -- February 1997 PN--176030

11A.0

Section Overview

11A.1

Hardware Overview

System Module

(CNC Version)

Section

11A

Connecting 1394 Digital Drive Systems

This section gives general information on connections to the CNC version of the Allen-Bradley 1394 Digital Drive. More detailed information can be found in the 1394 Digital AC Multi-Axis Motion Control System Users

Manual (publication 1394-5.0).

This drive is designed to interface to the Allen-Bradley 9/230 1394 Digital

CNC or 9/260, 9/290 1394 4 axis digital servo cards (8520-SM4). This section does not discuss connecting to an analog version of the 1394 drive system nor does it discuss general 1394 drive installation/connection. This section only covers connection to the 9/Series CNC.

The 1394 Digital Drive (CNC version) consists of the following major components:

Axis Modules

Status LED

(axis module)

Slider Interconnect with Termination Panel

Status LED

(system module indicates fiber optic ring fault)

Motor Power & Ground

Connections

E-Stop Connection

Fiber Optic Connection

CNC Connection

Resolver Inputs

Three-Phase Input Power

Motor Brake & Thermal

Sensor Termination

11A-1

Section 11A

Connecting 1394 Digital Drive Systems

System Module -- This is the largest module in the 1394 Digital Drive system (left most module). It contains the following circuit boards:

- CNC Interface Board -- This board provides the interface to the

Allen-Bradley 9/230 Digital 1394 CNC. Drive commands from the

CNC are wired to this board. Feedback from the 1326 motor resolver is passed to the CNC through this board after being converted from the 1326 motor resolver signal into encoder type A quad B and

U/V/W. Fiber optic connection to the 9/Series fiber optic I/O ring is provided through this board.

- CNC Wiring Board -- The 1326 motors’resolver is wired to this board which also provides power for resolver excitation. The Drive

OK relay contacts are also available on this board for connection to the 9/Series E-Stop string.

- Power Supply -- This supplies power to the system module as well as the axis modules. Attach incoming AC three-phase power here.

Axis Module - Connect up to four axis modules to the 1394 system.

Axis modules convert the DC power supplied by the system module to a variable AC voltage (460V AC input provides 460 AC out, derated

380V AC input provides 380V AC out). This voltage will have controlled phase, amplitude and frequency for regulating the speed, torque and direction of the 1326 AC Servomotors. The axis modules are available in a wide range of power ratings with continuous peak capabilities of 200% of continuous rating for short durations.

Make motor connections for power, ground, brake, and thermal sensor to each axis module. Each motor is wired to its own axis module.

1326 motors are described in the 1394 Digital AC Multiaxis Motion

Control System Users Manual. The 1326 series of motors operate at either 460V AC or 380V AC. Connection of these motors is made directly to the Axis Module.

Each 1326 motor is equipped with a resolver for motor commutation.

Resolvers are connected to the Wiring Board found in the system module. Resolver signals are converted to a A quad B and U/V/W encoder type signal on the CNC interface board before they are sent to the CNC.

For details/dimensions/specification/etc. on any of these components, refer to your 1394 Digital AC Multi-Axis Motion Control System Users

Manual.

11A-2

Section 11A

Connecting 1394 Digital Drive Systems

11A.2

Resolver Feedback

The 1326 servo motors that interface to the 1394 drive rely on resolvers mounted directly to the motor for proper commutation. For these resolvers to be properly interfaced to the 9/Series CNC their feedback must be converted to an A quad B signal. This is accomplished by the CNC interface board which takes the resolver feedback from the wiring board and converts it into an A quad B signal before sending this signal on to the

9/Series CNC.

A dip switch (SW1) on the CNC interface board determines the number of encoder counts per revolution this resolver feedback is translated into. The bottom four switches of dip switch SW1 selects between 8192 or 32768 counts per motor revolution as follows:

System Module

CNC Wiring Board

CNC Interface Board

Press Cover

Release to Open

Open Cover

ASRN 0

ASRN 1

FB3

FB2

FB1

FB0

Switch SW1

Left (away from Interface Board) = 32768 counts

Right (towards interface board) = 8192 counts

These switches set the number of counts per/rev for each feedback device connected to this 1394 drive. CNC1 corresponds to the feedback device connected to FB0, CNC2 corresponds to the feedback device connected to

FB1, etc.. You must also indicate your dip switch selections by selecting the appropriate number of counts per motor revolution in AMP for each servo.

11A-3

Section 11A

Connecting 1394 Digital Drive Systems

System Module

(cover removed)

CNC Wiring Board

Resolver Connectors

CNC Interface Board

Maximum Axis Speeds

Maximum axis speeds are limited by the CNC interface boards ability to decode resolver feedback and convert it into encoder A quad B feedback.

The maximum motor RPM when set for 32768 counts/rev is 3000 RPM.

Actual final axis speed is based on gearing and lead screw pitch.

Exceeding this motor speed can result in feedback overflow on the CNC interface board and a feedback error will be generated.

Connecting Resolver Feedback

Resolver feedback is wired directly from the motor mounted resolver to the

CNC wiring board found in the system module. This cable can be purchased directly from Allen-Bradley (cat no 1326-CCU-xxx).

CNC Wiring Board

TB1

DROK

TB3

6466

FB0 FB1 FB2 FB3

Resolver Connectors

11A-4

Section 11A

Connecting 1394 Digital Drive Systems

11A.3

Connecting the 9/Series

We recommend wiring feedback as follows:

Resolver (attached to motor from axis module):

1 (slot zero in AMP)

2 (slot one in AMP)

3 (slot two in AMP)

4 (slot three in AMP)

Connect to feedback board:

FB0

FB1

FB2

FB3

Outputs A quad B to

CNC interface board:

CNC 1

CNC 2

CNC 3

CNC 4

Connect your 9/Series CNC directly to the 1394 system module using

Allen Bradley cable 8520-DSC. This cable carries drive signals from the

9/Series CNC to the 1394 drive system. It also returns motor feedback to the CNC from the resolvers (after it has been converted to A quad B on the

CNC interface board). Cable connections are made easily through the bottom of the system module.

Connect this cable between the CNC interface board (connectors CNC1 to

CNC4) and either the 1394 digital 9/230 (connectors J1 to J3) or the four axis 1394 digital servo card on the 9/260 or 9/290 (connectors J1 to J4).

CNC Interface Board

System Module

(cover removed)

CNC Wiring Board

Resolver Connectors

CNC Interface Board

Fiber Optic Connectors

CNC4

CNC3

CNC2

CNC1

Front of

System Module

11A-5

Section 11A

Connecting 1394 Digital Drive Systems

Each of these CNCx connectors on the CNC interface board corresponds to the motor and feedback device (if the feedback is wired to the CNC wiring board correctly) of the axis module (x). For example CNC1 is used for axis module 1 and FB0. CNC2 is for axis module2 and FB1. Ultimately the connector and feedback combinations you decide to use for each axis is configured in AMP however we recommend the following configuration:

Axis Number CNC Interface

Board

CNC 1

CNC 2

CNC 3

CNC 4

Four Axis

1394 Digital

Servo Card

1394 Digital

9/230 CNC

N/A

11A-6

Section 11A

Connecting 1394 Digital Drive Systems

Indicates twisted pair

44 Pin D-shell

(to CNC)

The CNC interface cable, 8520-DSC, terminates with a 44 pin miniature

D-shell at the CNC and a 26 pin D-shell at the 1394 CNC interface board.

This cable is 27 inches long. Pinouts are shown below:

C47

Shield wire, no connection at 1394 drive end.

U high

U low

V high

V low

W high

W low

A high

A low

B high

B low

Z high

Z low

Ret.

Ret

Status_O

26 Pin D-shell

(from 1394 System Module)

Status_L (gnd)

Axis Enable Request

Signal Common

Gnd 24V input return

11A-7

Section 11A

Connecting 1394 Digital Drive Systems

11A.4

1394 Addressing and Fiber

Optic Connections

The 1394 digital drive must be placed in the 9/Series fiber optic ring.

Configure this drive into the I/O ring using the I/O configuration utility as discussed in your 9/Series PAL Reference Manual. Since multiple 1394 drives (up to four) are allowed into the 9/Series I/O ring each drive must be given an independent ASRN address on the ring. This ASRN ring address is selected using a dip switch on the CNC interface module.

Switch SW1

Left (away from Interface Board) = Off

Right (towards interface board) = On

System Module

Address

Address 00

Address 01

Address 02

Address 03

ASRN1 ASRN0

Left Left

Left Right

Right

Left

Right

CNC Wiring Board

CNC Interface Board

Press Cover

Release to Open

Open Cover

ASRN 0

ASRN 1

AXIS 4

AXIS 3

AXIS 2

AXIS 1

11A-8

Section 11A

Connecting 1394 Digital Drive Systems

The 1394 digital drive receives configuration information through the

9/Series fiber optic ring. The drive also has the ability to pass drive error and status back to the CNC through this fiber optic connection.

Connections to the fiber optic ring are made on the bottom of the system module to the back of the CNC interface board. Refer to NO TAG for details on constructing fiber optic cables.

Input Wiring Board

Fiber Optic In (black)

Fiber Optic Out (red)

CNC 4

CNC 3

CNC 2

CNC 1

Feedback

Connectors

(FB0---FB3)

Bottom View

Important: I/O ring diagnostics for the 1394 Digital Drive is available and discussed on page 15A-29.

11A-9

Section 11A

Connecting 1394 Digital Drive Systems

11A.5

1394 Drive E-Stop

Connection (TB1)

System Module

(cover removed)

CNC Wiring Board

Resolver Connectors

CNC Interface Board

E--Stop connection is made to the 1394 CNC wiring board drive okay contactor (TB1 DROK). This relay contact is closed when 24V drive power (W1, W2) is applied and no faults are present on the drive. This relay is opened when a drive fault occurs or 24V drive power is lost.

DROK Specs.

115V AC/24V DC

1Amp (Inductive Load)

CNC Wiring Board

E-Stop

Connection

TB1

DROK

TB3

FB0 FB1 FB2 FB3

Important: To help you insert and remove wires on the Input Wiring

Board, the supplied “Terminal Block Operating Tool” (pictured below) should be used as shown.

Insert Tool in Rear Slot to Release Lock

Insert (or Remove)

Bare, Stripped Wire

11A-10

Section 11A

Connecting 1394 Digital Drive Systems

Figure 11.5

Recommended Connection of 3- phase Drive Power

1394 Power Strip

Bussman FRS--R--20A (min) 600 V AC or equivalent (qty 3) m3

Three-phase input

360 or 480V AC m2 m1 m

Bulletin 100

Contactor Power c1

DC+

INT

COL

U V

AC Bulletin 100--A30N x 3 (surge protector required) or

DC Bulletin 100--A30NZ x 3

Noise suppressor

Internal E-STOP relay K

12 V dc coil

Contact ratings:

30 V dc 1.4 A

Customer supplied

24V Power Supply

Output 24 V ac or

24 V dc

Customer

Supplied

Fuse c

Customer Supplied

E-Stop Control Relay

Noise suppressor

7 6 5 4

E-Stop Cont.

3 2 1

9/Series

E-Stop

Connector TB1

1394 TB1

DROK

Extreme overtravel switches

TB1

E-Stop String

Motor thermal switches may be connected directly

Remote

E-Stop button

ATTENTION: Brake control should not be directly released by the E-Stop status relay (or your customer supplied E-Stop control relay). Brakes should only be released by the PAL logic when it has determined that three phase power is available to the axis modules long enough for the motors to have sufficient power to hold position and the control is out of E-Stop.

11A-11

Section 11A

Connecting 1394 Digital Drive Systems

Important: To help you insert and remove wires on the Input Wiring

Board, the supplied “Terminal Block Operating Tool” (pictured below) should be used as shown.

Insert Tool in Rear Slot to Release Lock

Insert (or Remove)

Bare, Stripped Wire

11A.6

1394 Low Voltage Test

Points (TB3)

TB3 contains four test points used for testing power supply voltage on the

CNC interface board. Test voltages are as follows:

TB3

TB3 Test Point Voltage

TB3-1

TB3-2

TB3-3

TB3-4

+5V dc

Common

+15Vdc

--15Vdc

CNC Wiring Board

System Module

(cover removed)

CNC Wiring Board

Resolver Connectors

CNC Interface Board

TB1

DROK

TB3

FB0 FB1 FB2 FB3

Low Voltage

Test Points

11A-12

11A.7

1394 LEDs

Section 11A

Connecting 1394 Digital Drive Systems

If the correct voltages are not present at these test points, and incoming power to the drive is turned on, contact your local Allen-Bradley sales office for service information.

Two sets of LEDs are available on the 1394 drive CNC interface. One on the system module, and one on each axis module.

System Module LED

The system module LED (labeled STATUS) is used to indicate the status of the fiber optic I/O ring. If the LED is on (red) the fiber optic ring has failed at some point before the 1394 system module. If it is flashing, the fiber optic ring has failed at some point after the 1394 system module.

Axis Module LED

Each axis module has one LED visible from the front of the module

(labeled STATUS). Read this LED as follows:

Steady Green

Flashing Green

Flashing Red/Green

Flashing Red

Steady Red bus up, axis enabled bus up, axis not enabled ready, bus not up fault present hardware malfunction

11A-13

Section 11A

Connecting 1394 Digital Drive Systems

11A.8

General Wiring Overview

The following figure shows a typical interconnect diagram for a 9/Series

CNC to a 1394 drive. Note this figure only illustrates one servo connection, each 1394 drive can support up to four servos.

Figure 11.1

Wiring Diagram For Series 1394 Drives

9/Series

CNCs

Servo

Connector

CNC Interface

Board

1394

Power

Supply

DC+

COL

INT

To Cabinate

Ground Bar

User Supplied

24V AC or 24V DC

(non-polarized), 15A

Three-phase input

360-480V AC

1394 Axis Module

Thermostat and Brake Feedthru

U1 V1 W1 PE1 PE2 PE3 4 3 2 1 4 3 2 1

E-Stop string

1394 System Module

TB1

CNC Wiring Board

Drive OK Relay

DROK

END OF SECTION

1 2 3

T1 T2 T3

Servo

Motor

8 7 6 4 5 9

GND B2 B1 K2 K1

To next axis and User Brake

Control Input

Brake

Thermostat

Resolver

Ground Bar

11A-14

Publication 8520-6.2.11 -- February 1997

I--2

Index

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.11 -- February 1997

PN176030

9/Series Hardware

TAB 12

Analog Servo Drive Connection

8520-6.2.12 -- February 1996 PN--160485

Section

Wiring A-B Analog Drives

12.0 Section Overview

This section discusses the wiring of Allen-Bradley Analog servo drive amplifiers. This manual is not intended to be used in place of documentation that accompanies an A-B drive but should be used with such documentation. The following table lists the Allen-Bradley drives supported by the control that are covered in this section.

Table 12.A

A-B Drives Selection Guide References

A- B Drive Publication No.

1386 1386--5.0

1387B

1388

1387-5.0

1388-5.1

1389

1391

1392

1389-5.1

1391-5.0

1392-5.1

Figure No.

Figure 12.1

Figure 12.2

Figure 12.3

Figure 12.5

Figure 12.6

Figure 12.4

Title

DC PWM Servo Drive (Multi-Axis)

DC Spindle Drive (Analog) Product Data

DC PWM Servo Drive (Single Axis) Product Data Series B

AC Servo Amplifier (Multi--Axis) Product Data

AC Servo Amplifier (Single Axis) Product Data

High Performance AC Drive (460V and 230V) Product Data

For digital drive systems, refer to sections beginning on page 13A-1 (for

8520 systems) or page 11A-1 (for 1394 systems). For non A-B analog drives, refer to documentation prepared by the drive manufacturer along with the analog specifications given in this manual for your specific processor.

The figures in this section emphasize the wiring between the termination panel and E-STOP string to the drives. They do not show complete detailing of the drives. You should have your drive manual handy when you use these figures.

12-1

Section 12

Wiring A-B Analog Drives

Figure 12.1

Wiring Diagram for Series 1386 Drives

1771 HTE

Encoder

Termination

Panel

DRIVE

DR RET

SHLD

DRIVE

See note 1

See note 2

Reset 3

Common 2

E-STOP 1

Motherboard (9/260 and 9/290) or Processor board (9/230) terminal block BT1

If your control has terminal 8, then connect it to chassis ground.

If terminal 8 is not present on your control, then this type of grounding is not necessary.

E-STOP Status

Relay Contact connection

Connection to MTB

Panel E-STOP and E-STOP Reset

Other user defined

E-STOP

Devices

Axis overtravel

Remote

E-STOP

Button

Encoder

Motor

Drive OK

Board

TB1 -

1 Diff +

2 Diff --

3 Signal Common

4 Aux

5 Tach

6 Signal Common

TB2 -

1 Decoupled Curr

2 Sig Common

3 Reset

4 Interlock

5 Signal Clamp --

6 Signal Clamp +

7 Signal Clamp Ref

+ 15V dc

Common

-- 15V dc

1386 - AA Servo Amplifier

1386 - M

Chassis

Motor Power

Terminal Block

NOTE

1. We recommend installation of this connection. Remove it if excessive noise from chassis ground occurs.

2. The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

11368-I

12-2

Section 12

Wiring A-B Analog Drives

If your control has terminal 8, then connect it to chassis ground.

If terminal 8 is not present on your control, then this type of grounding is not necessary.

Reset 3

Common 2

E-STOP 1

Motherboard (9260 and

9/290) or Processor Board

(9/230) terminal block BT1

1771 HTE

Encoder

Termination

Panel

Figure 12.2

Wiring Diagram For Series 1387B Drives

115V ac

Status relay power

Connection to MTB

Panel E-STOP and E-STOP Reset

E-STOP status relay

See note

Velocity Command

User Power to drive logic

1387B Servo Amplifier (see note 1)

Control Power High

Control Power Low

Coast/DB Stop

Internal tie Point

High Accel/decel Rate

Internal Logic Power

Enable Input

TB2

Run Reference (+)

Run Reference (--)

Shield

Common

TB5

Fault

TB5

TB1

DRIVE

DR RET

SHLD

DRIVE

See note 2

Remote

E-STOP

Axis

Overtravel

NOTE:

1. The control works only with 1387 drives that use 115V ac and have the dynamic braking option. Refer to Bulletin 1387 User

Manual (Publication 1387-5.0) for power wiring and motor connection.

2. We recommend installation of this connection. Remove it if excessive noise from chassis ground occurs.

3. The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

Motor

Thermal

Overload

Drive

XFMR

Thermal

Overload

12-3

Section 12

Wiring A-B Analog Drives

Figure 12.3

Wiring Diagram For Series 1388 Drives

If your control has terminal 8, then connect it to chassis ground.

If terminal 8 is not present on your control, then this type of grounding is not necessary.

Status relay power

E-STOP status relay

240/480V AC

3 Phase

50/60Hz

120V ac

3 phase

50/60 Hz

Reset 3

Common 2

E-STOP 1

Connection to MTB

Panel E-STOP and E-STOP Reset

Bulletin 1388

Power

Transformer

P1 P2

Thermal

Switch

Motherboard (9260 and

9/290) or Processor Board

(9/230) terminal block BT1

DRIVE

DR RET

SHLD

Note 1

1771 HTE

Encoder

Termination

Panel

Axis

Overtravel

NOTE:

1. We recommend installation of this connection. Remove it if excessive noise from chassis ground occurs.

Remote

E-STOP

2. The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

Tach

P1 P2

Motor

Velocity

Command

Note 2

A3TB1

A2TB1

+ 23V dc

CR1

Drive

Fault

CR1

Bulletin 1388

DC Servo Amplifier

7 8 9

12-4

Section 12

Wiring A-B Analog Drives

Figure 12.4

Wiring Diagram For Series 1392 Drives

If your control has terminal 8, then connect it to chassis ground.

If terminal 8 is not present on your control, then this type of grounding is not necessary.

Reset 3

Common 2

E-STOP 1

Status relay power

+24V

E-STOP status relay

Connection to MTB Panel

E-STOP and

E-STOP

Reset

Motherboard (9260 and

9/290) or Processor Board

(9/230) terminal block BT1

E-STOP string

DRIVE

DR RET

SHLD

DRIVE

Remote

E -- stop

Note 1

Axis

Overtravel

Motor

Thermal

Switch

T2 P1 P2

Transformer

Thermal

Switch

Velocity Command

Note 2

ENCODER

CH A. HI

CH A. LO

A B SHLD

CH B. HI

CH B. LO

Z SHLD

CH Z. HI

CH Z. LO

+ Speed Ref.

-- Speed Ref.

Coast to Stop

Drive Enable

External Reset

Customer 0 Volts

Drive

Ready

Ground

Stud

Bulletin 1392

Servo Amplifier

(Standard Parallel

Interface J9

Main Control Board)

Encoder Fanout

Customer Outputs

A’

B’

Z’

Cust

+ 12V

Cust

0 Volts

78 77 76 75 74 73 72 71

1771 HTE

Encoder

Termination

Panel

NOTE:

1. We recommend installation of this connection. Remove it if excessive noise from chassis ground occurs.

2. The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

+12V Power Supply

(user -supplied)

12-5

Section 12

Wiring A-B Analog Drives

Figure 12.5

Wiring Diagram For Series 1389 Drives

Reset 3

Common 2

E-STOP 1

If your control has terminal 8, then connect it to chassis ground.

If terminal 8 is not present on your control, then this type of grounding is not necessary.

Motherboard (9260 and

9/290) or Processor Board

(9/230) terminal block BT1

System Ground

Status relay power

3 phase

Connection to MTB Panel

E-STOP and

E-STOP

Reset

DRIVE

DR RET

SHLD

Main Disconnect/Fuses

+240/480V ac

Control

Transformer

E-STOP status relay

E-STOP

String

Note 1

Frame

G2 G1 G0 X0

Axis

1389 Isolation

Transformer

120V ac

P1 P2

Thermal

Transformer

Switch

Overtravel

(Extreme)

Remote

E-STOP

Motor

Thermal

Switch

(see T1, T2 on

Bulletin 1326

Servo Motor)

230V ac

P1 P2

Transformer

Thermal

Switch

(see P1, P2 above)

TB2 -- 1

TB2 -- 2

TB2 -- 3

TB2 -- 4

TB2 -- 5

TB2 -- 6

TB2 -- 7

TB2 -- 8

TB2 -- 9

TB2 -- 10

1771 HTE

Encoder

Termination

Panel

-- Ref + Ref

NOTE:

1. We recommend installation of this connection. Remove it if excessive noise from chassis ground occurs.

Note 2

2. The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

Velocity Command

Power

Supply

TB1 -- 1

TB1 -- 2

TB1 -- 3

TB1 -- 7

TB1 -- 8

Reset

Reset Return

Bus UV

(isolated)

Enable Source

System

11372-I

12-6

Section 12

Wiring A-B Analog Drives

Power

Supply

J2 -- 1,4

J2 -- 2,5

J2 -- 3,6

J2 -- 7

J2 -- 8

J2 -- 9

J1 -- 5

J1 -- 1,4,7

J1 -- 3,6,9

J1 -- 2

J1 -- 8

Chassis

Module

Chassis

Ground Stud

J1 -- 3

Figure 12.5 (continued)

Wiring Diagram For Series 1389 Drives

J1 -- 1

1389 Drive Servo Amplifier

J1 -- 2

J2 -- 1

J2 -- 2

J2 -- 3

J2 -- 4

J2 -- 5

J2 -- 6

+12V

TB2 -- 1 (Rotor 1)

TB2 -- 2(Rotor 2)

TB2 -- 3 (Shield)

TB2 -- 4 (Sine 1)

TB2 -- 5 (Sine 3)

TB2 -- 6 (Shield)

TB2 -- 7 (Cos 4)

TB2 -- 8 (Cos 2)

TB2 -- 9 (Shield)

TB2 -- 10 (Shield)

GND

-- 12V

Sys

Enable

Sys

Pur

Velocity

Command

Axis

Fault

Torque

Clamp

CMD

Common

Ref +

Ref --

Shield

Limit

CMD

Pos Source

Pos RTN

Neg Source

Neg RTN

Source

CMD

RTN

Drive OK

(isolated)

TB3 -- 1

TB3 -- 2

TB3 -- 3

GND

BK1

BK2

Motor

Thermal

Switch

Brake

Option

Motor

Blk

Wht

Rotor 1 (Red/White)

SINE 1

(Red)

Rotor 2

(Yel/Wh)

Blk

Red

Blk

Grn

SINE 3

(Blk)

COS 2

(Yel)

COS 4 (Blue)

Resolver

Shield N.C.

Bulletin 1326

Servo Motor

TB1 -- 1 Tach Output

TB1 -- 2 ICMD and Torque Monitor

TB1 -- 3

TB1 -- 4

TB1 -- 5

TB1 -- 6

TB1 -- 7

TB1 -- 8

TB1 -- 9

TB1 -- 10

TB1 -- 11

TB1 -- 12

TB1 -- 13

TB1 -- 14

TB1 -- 15

11372b-I

12-7

Section 12

Wiring A-B Analog Drives

Reset 3

Common 2

E-STOP 1

If your control has terminal 8, then connect it to chassis ground.

If terminal 8 is not present on your control, then this type of grounding is not necessary.

Motherboard terminal block BT01

1771 HTE

Encoder

Termination

Panel

DRIVE

DR RET

SHLD

Status relay power

Figure 12.6

Wiring Diagram For Series 1391 Drives

Connection to MTB

Panel E-STOP and E-STOP Reset

Note 1

E-STOP status relay

Note 2

Velocity

Command

Remote

E-STOP

TB4

115V ac

120V ac 1 amp

DROK (closed = OK)

TB4

TB2

-- Ref

+ Ref

+23V d c

TB2

Enable

Input

Bulletin 1391

Servo Amplifier

Axis

Overtravel

TB4 TB4

18 17

DROK

See Bulletin

1391 Drive above

K1 K2

See Bulletin

1326 Motor above

Enable

Source

P1 P2

See Drive

Transformer above

NOTE:

1. We recommend installation of this connection. Remove it if excessive noise from chassis ground occurs.

2. The connection from the termination panel to the drive should be as short as possible. We recommend less than 20 ft.

12-8

Section 12

Wiring A-B Analog Drives

Figure 12.6 (continued)

Wiring Diagram For Series 1391 Drives

System

Disconnect

Controller

Main Power

Controller GND

User

Power

User System GND

Logic

Supply

(36VCT)

Bus

Supply

(230V a c )

5A 125V

Bus MDX5

5A 125V

Bus MDX5

GND

Stud

MCB

From TB1 -- 1

Connect to

Cabinet GND

From

Motor GND

(see CAUTION)

From Motor

Cable Shield

TB4

Phase Insensitive

TB5

Sec.

Mains

MPT

Sec.

From GND

Stud

Cabinet

GND

Main

GND

Motor

Bulletin 1391 Drive

+ BUS

TB5

Shunt

Resistor

Wiring

Resolver

Connect to

GND Stud

Bulletin 1326

Servo Motor

CAUTION:

These lines are PHASE

SENSITIVE. failure to connect these lines correctly at both the transformer and controller will result in damage to the controller.

11374b-I

END OF SECTION

12-9

Publication 8520-6.2.12 -- February 1996

I--2

Index

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.12 -- February 1996

PN160485

9/Series Hardware

TAB 13

8520 Digital Drive Systems

8520-6.2.13 -- August 1998

Series 8520 Digital Drives and Series 8500 Digital Servo Motors

PN--176443

13A.0

Section Overview

13A.1

8520 Digital Servo

Amplifiers

Section

13A

Connecting 8520 Digital Drive Systems

This section details the connections for the 8520-AX-D digital drive.

For Information:

8520 Digital Servo Amplifiers Option

Specifications

Selecting a Three Phase Transformer

8520 Digital Servo Amplifiers Fault Indicators

8520 Digital Servo Amplifiers Jumper Settings

8520 Digital Servo Amplifiers Shunt

Specifications

8500 Digital Servo Motors

Feedback Devices

See Page:

13A-2

13A-11

13A-14

13A-16

13A-19

13A-24

13A-28

The 8520 Digital Servo Amplifier receives low-level Pulse Width

Modulated (PWM) command signals from the servo module and translates them to drive the axis servo motors. At the same time, it constantly senses the amount of current being used by each motor and returns this information to the 8520 digital servo module for use in determining motor load.

The 8520 digital servo amplifier also receives an “Axis enable” signal from the servo module and returns a “Drive OK” signal if certain protection and motor tests are successful.

Important: The 8520 digital servo amplifier should be separated or isolated from the servo module and CPU boards because of the electrical noise it generates. Refer to page 2A-10 for unit mounting spacing and other noise prevention techniques that will have to be followed when installing this unit.

Figure 13A.1 shows the interface between the 8520 digital servo module and the servo amplifier.

13A-1

Section 13A

Connecting 8520 Digital Drive Systems

Figure 13A.1

8520 Digital Servo Amplifier Interface

Servo Module or 9/230 CNC

Servo Connector

PWM pulse (A, B, C)

Axis enable

Drive OK

Current signal (analog la, lb)

Servo Connector

Servo

Amplifier

CNA1

(Axis 1)

CNA2

(Axis 2)

CNA3

(Axis 3)

Analog Out

Velocity signal (analog)

Spindle amplifier

Important: The configuration of the 8520 digital servo module output ports with the 8520 digital servo amplifier connectors will vary depending on the AMP configuration of the system. Refer to the 9/Series CNC 9/230,

9/260, and 9/290 AMP Reference Manual, publication 8520-6.4, for more information.

13A.2

8520 Digital Servo Amplifier

Options Specifications

There are three 8520 digital servo amplifier options available. These can be connected in any combination to drive up to nine digital servo axes

(9/290). Configurations should be based on motor size and take into consideration the per axis rated current limitations of each amplifier.

Table 13A.A lists the 8520 digital servo amplifier options and their corresponding specifications.

13A-2

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.A

8520 Digital Servo Amplifier Options

Specifications

Number of Controllable Axes

Rated Current A(rms)/axis

Max. Output Current A(rms)/axis

With Internal Fan

External Input Power Source Fuse Rating

Input Power Source Main Circuit

Control Circuit

Control Method

Dynamic Brake/Shunt Resistor

Ambient Temperature

Humidity

Weight Kg (lbs)

Amplifier Options

1AX-D 2AX-D 3AX-D

21.0

42.0

Yes

6.0

12.0

24.0

20A 15A 10A

3 Phase 170-253 V ac 50/60 Hz

Single Phase 170-253 V ac 50/60 Hz

Transistor PWM Control

Internal/External Internal/External Internal/External

0 to 55

95% or less (No Dew Condensation)

10.1 (4.6) 9.6 (4.35) 15 (6.8)

13A-3

Section 13A

Connecting 8520 Digital Drive Systems

13A.2.1

1AX-D Servo Amplifier

Connectors and Pin

Assignments

TB2

CNA1

Circuit breaker

Figure 13A.2 shows the 1AX-D (1 axis) 8520 digital servo amplifier connectors and terminal blocks.

TB3

TB1

TB4

11284-I

Figure 13A.2

1AX-D Servo Amplifier Connectors and Terminal Blocks and Pin

Assignments

Mating Connector Connector on

1AX-D Amplifier

CNA1

TB1

TB2

TB3

TB4

Connected To

3-axis Digital Servo Module

4-axis Digital Servo Module

Power Source and Motor

External Shunt Resistor

System Ready on E-STOP

String

Thermal Switch on Motor

CN2/CN3/CN4

J1/J2,/J3 /J4

Figure 13A.3

8520 Digital Servo Amplifier Connector CNA1, Honda MR-25RMA and

1AX-D Servo Amplifier Connector CNA1 Pin Assignments

Pin No.

Connection Pin No.

ENABLE

/ENABLE

Shield

STATUS

/STATUS

N.C.

PWM_A

/PWM_A

PWM_B

/PWM_B

Connection

/Ib

N.C.

PWM_C

/PWM_C

N.C.

/Ia

Shield

13A-4

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.B

1AX-D Servo Amplifier Terminal Block TB1 Terminal Assignments

Term.

Connection

3 f

200v/230vf

1 f 200v/230vf 2

3 f

200v/230vf

1 f 200v/230v-1 f1

1 f

200v/230v-1 f

-2

Term.

Connection

Motor 1f

Motor 1f B

Motor 1f

Motor 1-

Ground and Shield

Table 13A.C

1AX-D Servo Amplifier Terminal Block TB2 Terminal Assignments

Term. No.

Connection

DC+

DC-

Shunt

External

Table 13A.D

1AX-D Servo Amplifier Terminal Block TB3 Terminal Assignments

Term. No.

Connection

SYSTEM READY (Contact Output)

SYSTEM READY (Contact Input)

Typically TB3 is used as a relay in your E-STOP string. Terminal 1 and

Terminal 2 is in a closed connection when the drive is operating correctly and in an open connection when the drive is in a fault condition.

Table 13A.E

System Ready Contact Ratings

up to 24V max.

up to 1.4 A up to 30 Watts max.

up to 230V max.

up to 1.4 A up to 30 Watts max.

Table 13A.F

1AX-D Servo Amplifier Terminal Block TB4 Terminal Assignments

Term. No.

Connection

TSW1-1 (For Motor 1)

TSW1-2 (For Motor 1)

13A-5

Section 13A

Connecting 8520 Digital Drive Systems

Important: Terminal block TB4 is an optional connector that provides a convenient connection to the thermal overload switches of the servo amplifier. This terminal block is typically used to interface the thermal overload switches with PAL or the system E-STOP string. The servo amplifier will operate normally without any external connections to terminal block TB4.

13A.2.2

2AX-D Servo Amplifier

Connectors and Pin

Assignments

TB2

CNA2

CNA1

Circuit breaker

Figure 13A.4 shows and lists the 2AX-D 8520 digital servo amplifier connectors and terminal blocks.

TB3

TB1

TB4

11286-I

Figure 13A.4

2AX-D Servo Amplifier Connectors and Terminal Blocks

Connector on

2AX-D Amplifier

CNA1

CNA2

CNA1

CNA2

TB1

TB2

TB3

TB4

Connected To

3-axis Digital Servo Module

4-axis Digital Servo Module

Power Source and Motors

External Shunt Resistor

System Ready on E-STOP String

Thermal Switches on Motors

Mating Connector

CN2/CN3/CN4

J1/J2,/J3 /J4

13A-6

Section 13A

Connecting 8520 Digital Drive Systems

11285-I

Figure 13A.5

8520 Digital Servo Amplifier Connectors CNA1 and CNA2

, Honda

MR-25RMA and Pin Assignments

Pin No.

Connection Pin No.

ENABLE

/ENABLE

Shield

STATUS

/STATUS

N.C.

PWM_A

/PWM_A

PWM_B

/PWM_B

Connection

PWM_C

/PWM_C

N.C.

/Ia

Shield

/Ib

N.C.

Table 13A.G

2AX-D Servo Amplifier Terminal Block TB2 Terminal Assignments

Term. No. Connection

3 f 200v/230vf 1 f

200v/230vf

3 f 200v/230vf 3

1 f

200v/230v-1 f

-1

1 f

200v/230v-1 f

-2

Motor 1f

Term. No. Connection

Motor 1-

Motor 2f C f

Motor 2f B

Motor 2f

Motor F Ground -1 and Shield

Motor F Ground-2 and Shield

Table 13A.H

2AX-D Servo Amplifier Terminal Block TB2 Terminal Assignments

Term. No.

Connection

DC+

DC-

External

13A-7

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.I

2AX-D Servo Amplifier Terminal Block TB3 Terminal Assignments

Term. No.

Connection

SYSTEM READY (Contact Output)

SYSTEM READY (Contact Input)

Typically TB3 is used as a relay in your E-STOP string. Terminal 1 and

Terminal 2 is an open connection when the drive is in a fault condition and a closed connection when the drive is operating correctly.

Table 13A.J

System Ready Contact Ratings

up to 24V max.

up to 1.4 A up to 30 Watts max.

up to 230V max.

up to 1.4 A up to 30 Watts max.

Table 13A.K

2AX-D Servo Amplifier Terminal Block TB4 Terminal Assignments

Term. No.

Connection

TSW1-1 (For Motor 1)

TSW1-2 (For Motor 1)

TSW2-1 (For Motor 2)

TSW2-2 (For Motor 2)

Important: Terminal block TB4 is an optional connector that provides a convenient connection to the thermal overload switches of the servo amplifier. This terminal block is typically used to interface the thermal overload switches with PAL or the system E-STOP string. The servo amplifier operates normally without any external connections to terminal block TB4.

13A-8

Section 13A

Connecting 8520 Digital Drive Systems

13A.2.3

3AX-D Servo Amplifier

Connectors and Pin

Assignments

TB2

CNA2

CNA1

Circuit breaker

Figure 13A.6 shows and lists the 3AX-D (3 axis) 8520 digital servo amplifier connectors and terminal blocks.

Figure 13A.6

3AX-D Servo Amplifier Connectors and Terminal Blocks

TB3

TB1

TB4

11287-I

Connector on

3AX-D Amplifier

CNA1

CNA2

CNA3

CNA1

CNA2

CNA3

TB1

TB2

TB3

TB4

Connected To

3-axis Digital Servo Module

4-axis Digital Servo Module

Power Source and Motors

External Shunt Resistor

System Ready on E-STOP

String

Thermal Switches on Motors

Mating

Connector

CN2/CN3/CN4

J1/J2,/J3 /J4

Figure 13A.7

8520 Digital Servo Amplifier Connectors CNA1, CNA2 and CNA3,Honda

MR-25RMA and Pin Assignments

11285-I

Pin No.

Connection Pin No.

ENABLE

/ENABLE

Shield

STATUS

/STATUS

N.C.

PWM_A

/PWM_A

PWM_B

/PWM_B

Connection

/Ib

N.C.

PWM_C

/PWM_C

N.C.

/Ia

Shield

13A-9

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.L

3AX-D Servo Amplifier Terminal Block TB1 Terminal Assignments

Term. No. Connection

3 f

200v/230vf

1 f 200v/230vf 2

3 f

200v/230vf

1 f 200v/230v-1 f -1

1 f

200v/230v-1 f

-2

Motor 1f A

Motor 1f

Motor 1-F Ground and Shield

Term. No. Connection

Motor 2-

Motor 2f

A f B

Motor 2f

Motor 2-F Ground and Shield

Motor 3f

Motor 3f B

Motor 3f

Motor 3-F Ground and Shield

Table 13A.M

3AX-D Servo Amplifier Terminal Block TB2 Terminal Assignments

Term. No.

Connection

DC+

DC-

Shunt

External

Table 13A.N

3AX-D Servo Amplifier Terminal Block TB3 Terminal Assignments

Term. No.

Connection

SYSTEM READY (Contact Output)

SYSTEM READY (Contact Input)

Typically TB3 is used as a relay in your E-STOP string. Terminal 1 and

Terminal 2 is in a closed connection when the drive is operating correctly and in an open connection when the drive is in a fault condition.

Table 13A.O

System Ready Contact Ratings

up to 24V max.

up to 1.4 A up to 30 Watts max.

up to 230V max.

up to 1.4 A up to 30 Watts max.

13A-10

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.P

3AX-D Servo Amplifier Terminal Block TB4 Terminal Assignments

Term. No.

Connection

TSW1-1 (For Motor 1)

TSW1-2 (For Motor 1)

TSW2-1 (For Motor 2)

TSW2-2 (For Motor 2)

TSW3-1 (For Motor 3)

TSW3-2 (For Motor 3)

Important: Terminal block TB4 is an optional connector that provides a convenient connection to the thermal overload switches of the servo amplifier. This terminal block is typically used to interface the thermal overload switches with PAL or the system E-STOP string. The servo amplifier operates normally without any external connections to terminal block TB4.

13A.3

Selecting an A-B 1389

Transformer for 8520 Digital

Servo Amplifiers

This section gives you the information you need to determine which A-B

1389 transformer to use with your application. Its also gives the dimensions of each type of A-B 1389 transformer.

Important: The 9/230, 9/260, and 9/290 8520 digital servo amplifier is compatible only with an Allen-Bradley 1389 transformer.

Table 13A.A provides the formulas you need to size the type of transformer for the application.

13A-11

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.A

Formulas for Determining Transformer Size

If you are using a machine tool application with:

Varying loads on the motor

(Machine Tool Duty)

Constant acceleration and deceleration

(Rapid Accel/Decel Duty)

Motors that perform continuously at or near peak capacity

(Continuous Duty)

Use this formula to calculate the minimum transformer

KVA

Number of Axes

Machine Tool Duty

KW (Largest Motor) x 0.43 + 0.2

KW (Largest Motor) x 0.61 + 0.4

KW (Largest Motor) x 0.86 + 0.6

KW (Largest Motor) x 1.28 + 0.8

Number of Axes

All

KW (Largest Motor) x 1.82 + 1.0

KW (Largest Motor) x 2.60 + 1.2

Rapid Accel/Decel Duty

KW (Largest Motor) x 0.60 + 0.2

KW (Largest Motor) x 0.85 + 0.4

KW (Largest Motor) x 1.20 + 0.6

KW (Largest Motor) x 1.80 + 0.8

KW (Largest Motor) x 2.50 + 1.0

KW (Largest Motor) x 3.50 + 1.2

Continuous Duty

KW (Total of All Motors) x 1.2 + 1.0

If you are using 8520 digital servo amplifiers, select a transformer from this list of Allen-Bradley 1389 transformers. Base your selection on the calculated minimum transformer KVA rating such that the selected transformer’s KVA rating is equal to or larger than the calculated value:

Catalog Number Rating (KVA) Primary Voltage and Frequency

1389-T015DA 1.5

240/480V ac, 3 f 60Hz

1389-T035DA 3.5

1389-T050DA

1389-T100DA

1389-T125DA

1391-TA2

5.0

10.0

12.5

NEMA 1 Transformer Enclosure

The dimensions of the Allen-Bradley 1389 transformers are shown in

Figure 13A.8 and Figure 13A.9.

13A-12

Section 13A

Connecting 8520 Digital Drive Systems

Figure 13A.8

Allen-Bradley 1389 Transformer Dimensions

(in)

Slot

0.22R

13.5

(0.53)

11.2 ref.

(0.44)

B max.

C max.

A max.

11195-I

1389-

T015DA

T035DA

T050DA

T100DA

T125DA

Table 13A.B

Allen-Bradley 1389 Transformer Dimensions mm (in.)

228 mm (9 in)

279 mm (11 in)

254 mm (10 in)

279 mm (11 in)

330 mm (13 in)

356 mm (14 in)

305 mm (12 in) 317 mm (12.5 in) 406 mm (16 in)

127 mm (5 in)

E Weight

79 mm (3.10 in) 12.7 kg (28 lbs)

152 mm (6 in) 114 mm (4.5 in) 27.2 kg (60 lbs)

152 mm (6 in) 133 mm (5.25 in) 34.0 kg (75 lbs)

203 mm (8 in) 149 mm (5.85 in) 50.8 kg (112 lbs)

203 mm (8 in) 143 mm (5.63 in) 59.5 kg (131 lbs)

Figure 13A.9

Allen-Bradley 1389 Transformer Dimensions

469.9

(18.50)

355.6

(14.00)

Front Side

431.8

(17.00)

419.1

(16.50)

340.8

(12.00)

11196-I

13A-13

Section 13A

Connecting 8520 Digital Drive Systems

13A.4

8520 Digital Servo Amplifier

Fault Indicators

This section discusses faults and how they are detected on the 8520 digital servo amplifier.

System Ready Faults

The system checks that the servo amplifier is ready using two methods:

System Ready Connector (TB3)

The System Ready (on TB3) contact makes sure that the control board of the servo amplifier is ready, the power circuit of the DC bus is ready, and the system relay is closed.

Table 13A.C

System Ready Contact Ratings

DC AC

24V dc @ 1.4 A (max. 30 W) 230V ac @ 1.4 A (max. 30 W)

Axis status output (CNA1, CNA2, and CNA3)

The Axis status output contact is connected to the servo module and is checked by the servo module’s CPU on a per axis basis. If this contact is not active, the servo module recognizes that the amplifier is in a fault condition and sends the message “SERVO AMPLIFIER FAULT” sent to the control. This is pre-wired through servo cable CN20.

LED Indicators

Table 13A.D through Table 13A.F lists the symbol, indication, and color of the 8520 digital servo amplifier fault and ready status indicators (note the

LED indicators are numbered on the 3AX-D servo amplifier).

Table 13A.D

1AX-D (1 axis) Servo Amplifier Indicators

Symbol Fault or Ready Indication

Over Temperature

Bus Undervoltage

OC Over Current

AXF Axis 1 Fault

RDY System Ready

OV Bus Overvoltage

CVF Control Voltage Fault

EAX1 Axis 1 Enable

Color

Red

Yellow

Red

Green

Red

Green

TB2

CNA1

Circuit breaker

Location of

LEDs

TB3

TB1

TB4

13A-14

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.E

2AX-D (2 axis) Servo Amplifier Indicators

Symbol

(block 1)

CVF

RDY

AX1F

AX2F

Fault or Ready Indication

Control Voltage Fault

System Ready

Bus Undervoltage

Over Temperature

Bus Overvoltage

Axis 1 Fault

Axis 2 Fault

Over Current

Color

Red

Green

Yellow

Red

Symbol

(block 2)

EAX1

EAX2

Fault or Ready Indication

Axis 1 Enable

Axis 2 Enable

Color

Green

TB2

Location of block 1 LEDs

CNA2

CNA1

Circuit breaker

Location of block 2 LEDs

TB3

TB1

TB4

Table 13A.F

3AX-D (3 axis) Servo Amplifier Indicators

Symbol Fault or Ready Indication

RDY

CVF

AX1F

AX2F

AX3F

EAX1

EAX2

EAX3

System Ready

Over Temperature

Bus Overvoltage

Bus Undervoltage

Control Voltage Fault

Over Current

Axis 1 Fault

Axis 2 Fault

Axis 3 Fault

Axis 1 Enable

Axis 2 Enable

Axis 3 Enable

Color

Red

Green

Red

Yellow

Green

TB2

CNA2

CNA1

Circuit breaker

Location of

LEDs

CNA3

TB3

TB1

TB4

13A-15

Section 13A

Connecting 8520 Digital Drive Systems

13A.5

8520 Digital Servo Amplifier

Jumper Settings

Table 13A.G through Table 13A.L list the 8520 digital servo amplifier jumper settings. These jumpers are used to configure the 8520 digital servo amplifier to supply 200% or 300% of the motor rated current, enable or disable the servo motors, latch or unlatch the bus under voltage fault detector, and select the internal or external shunt resistor.

ATTENTION: Incorrect jumper settings can cause damage to the servo motors and/or servo amplifiers.

Table 13A.G

1AX-D (1 axis) Servo Amplifier Jumper Settings

J1 J2 J3 J4

11.8

13.1

14.4

15.7

6.5

7.8

9.1

10.4

Axis 1 - - CNA1

Motor Rated Current

200%

1.3

2.6

3.9

5.2

300%

1.3

2.6

3.9

5.2

17.0

18.3

19.6

20.9

>AMP Limit

6.5

7.8

9.1

10.4

11.8

13.1

>AMP Limit

“

J10

For 200% of motor rated current, the following jumpers are shorted:

- AXIS 1: J5, J6, J11, J12

For 300% of motor rated current, the following jumpers are open:

- AXIS 1: J5, J6, J11, J12

13A-16

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.H

1AX-D Servo Amplifier Jumper Settings (continued)

J13 Short -- Enable Axis Motor

Open -- Disable Axis Motor

J14 Short -- Bus Under Voltage FAULT not Latched

Open -- Bus Under Voltage FAULT Latched

J15 Short -- Internal Shunt Resistor Used

Open -- External Shunt Resistor Used

Table 13A.I

2AX-D (2 axis) Servo Amplifier Jumper Settings

3.0

3.4

3.7

4.1

1.5

1.9

2.2

2.6

4.5

4.9

5.2

5.6

6.0

Axis 1 - - CNA1

Axis 2 - - CNA2

Motor Rated Current

200% 300%

0.4

0.7

1.1

0.4

0.7

1.1

>AMP Limit

1.5

1.9

2.2

2.6

3.0

3.4

3.7

>AMP Limit

“

J13

J14

J15

J16

J19

J20

J21

J10

J22

For 200% of motor rated current, the following jumpers are shorted:

- AXIS 1: J5, J6, J11, J12 AXIS 2: J17, J18, J23, J24

For 300% of motor rated current, the following jumpers are open:

- AXIS 1: J5, J6, J11, J12 AXIS 2: J17, J18, J23, J24

13A-17

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.J

2AX-D Servo Amplifier Jumper Settings (continued)

J25 Short -- Enable Axis 1 Motor

Open -- Disable Axis 1 Motor

J26 Short -- Enable Axis 2 Motor

Open -- Disable Axis 2 Motor

J27 Short -- Bus Under Voltage FAULT not Latched

Open -- Bus Under Voltage FAULT Latched

J28 Short -- Internal Shunt Resistor Used

Open -- External Shunt Resistor Used

Table 13A.K

3AX-D (3 axis) Servo Amplifier Jumper Settings

5.9

6.7

7.5

8.2

3.0

3.7

4.5

5.2

9.0

9.7

10.4

11.2

11.9

Axis 1 - - CNA1

Axis 2 - - CNA2

Axis 3 - - CNA3

Motor Rated Current

200% 300%

0.7

1.5

2.2

0.7

1.5

2.2

>AMP Limit

3.0

3.7

4.5

5.2

5.9

6.7

7.5

>AMP Limit

“

J13

J25

J14

J26

J15

J27

J16

J28

J19

J31

J20

J32

J21

J33

J10

J22

J34

For 200% of motor rated current, the following jumpers are shorted:

- AXIS 1: J5, J6, J11, J12 AXIS 2: J17, J18, J23, J24

- AXIS 3: J29, J30, J35, J36

13A-18

Section 13A

Connecting 8520 Digital Drive Systems

For 300% of motor rated current, the following jumpers are open:

- AXIS 1: J5, J6, J11, J12 AXIS 2: J17, J18, J23, J24

- AXIS 3: J29, J30, J35, J36

Table 13A.L

3AX-D Servo Amplifier Jumper Settings

(continued)

J37 Short -- Enable Axis 1 Motor

Open -- Disable Axis 1 Motor

J38 Short -- Enable Axis 2 Motor

Open -- Disable Axis 2 Motor

J39 Short -- Enable Axis 3 Motor

Open -- Disable Axis 3 Motor

J40 Short -- Bus Under Voltage FAULT not Latched

Open -- Bus Under Voltage FAULT Latched

J41 Short -- Internal Shunt Resistor Used

Open -- External Shunt Resistor Used

13A.6

8520 Digital Servo Amplifier

Shunt Specifications

When the servo amplifier is installed as recommended and E-STOP occurs, the control sets the velocity command to zero. If the axes are in motion at that time, they will coast to a stop rather than being rapidly decelerated as they would be under servo amplifier control.

To improve axis stopping time when E-STOP occurs, the 8520 digital servo amplifier employs a dynamic brake. This brake is in the form of a power resistor that is shunted across the motor terminals. Power generated by the motor is dissipated through this resistor, thereby driving the motor to a rapid stop even though the 8520 digital servo amplifier is off.

There are three shunt resistor options that can be used with the 8520 digital servo amplifiers. One involves using the internal shunt resistor supplied with the amplifiers, while the others require purchase and installation of an external shunt resistor.

The following equations should be used to size a shunt resistor for the desired application. First, use these equations to solve for the peak power

P, and the average power W. Then apply those values to the chart below to determine the appropriate shunt option.

P = (.00054) (J) (N

)

W = (.0000108) (J) (N

)

(T)

13A-19

Section 13A

Connecting 8520 Digital Drive Systems

Where:

- J = total motor and axis inertia measured at motor shaft, summed for all motors connected to the servo amplifier [Kg cm s

]

- N = maximum motor speed [rpm]

- T = desired deceleration time from maximum motor speed to stop

[sec.]

Important: These equations are for approximating shunt resistor requirements. They can produce worst case data that is unrealistic for most applications. For example, in most machine tool applications it is unlikely that all axes will ever be traveling simultaneously at their maximum speed.

Factor the type of duty expected for your machine into these equations.

Shunt Resistor Selection Chart

< 180

< 1100

Shunt Option #1

1100

< 1800

Shunt Option #2

1800

180

< 540

Shunt Option #2 Shunt Option #2 1

540

< 810

Shunt Option #3 Shunt Option #3 1

810

2 2 2

Not possible with current configuration. Move one or more motors to another servo amplifier, or reduce inertia, or reduce motor speed.

Not possible with current configuration. Move one or more motors to another servo amplifier, or reduce inertia, or reduce motor speed, or increase time from maximum speed to stop.

Table 13A.M lists the internal/external shunt resistor, contactor, and fuse specifications.

Table 13A.M

Internal/External Shunt Specifications

Specifications

Shunt Location

Shunt Resistance

Shunt Continuous Rating

Shunt Duty Cycle Limit (determined by servo amplifier jumper settings)

Shunt Fuse Rating

Shunt Contactor Size

Shunt Options

Option #1 Option #2 Option #3

Internal External External

16 ohms

196 watts

2 sec

10 ohms

600 watts

5 sec

10 ohms

900 watts

5 sec

15A/600V non-time delay

15A/600V or greater

13A-20

Section 13A

Connecting 8520 Digital Drive Systems

After determining system shunt requirements, terminal block (BT2) on each of the 8520 digital amplifiers should be jumpered for either an internal shunt resistor or an external shunt resistor.

Figure 13A.10 and Figure 13A.11 illustrate this procedure.

Figure 13A.10

Shunt Resistor Connections for 2AX-D Servo Amplifiers

Using Internal Shunt Resistor

Using External Shunt Resistor

Contacts

(minimum 4 contacts in series)

External shunt resistor

Fuse

Contacts

(minimum 4 contacts in series)

EXT

TB2

EXT

TB2

INT/

EXT

INT/

EXT

INT

To internal shunt resistor

11288-I

To internal shunt resistor

Figure 13A.11

Shunt Resistor Connections for 1AX-D and 3AX-D Servo Amplifiers

Using External Shunt Resistor

Using Internal Shunt Resistor

Contacts

(minimum 4 contacts in series)

External shunt resistor

Fuse

Contacts

(minimum 4 contacts in series)

Shunt EXT Shunt EXT

TB2 TB2

Internal shunt resistor

11289-I

13A-21

Section 13A

Connecting 8520 Digital Drive Systems

13A.7

8520 Drive Power

Distribution

Normally-closed contacts must be installed as shown in Figure 13A.10 and

Figure 13A.11. These four contacts should be held open whenever the

8520 digital servo amplifier is energized and should be closed by the emergency stop circuitry. You must wire at least four contacts in series to safely break this connection. Allen-Bradley 100-A30ND3 contactors with added deck 195-FAD4 are recommended. Refer to a 1389 transformer manual for special requirements and additional information on the normally-closed contactor. Details on emergency stop wiring start on page 6-1.

ATTENTION: The four normally closed contacts shown in

Figure 13A.10 and Figure 13A.11 should not be used on machines with large non-counter balanced vertical axes. No contacts are required. Under a normal shut down, leaving these contacts out allows the drive to maintain torque for a longer period of time. This provides more time for holding brakes to set.

Important: Jumpers on the 8520 digital servo amplifier circuit boards must be set for internal or external shunt resistor. These jumpers control the duty cycle (amount of continuous “on” time) for the shunt resistors.

Important: The external shunt resistor should be mounted in an area where the heat it generates will not adversely affect other components of the control.

Important: The shunt contacts should not be closed while 3-phase power is applied to the drive amplifier. The shunt circuitry is sized to dynamic braking of the axis when E-stop is applied and 3-phase power is removed from the amplifier.

ATTENTION: To guard against electrical shock hazards, never make connections or disconnections at the ac distribution network unless the main ac disconnect switch is open and locked.

Figure 13A.1 shows how power is distributed from the supply to the transformer and amplifier.

13A-22

Section 13A

Connecting 8520 Digital Drive Systems

230V ac

Disconnect Switch

Customer transformer

Figure 13A.1

Power Distribution from the Supply to the Transformer and Amplifier

Fuse

Contactors

8520 digital

Servo Amplifier

A-B 1389 transformer

Dynamic Brake circuitry (shunt resistor, fuse, contactor).

Internal drive logic fuse

Refer to drives interface section.

Motor

115V ac

Main power supply

Fuse size based on customer needs

Customer power supply (24V dc)

9/260 and 9/290

E-Stop Status

Relay Contact

E-Stop Function

Main power circuit fuse sizing is determined by the following equation:

Fuse capacity (A) = (Tr) x 974.3

Where:

Tr = Transformer size calculated on page 13A-12 (in kW)

V = minimum 3 phase input voltage (V ac)

Contactor sizing is such that its capacity is greater than that of the fuses.

Refer to section 4.2 to size the transformer.

May not be necessary on PS2 24V is part of the power supply.

System ready

11194-I

13A-23

Section 13A

Connecting 8520 Digital Drive Systems

13A.8

8500 Digital Servo Motors

The 8500 digital servo motors are used to drive the axes of the 8520 digital servo drive system. The 8500 digital servo motors have a feedback device mounted on them that provides position and velocity data to the servo module. A second feedback device can be mounted directly on the axis

(such as a linear slide) to provide greater precision for positioning feedback. On these systems with multiple feedback devices, the motor mounted encoder is used for motor commutation and velocity feedback.

13A.8.1

8500 Digital Servo Motor

Options

The control uses a digital velocity command scheme to improve motor performance and efficiency. This requires the use of servo motors designed for 8520 digital drive application.

The 8520 digital servo drive system can be configured to handle various

8500 digital servo motors. Table 13A.N lists the 1000/2000 RPM servo motor options and their specifications.

Table 13A.N

1000/2000 RPM 8500 Digital Servo Motor Options and Specifications

Specifications 1000/2000 RPM 8500 Digital Servo Motor Options

8500-A1C 8500-A2C 8500-B1C 8500-B2C 8500-B3C

Rated Output/Axis

Rated Torque

Continuous Max. Torque

Instantaneous Max. Torque kW (HP) kg

cm (lb

in) kg

cm (lb

in) kg

cm (lb

in)

Arms rpm

Rated Current

Rated Revolution

Maximum Rated Revolution

Torque Constant rpm kg

cm/A (lb

in/A)

Rotor Inertia

(J) g

(lb

in s

2 x10

-3

)

(GD

/4) kg

(lb

)

Power Rate

Mechanical Time Constant

Electrical Time Constant kW/s ms ms

0.3 (0.4)

29 (25)

30 (26)

87 (76)

3.0

10.3 (8.9)

0.6 (0.8)

58 (50)

5.8

10.6 (9.2)

1.2 (1.6)

117 (102)

60 (52) 120 (104) 220 (191) 330 (286)

174 (151) 2 351 (305) 2 390 (339) 2 703 (610) 2

11.7

1000

2000

10.4 (9.0)

2.0 (2.7) 3.0 (4.1)

195 (169) 290 (252) 1

18.8

10.9 (9.5)

26 1

11.8 (10.2)

13.8 (12.0) 24.8 (21.5) 68.2 (59.2) 112 (97.2) 146 (126.7)

13.5 (4.61) 24.3 (8.31) 66.8 (22.8) 110 (37.6) 143 (48.9)

6.1

8.3

4.2

13.3

5.9

5.4

19.7

6.9

10.4

33.2

5.2

12.9

57.0

4.1

15.3

Number of Pole poles 8

Weight kg (lb) 10 (15) 15 (33) 24 (53) 32 (71) 43 (95)

The rated current available for the 8500-B3C digital servo motor is limited to 21 amps (rms) by the amplifiers maximum output rating.

This limits the available rated torque to 232 kg.cm (203 lb.in).

These values will vary depending on the amplifier selected to operate these motors. You may need to recalculate these values based on your amplifier selection.

Important: 8500 digital servo motor mounting dimensions start on page 13B-1.

13A-24

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.O lists the 1500/2500 RPM 8500 digital servo motor options and their specifications.

Table 13A.O

1500/2500 RPM 8500 Digital Servo Motor Options and Specifications

Specifications 1500/2500 RPM 8500 Digital Servo Motor Options

8500-A1D 8500-A2D 8500-A3D 8500-B1D 8500-B2D

Rated Output/Axis

Rated Torque

Continuous Max. Torque

Instantaneous Max. Torque

Power Rate

Mechanical Time Constant kW (HP) kg

cm (lb

in) kg

cm (lb

in) kg

cm (lb

in) kW/s ms

0.45 (0.6)

29 (25)

30 (26)

87 (76)

6.0

8.3

0.85 (1.2)

55 (48)

60 (52)

165 (143)

5.7

1.3 (1.8)

85 (74)

90 (72)

255 (221)

18.9

4.7

1.8 (2.4)

117 (102)

120 (104)

234 (203)

19.7

6.8

2.9 (3.9)

190 (165)

230 (200)

380 (330)

Rated Current

Rated Revolution

Maximum Rated Revolution

Torque Constant

Arms rpm

Rotor Inertia

(J) g

(lb

in s

2 x10

-3

)

(GD

/4) kg

(lb

)

3.8

rpm kg

cm/A (lb

in/A) 8.2 (7.1)

13.8 (12.0)

13.5 (4.61)

6.2

9.4 (8.2)

24.8 (21.5)

24.3 (8.31)

9.7

1500

2500

9.4 (8.2)

37.4 (32.5)

36.7 (12.5)

8.4 (7.3)

68.2 (59.2)

66.8 (22.8)

10.0 (8.7)

112 (97.2)

110 (37.6)

31.5

5.1

Electrical Time Constant

Number of Pole ms poles

4.2

5.5

6.4

10.4

13.0

Weight kg (lb) 10 (22) 15 (33) 21 (46) 24 (53) 32 (71)

These values will vary depending on the amplifier selected to operate these motors. You may need to recalculate these values based on your amplifier selection.

Important: 8500 digital servo motor mounting dimensions start on page 13B-1.

13A-25

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.P lists the general motor specifications that apply to all of the previously listed 8500 digital servo motors.

Table 13A.P

8500 Digital Servo Motor General Specifications

Item Specification

Ambient Temperature

Ambient Humidity

Brake Voltage

Brake Holding Torque

C to +40

20-80% (No Dew Condensation)

90V dc

A Series - 90 Kg - cm 16.2 watts

B Series - 360 Kg - cm 31 watts

Drive Method

Enclosure

Excitation Method

Isolation Voltage

Insulation Resistance

Mounting

Oil Seal

Direct Drive

Totally-enclosed, Self-Cooled

(Equivalent to IP-55 Rating)

Permanent Ferrite Magnet

1500 V ac, 1 min.

500 V dc, 10M Ohms or more

Flange Mounted

Nitril Rubber 1

Thermostat

N.C.

- Opens at 155

- Closes at 110 ° C ± 20 ° C

Oil sealed motors should be operated under the following conditions:

Optimum oil level should be below the oil seal lip

Oil should be splashed to oil seal

All 8500 digital servo motors listed are equipped with thermal overload switches. These are normally closed switches that open when the motor temperature exceeds a safe limit.

The system installer has two choices for implementing these safety switches. They can be wired directly into the E-STOP string, or they can cause an input to PAL through an I/O device.

Wiring these switches directly into the E-STOP string provides an immediate and very reliable response to over-temperature conditions. The disadvantage in doing this is that the drives will be shut down no matter where the machine is in an operation and cannot be restarted until the over-temperature condition is resolved.

If the over-temperature switches are wired as inputs to PAL, the PAL program can be written to handle the situation in a controlled manner. PAL can be programmed to allow the completion of an operation, or to move the axes to a safe position before shutting down the machine.

13A-26

Section 13A

Connecting 8520 Digital Drive Systems

13A.8.2

8500 Digital Servo Motor

Connector and Pin

Assignments

The 8500 digital servo motor leads must be connected as shown below.

The servo motor rotation, as viewed from the shaft end, will depend on the value of the SIGN OF FEEDBACK AMP parameter. Refer to the

9/260-9/290 AMP Reference Manual, publication 8520-6.4, for more information.

Important: The A series 8500 digital servo motor connector (without brake) is slightly smaller than the B series servo motor connector (without brake). The pin layout of these connectors is the same.

Figure 13A.2 lists the pin assignments for the 8500 digital servo motor connector without brake.

Figure 13A.2

A and B Series 8500 Digital Servo Motor Connector Pin Assignments

(without brake)

Pin Signal

A PHASE A (U)

B PHASE B (V)

C PHASE C (W)

D Ground and Shield

Pin Signal

E Thermal Protector

F Thermal Protector

Figure 13A.3 shows the pin layout for the A series 8500 digital servo motor connector with brake.

Figure 13A.3

A Series 8500 digital Servo Motor Connector Pin Assignments (with brake)

Pin

A --

Signal

B Phase C (W)

C Brake Terminal

D Brake Terminal

E Ground and Shield

Pin Signal

F Phase A (U)

G Thermal Protector

H Thermal Protector

I Phase B (V)

Important: The A series 8500 digital servo motor connector (with brake) is slightly smaller and its pin layout is different than the B series 8500 digital servo motor connector (with brake).

13A-27

Section 13A

Connecting 8520 Digital Drive Systems

13A.9

Feedback Devices

Figure 13A.3 lists the pin assignments for the A series 8500 digital servo motor connector with brake.

Figure 13A.4 shows the pin layout and pin assignments for the B series

8500 digital servo motor connector with brake.

Figure 13A.4

B Series 8500 Digital Servo Motor Connector and Pin Assignments (with brake)

Pin Signal

A Thermal Protector

B Thermal Protector

C --

D Phase A (U)

E Phase B (V)

Pin Signal

F Phase C (W)

G Ground and Shield

H Brake Terminal

I Brake Terminal

Each servo motor is equipped with a feedback device that is mounted on the end of the motor that is opposite the shaft end. This feedback device can be either an absolute or an incremental encoder. The servo module supplies these encoders with their required +5V power supply.

Each servo motor may also be equipped with a second feedback device for greater accuracy for positioning feedback. This second feedback device is normally mounted directly to the moving axis member to avoid inaccuracies caused by the motor gearing and drive components. When a second feedback device is used the motor mounted encoder must remain and is used for velocity feedback as well as motor commutation.

The spindle motor can also be equipped with a feedback device. This feedback device must be an incremental encoder with A quad B format.

The servo module can supply the spindle encoder with +5V or +15V power.

13A-28

Section 13A

Connecting 8520 Digital Drive Systems

Table 13A.Q lists the servo encoder specifications.

Table 13A.Q

Servo Encoder Specifications

Number of Pulse

Number of Multi-turning

Absolute Encoder

8192 pulse/rev

± 99999 turns

Incremental Encoder

6000 pulse/rev

Resolution

Supply Voltage

8192

4 = 32768 counts/rev 6000

4 = 24000 counts/rev

+5V (+10%, -1%)

Battery Backup Voltage 2.9V to 4.5V

+5V (+10%, -1%)

N/A

Weight 500 g 500 g

Incremental Encoders

Incremental encoders provide coarse axis position feedback to the servo module. These encoders also provide U, V, and W motor phase signals for use in motor commutation until the first marker is detected. After the first marker is detected, the servo module determines incremental axis position from the A, B, and C signals which are output by the encoder.

After initial power-up, the control must determine motor phasing by finding the encoder marker. Until this marker is found, phasing is estimated using the U, V, and W phase signals. This limits motor power to approximately 85% of maximum.

After the first marker is detected, the exact electrical position is known.

Since precise commutation is now possible, full power is possible.

An axis homing cycle is required to establish axis position after the motor is phased. Once axis position is established, axis position feedback is transmitted back to the servo module in an A quad B format with marker.

This feedback transmission takes place on an incremental basis.

ATTENTION: Do not adjust encoder alignment. Commutation requires the encoder marker to be aligned with the windings of the servo motor. This alignment process is done during the mounting of the incremental or absolute encoder to the servo motor.

13A-29

Section 13A

Connecting 8520 Digital Drive Systems

Absolute Encoders

Absolute encoders are an “intelligent” feedback device that provide absolute axis position feedback to the servo module. These encoders incorporate a turns counter register and an absolute single turn encoder.

The turns counter register holds the number of turns the motor has made since the motor was last homed. The absolute single turn encoder holds the number of pulses encountered, since the marker was last detected to the present position.

The servo module requests position data from the absolute encoder after power up. The values contained in the turns counter register and the single turn encoder are sent to the servo module on the A channel of the encoder signal cable. These values are used by the servo module to calculate the absolute axis position.

Once the absolute axis position is determined, the absolute encoder transmits axis position feedback just like an incremental encoder. Precise commutation is possible immediately after power up when using the absolute encoder. Motor winding position is determined using the data provided by the absolute single turn encoder.

The absolute encoder is supplied with battery backup. This allows the absolute encoder to retain the absolute position of an axis even after power to the control is turned off. This eliminates the need to home axes every time the control is turned on, and also provides a means for limited recovery from a power failure during machining operations.

The battery power originates from the batteries plugged into the servo module. Even if battery backup fails, or the encoder cable is temporarily disconnected, the encoder will still maintain position data for up to 24 hours. This also allows for battery replacement without loss of data.

When an encoder other than the standard incremental or absolute encoder provides feedback to the servo module, typically the spindle feedback device, the maximum encoder channel frequency will have to be determined.

The following formula is used to calculate the maximum encoder channel frequency:

5 x 10

Maximum Encoder Channel Frequency =

360

90-Eq x 1.15

Where:

5 x 10

= Control’s Feedback Clock Frequency

= Encoder Quadrature Error in Degrees

1.15 = Feedback Clock Safety Factor

13A-30

Section 13A

Connecting 8520 Digital Drive Systems

13A.9.1

Incremental Encoder

Feedback Interface

G F

This value is then compared to the actual A channel frequency of the encoder which is determined by the following formula:

(Lines/Rev.) x (Max. Operating RPM) x (min./60sec.)

As long as the actual encoder A channel frequency does not exceed the maximum encoder channel frequency calculated above, the servo module should process the encoder feedback data without a quadrature fault.

Figure 13A.5 shows the interface between the 8500 digital servo module and servo motors with incremental encoders.

Figure 13A.5

Incremental Encoder to 8520 Digital Servo Module Interface

Servo module or 9/230 CNC

Feedback device

(incremental encoder)

Servo Connector

Channel signals (A, B, Z, U, V, W)

Power supply (+5V dc)

Servo motor

Servo Connector

Servo motor

Servo Connector

Servo motor

Analog Out

11092-I

Figure 13A.6 shows the connector and pin assignments used to interface the incremental encoder with the 8520 digital servo module.

Figure 13A.6

Incremental Encoder Feedback Connector and Pin Assignments

Incremental Encoder

Pin Signal

A A Channel Output

B /A Channel Output

C B Channel Output

Pin Signal

K U Channel Output 2

L /U Channel Output 2

M V Channel Output 2

D /B Channel Output

E Z Channel Output 1

N /V Channel Output 2

P W Channel Output 2

F /Z Channel Output 1 R /W Channel Output 2

G 0V S --------------------------------

H +5V dc

J Frame Ground

T --------------------------------

---------------------------------

Connector Type: Cannon MS3102A20-29P

Signal Output Circuit: Differential Line Driver

The Z channel output is used for the marker signal.

The U, V, and W channels are used for motor phasing only

13A-31

Section 13A

Connecting 8520 Digital Drive Systems

13A.9.2

Absolute Encoder Feedback

Interface

G F

Figure 13A.7 shows the interface between the 8520 digital servo module and the 8500 digital servo motors with absolute encoders.

Figure 13A.7

Absolute Encoder to 8520 Digital Servo Module Interface

Servo module or 9/230 CNC Feedback device

(Absolute encoder)

Servo Connector

Channel signals (A, B, Z)

Power supply (+5V dc)

Battery (+V dc)

Servo motor

Servo Connector

Servo motor

Servo Connector

Servo motor

Battery

Connector

Battery

11093-I

Figure 13A.8 shows the connector and lists the pin assignments used to interface the absolute encoder with the 8520 digital servo module.

Figure 13A.8

Absolute Encoder Feedback Connector and Pin Assignments

Absolute Encoder

Pin Signal Pin Signal

A A Channel Output

B /A Channel Output

C B Channel Output

D /B Channel Output

K --------------------------------

L --------------------------------

M --------------------------------

N --------------------------------

E Z Channel Output 1 P --------------------------------

F /Z Channel Output 1 R Encoder Reset Pin

G 0V

H 5V (power supply)

0V (battery)

+V (battery)

J Frame Ground ---------------------------------

Connector Type: Cannon MS3102A20-29P

Signal Output Circuit: Differential Line Driver

The Z channel output is used for the marker signal

13A-32

Section 13A

Connecting 8520 Digital Drive Systems

13A.9.3

Resetting Absolute

Encoders on an 8500 Digital

Servo Motor

The turns counter register of an absolute encoder can be reset to zero at system start up or if the absolute encoder’s battery backup has failed.

Resetting an Absolute Encoder on the 9/230

At the control:

Move the axis that the absolute encoder is configured for in AMP to the desired zero coordinate position for that axis.

Turn OFF the control and the main ac power switch.

ATTENTION: Never adjust the control unless the main AC disconnect switch is open (off) and locked.

Disconnect the battery that supplies battery backup to the absolute encoder being reset.

Determine whether it is easier to disconnect and access connectors at the servomotor or at the control.

If accessing connectors at the 8500 digital servo motor: a.

Remove the cable that is connected to the absolute encoder to be reset.

At the encoder, use a jumper to short pin R to pin S of the absolute encoder for at least 2 minutes.

G F

13A-33

Section 13A

Connecting 8520 Digital Drive Systems

If accessing connectors at the control: a.

Disconnect the absolute encoder signal cable from the servo connector on the control (J1, J2, or J3).

At the cable, use a jumper to short pin 16 to pin 34 (which connect to pins S and R of the absolute encoder) for at least 2 minutes.

After shorting the pins together for the required time:

Make sure the control is OFF.

Reconnect the encoder cable to the control.

Make sure the battery that supplies battery backup to the absolute encoders is good and reconnect it.

ATTENTION: Battery power must be supplied to the absolute encoders prior to turning the control “ON”. Power turn-on without first connecting the absolute encoder battery may result in a “Servo AMP Error.” The control remains in E-STOP and

E-STOP reset is ignored. To recover from this condition, follow the procedure for resetting absolute encoders.

Leave the motor connected to the backup battery through the feedback cable for at least 1 second before turning the control ON.

The axis is then ready to be homed.

13A-34

Section 13A

Connecting 8520 Digital Drive Systems

Resetting an Absolute Encoder on the 9/260 and 9/920

Important: The following procedure is no necessary if you are using distance--coded markers or a Stegmann feedback device.

At the control:

Move the axis that the absolute encoder is configured for in AMP to the desired zero coordinate position for that axis.

Turn OFF the control and the main ac power switch.

ATTENTION: Never adjust the control unless the main AC disconnect switch is open (off) and locked.

At the servo module:

Disconnect the battery that supplies battery backup to the absolute encoder being reset.

Determine whether it is easier to disconnect and access connectors at the servomotor or at the servo module.

If accessing connectors at the 8500 digital servo motor: a.

Remove the cable that is connected to the absolute encoder to be reset.

At the encoder, use a jumper to short pin R to pin S of the absolute encoder for at least 2 minutes.

G F

11294-I

13A-35

Section 13A

Connecting 8520 Digital Drive Systems

If accessing connectors at the 8520 digital servo module: a.

Disconnect the absolute encoder signal cable from the encoder feedback port on the servo module (CN5, CN6, or CN7).

At the cable, use a jumper to short pin 12 to pin 1 (which connect to pins S and R of the absolute encoder) for at least 2 minutes.

3 4 5 6

10 11 12 13

14 15 16 17 18 19 20

11295-I

After shorting the pins together for the required time:

Make sure the control is OFF.

Reconnect the encoder cable to the control.

Make sure the battery that supplies battery backup to the absolute encoders is good and reconnect it.

E-STOP reset is ignored. To recover from this condition, follow the procedure for resetting absolute encoders.

Leave the motor connected to the backup battery through the feedback cable for at least 1 second before turning the control ON.

The axis is then ready to be homed.

13A-36

Section 13A

Connecting 8520 Digital Drive Systems

13A.9.4

Using a Second Feedback

Device

A second feedback device can be attached to your machine (normally mounted directly to the moving axis member to avoid inaccuracies caused by the motor gearing).

When using a second feedback device, the incremental or absolute encoder mounted on the 8500 digital servo motor provides current and velocity loop feedback while a non-motor mounted second feedback device provides axis position feedback.

In many cases a system may not have enough feedback ports for all the closed loop axes and also to support additional second feedback devices.

In these cases extra positioning feedback ports are available for the 8520 digital servo module using the optional feedback module. The optional feedback module is available only on the 9/260 and 9/290 controls that use the 3-axis servo module. The optional feedback module is not supported by the 4-axis servo module.

For detals on using a second feedback device with an 8500 Series motor refer to the section covering your specific 9/Series processor or servo card.

END OF SECTION

13A-37

Section 13A

Connecting 8520 Digital Drive Systems

13A-38

Publication 8520-6.2.13 -- August 1998

I--2

9/Series, PAL, PLC, SLC 5/03, SLC 5/04, DH+, and INTERCHANGE are trademarks of Allen-Bradley Company, Inc.

Worldwide representation.

Argentina ·Australia ·Austria ·Bahrain ·Belgium ·Brazil ·Bulgaria ·Canada ·Chile ·China, PRC ·Colombia ·Costa Rica ·Croatia ·Cyprus ·Czech Republic ·

Denmark ·Ecuador ·Egypt ·El Salvador ·Finland ·France ·Germany ·Greece ·Guatemala ·Honduras ·Hong Kong ·Hungary ·Iceland ·India ·Indonesia ·

Ireland ·Israel ·Italy ·Jamaica ·Japan ·Jordan ·Korea ·Kuwait ·Lebanon ·Malaysia ·Mexico ·Netherlands ·New Zealand ·Norway ·Pakistan ·Peru ·

Philippines ·Poland ·Portugal ·Puerto Rico ·Qatar ·Romania ·Russia--CIS ·Saudi Arabia ·Singapore ·Slovakia ·Slovenia ·South Africa, Republic ·Spain ·

Sweden ·Switzerland ·Taiwan ·Thailand ·Turkey ·United Arab Emirates ·United Kingdom ·United States ·Uruguay ·Venezuela ·Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 8520-6.2.13 -- August 1998

PN176442

9/Series Hardware

TAB 14

System Startup

852062--RM014A--EN--P -- November 2000 PN--176962

14A.0

Section Overview

14A.1

Initial Control Power

Up and Servo Start-Up

Procedures

Section

14A

System Start-Up

This section discusses the recommended 9/Series start up procedure. We recommend following this procedure where it is appropriate for your application. Additional start up procedures for deskew axes are also available in section 14B.

Once all the components of the control have been installed, the control can be turned on. The following procedure is recommended:

Important: The following procedure is designed to provide a basic start up procedure for standard motors. Contact the Rockwell Automation Web based Bulletin Board System . . . .

(http:// www. ab. com/ mem/ technotes/ techmain. html) for start up information on non-standard motors and motor tuning procedures. Should there be any problems connecting to the bulletin board, please contact the Rockwell Automation / Allen-Bradley CNC

Technical support group at 440--646--6800.

ATTENTION: It is recommended that the motors be mechanically disconnected from the axes during initial power up. If your system contains a split axis, both servos of the split axis must be reconfigured as independent axes for this procedure.

14A-1

Section 14A

System Start-Up

Prior to pressing the “ON” button on the MTB panel:

Check all wiring connections, both electrical and fiber optic. Make sure inter-module connections correspond to the system wiring diagram covered starting on page 7A-1. Make sure grounding is adequately wired as directed on page 4D-10. If absolute encoders are used make sure the battery for absolute feedback is connected.

Check the external ac power supply. Make sure it will supply

115/230 V ac to the main power supply. Also test that the servo amplifiers are receiving proper voltage. If an analog servo system is being used refer to the manufactures documentation for amplifier power requirements. If a digital servo system is being used, the 8520 servo amplifiers should be receiving 3

220-240 V ac, and the 1394 or 9/440 system should be receiving 3

380 or 460 V ac.

Turn “ON” the circuit that supplies the external ac power. Do not push the power “ON” button on the MTB panel. Make sure the ac

POWER indicator located on the front top of the main power supply is illuminated.

Make sure the E-Stop button is depressed.

Check the terminal block connections and the jumper settings of the servo amplifier. For an analog system refer to drives documentation provided by the manufacturer. For a digital system check against the terminal block connection and jumper setting tables starting on page

13A-1 (for 8520 drives), 11A-1 (for 1394 drives), or 5A-28 (for 9/440 CNCs).

Check the incoming ac for logic power to the servo amplifiers. For an analog system refer to documentation provided by the drives manufacturer. For a digital drive system, verify that the voltage listed below is present at the following terminals of the servo amplifier using a volt meter:

8520 Drives

TB1-4 to TB1-5 170 to 253 V ac

The 8520 digital servo amplifier circuit board contains a green

SYSTEM READY indicator light and a yellow BUS UNDER

VOLTAGE indicator light. Both of these indicators should be illuminated. The SYSTEM READY indicator light indicates that the servo amplifier is receiving logic power. The BUS UNDER

VOLTAGE indicator light indicates that 3 is not present at the TB1 terminal block.

Æ 230 V ac motor power

14A-2

Section 14A

System Start-Up

1394 Drive

Power terminal block

W1 and W2 24 V ac or dc and check test points on the wiring board:

TB3 Test Point Voltage

TB3-1

TB3-2

TB3-3

TB3-4

+5V dc

Common

+15Vdc

--15Vdc

The status LEDs on the axis modules should flash red and green alternately, indicating the system is ready and waiting for full bus voltage. The Status LED on the system module should be red.

The system module LED only illuminates when a fiber optic ring fault occurs. It should be off anytime the CNC is powered up.

9/440 CNC/drive systems

Assuming you wired your 9/440 as discussed starting on page

5A-28, power should be applied to your on/off control assembly but no drive power should be present. Both 24 V logic power and three phase should not be available to the system module at this point.

After performing the above checks:

Make sure the E-Stop button is depressed. Using the “ON” button on the MTB panel, turn on power to the control. The main menu screen should appear after the CRT warms up. For 1394 systems, the system module LED should turn off provided the fiber optic ring is functioning correctly. On 9/440 CNC systems, the status LED as well as the Xilinx and Watchdog LED should all be on.

If using a 1394 digital drive (not available for 9/440 CNC) check the

1394 I/O device monitor page to check fault status and addressing

(see page 15A-29).

Using ODS, assign the AMP