MDS Kurulum Kılavuzu

MDS Kurulum Kılavuzu
Modular Drive System
Installation Manual
400525-02
Revision A1
February 27, 2002
© Control Techniques Drives, Inc. 2001, 2002
Modular Drive System
Installation Manual
Information furnished by Control Techniques Drives Inc. (Control Techniques) is believed to be
accurate and reliable. However, no responsibility is assumed by Control Techniques for its use.
Control Techniques reserves the right to change the design or operation of the equipment described
herein and any associated motion products without notice. Control Techniques also assumes no
responsibility for any errors that may appear in this document. Information in this document is subject
to change without notice.
P/N 400525-02
Revision: A1
Date: February 27, 2002
© Control Techniques Drives, Inc. 2001, 2002
© Control Techniques Drives, Inc. 2001, 2002
Part Number: 400525-02
Revision: A1
Date: February 2002
Printed in United States of America
Information in this document is subject to change without notice. No part of this document may be
reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose,
without the express written permission of Control Techniques.
The following are trademarks of Control Techniques and may not be reproduced in any fashion
without written approval of Control Techniques: EMERSON Motion Control,
EMERSON Motion Control PowerTools, AXIMA, “Motion Made Easy.”
Control Techniques is a division of EMERSON Co.
Control Techniques, Inc. is not affiliated with Microsoft Corporation, owner of the Microsoft,
Windows, and Windows NT trademarks.
IBM is a registered trademark of International Business Machines Corporation.
Modbus and Shawmut are registered trademarks of Gould, Inc.
Schaffner is a registered trademark of Schaffner
Data Highway Plus is a trademark of Allen-Bradley
This document has been prepared to conform to the current released version of the product. Because
of our extensive development efforts and our desire to further improve and enhance the product,
inconsistencies may exist between the product and documentation in some instances. Call your
customer support representative if you encounter an inconsistency.
ii
Customer Support
Control Techniques
12005 Technology Drive
Eden Prairie, Minnesota 55344-3620
U.S.A.
Telephone: (952) 995-8000 or (800) 397-3786
It is Control Techniques’ goal to ensure your greatest possible satisfaction with the operation
of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is
why we offer you so many ways to get the support you need. Whether it’s by phone, fax or
modem, you can access Control Techniques support information 24 hours a day, seven days
a week. Our wide range of services include:
FAX
(952) 995-8099
You can FAX questions and comments to Control Techniques. Just send a FAX to the number
listed above.
Website and Email
www.emersonct.com
Website: www.emersonct.com
Email: [email protected]
If you have Internet capabilities, you also have access to technical support using our website.
The website includes technical notes, frequently asked questions, release notes and other
technical documentation. This direct technical support connection lets you request assistance
and exchange software files electronically.
Technical Support
(952) 995-8033 or (800) 397-3786
Email: [email protected]
Control Techniques’ “Motion Made Easy” products are backed by a team of professionals
who will service your installation. Our technical support center in Eden Prairie, Minnesota is
ready to help you solve those occasional problems over the telephone. Our technical support
center is available 24 hours a day for emergency service to help speed any problem solving.
Also, all hardware replacement parts, if needed, are available through our customer service
organization.
When you call, please be at your computer, with your documentation easily available, and be
prepared to provide the following information:
•
Product version number, found by choosing About from the Help menu
•
The type of controller or product you are using
iii
•
Exact wording of any messages that appear on your screen
•
What you were doing when the problem occurred
•
How you tried to solve the problem
Need on-site help? Control Techniques provides service, in most cases, the next day. Just call
Control Techniques’ technical support center when on-site service or maintenance is
required.
Training Services
(952) 995-8000 or (800) 397-3786
Email: [email protected]
Control Techniques maintains a highly trained staff of instructors to familiarize customers
with Control Techniques’ “Motion Made Easy” products and their applications. A number of
courses are offered, many of which can be taught in your plant upon request.
Application Engineering
(952) 995-8000 or (800) 397-3786
Email: [email protected]
An experienced staff of factory application engineers provides complete customer support for
tough or complex applications. Our engineers offer you a broad base of experience and
knowledge of electronic motion control applications.
Customer Service (Sales)
(952) 995-8000 or (800) 397-3786
Email: [email protected]
Authorized Control Techniques distributors may place orders directly with our Customer
Service department. Contact the Customer Service department at this number for the
distributor nearest you.
Document Conventions
Manual conventions have been established to help you learn to use this manual quickly and
easily. As much as possible, these conventions correspond to those found in other Microsoft®
Windows® compatible software documentation.
Menu names and options are printed in bold type: the File menu.
Dialog box names begin with uppercase letters: the Axis Limits dialog box.
Dialog box field names are in quotes: “Field Name.”
Button names are in italic: OK button.
Source code is printed in Courier font: Case ERMS.
iv
In addition, you will find the following typographic conventions throughout this manual.
This
Represents
bold
Characters that you must type exactly as they appear. For example, if you are directed to type
a:setup, you should type all the bold characters exactly as they are printed.
italic
Placeholders for information you must provide. For example, if you are directed to type
filename, you should type the actual name for a file instead of the word shown in italic type.
ALL CAPITALS
Directory names, file names, key names, and acronyms.
SMALL CAPS
Non-printable ASCII control characters.
KEY1+KEY2
example: (Alt+F)
A plus sign (+) between key names means to press and hold down the first key while you press
the second key.
KEY1,KEY2
example: (Alt,F)
A comma (,) between key names means to press and release the keys one after the other.
“Warning” indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.
“Caution” indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury.
“Caution” used without the safety alert symbol indicates a potentially hazardous situation
that, if not avoided, may result in property damage.
Note
For the purpose of this manual and product, “Note” indicates essential information about
the product or the respective part of the manual.
Throughout this manual, the word “drive” refers to an MDS.
Throughout this manual. the word “FM-3” refers to an FM-3, FM-3DN or FM-3PB.
Throughout thie manual the word “FM-4” refers to an FM-4, FM-4DN or FM-4PB.
v
Safety Instructions
General Warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages
used in the product can cause severe electric shock and/or burns and could be lethal. Extreme
care is necessary at all times when working with or adjacent to the product. The installation
must comply with all relevant safety legislation in the country of use.
Qualified Person
For the purpose of this manual and product, a “qualified person” is one who is familiar with
the installation, construction and operation of the equipment and the hazards involved. In
addition, this individual has the following qualifications:
•
Is trained and authorized to energize, de-energize, clear and ground and tag circuits and
equipment in accordance with established safety practices.
•
Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
•
Is trained in rendering first aid.
Reference Materials
The following related reference and installation manuals may be useful with your particular
system.
• PowerTools Software User’s Guide (P/N 400503-01)
• FM-1 Speed Module Reference Manual (P/N 400506-01)
• FM-2 Indexing Module Reference Manual (P/N 400507-01)
• FM-3 Programming Module Reference Manual (P/N 400508-01)
• FM-4 Programming Module Reference Manual (P/N 400509-01)
• FM-3 and FM-4 DeviceNet Module Reference Manual (P/N 400508-03)
• Function Module Installation Manual (400506-03)
• FM-3 and FM-4 Profibus Module Reference Manual (P/N 400508-04)
vi
Underwriters Laboratories Listed
LISTED 768R
IND. CONT. EQ.
The MDS Digital Servo Drives are marked with the “UL Listed” label after passing a rigorous
set of design and testing criteria developed by UL (UL508C). This label indicates that UL
certifies this product to be safe when installed according to the installation guidelines and
used within the product specifications.
The “conditions of acceptability” required by UL are:
•
The drive surrounding air ambient temperature must be 40° C (104° F) or less.
•
MDS surrounding air ambient temperature can be up to 50°C (122° F) with 3% linear
derating for every degree above 40° C (104° F)
•
This product is suitable for use on a circuit capable of delivering not more than 10,000
RMS symmetrical amperes, 480 volts maximum.
•
Motors must incorporate an overload protection device such as an overtemperature
switch.
Drive Overload Protection
The drive output current overload protection is provided by the drive and is not adjustable.
This overload protection is based on maximum continuous output current capacity. It will
allow up to 200 percent of the drive rated current to be delivered for the amount of time
determined by the following chart.
Rated output current (Amps RMS)
Drive Module Model
Continuous
MD-404
4
Peak
8
MD-407
7
14
MD-410
10
20
MD-420
20
40
MD-434
34
68
vii
Drive Output Current vs. Time graph
60
Time (seconds)
50
40
30
20
10
0
100
125
150
175
200
% Drive Rated Current
CE Declaration of Conformity
The MDS Drive and Power Modules are marked with the “Conformite Europeenne Mark”
(CE mark) after passing a rigorous set of design and testing criteria. This label indicates that
this product meets safety and noise immunity and emissions (EMC) standards when installed
according to the installation guidelines and used within the product specifications.
viii
Declaration of Conformity
Manufacturer’s Name:
Control Techniques/Emerson Industrial Automation
Manufacturer’s Address:
12005 Technology Drive
Eden Prairie, MN 55344
USA
Declares that the following products:
Products Description:
Modular Drive System (MDS)
Model Number:
MP-1250/MP-2500/MP-5000
MD-407/MD-410/MD-420/MD-434
Conforms to the following product specification:
Electomagnetic Compatibility (EMC):
EN 55011/1998 w/Amendment A1:1999 Class A Group 1, CISPR 11/1990 Class A Group 1
EN 61800-3, 1996:
IEC 1000-4-2/1995; EN 61000-4-2, 6kV CD
IEC 1000-4-3/1995; EN 61000-4-3, ENV 50140/1993, 80%
AM, 10V/m @ 3 m
IEC 1000-4-4/1995; EN 61000-4-4, 2 kV ALL LINES
EN 61000-4-5, 1kV L-L, 2kV L-G
Supplementary information:
The products herewith comply with the requirements of the Low Voltage Directive (LVD) 73/23/EEC and EMC
Directive 89/336/EEC
This servo drive system is intended to be used with an appropriate motor, electrical protection components, and
other equipment to form a complete end product or system. MDS must only be installed by a professional
assembler who is familiar with safety and electromagnetic compatibility (“EMC”) requirements. The assembler is
responsible for ensuring that the end product or system complies with all the relevant laws in the country where it
is to be used. Refer to the information on EMC standards that the MDS complies with, as well ar the product
manual for installation guidelines.
January 31, 2002
John Wiegers/ Director Enigineering
Date
European Contact:
Sobetra Automation
Langeveldpark Lot 10
P. Dasterleusstraat 2
1600 St. Pieters Leeuw, Belgium
ix
x
Modular Drive System Installation Manual
Safety Considerations
Safety Precautions
This product is intended for professional incorporation into a complete system. If you install
the product incorrectly, it may present a safety hazard. The product and system may use high
voltages and currents, carries a high level of stored electrical energy, or is used to control
mechanical equipment which can cause injury.
You should give close attention to the electrical installation and system design to avoid
hazards either in normal operation or in the event of equipment malfunction. System design,
installation, commissioning and maintenance must be carried out by personnel who have the
necessary training and experience. Read and follow this safety information and the instruction
manual carefully.
Enclosure
This product is intended to be mounted in an enclosure which prevents access except by
trained and authorized personnel, and which prevents the ingress of contamination. This
product is designed for use in an environment classified as pollution degree 2 in accordance
with IEC664-1. This means that only dry, non-conducting contamination is acceptable.
Setup, Commissioning and Maintenance
It is essential that you give careful consideration to changes to drive settings. Depending on
the application, a change could have an impact on safety. You must take appropriate
precautions against inadvertent changes or tampering. Restoring default parameters in certain
applications may cause unpredictable or hazardous operation.
Safety of Machinery
Within the European Union all machinery in which this product is used must comply with
Directive 89/392/EEC, Safety of Machinery.
The product has been designed and tested to a high standard, and failures are very unlikely.
However the level of integrity offered by the product’s control function – for example stop/
start, forward/reverse and maximum speed – is not sufficient for use in safety-critical
applications without additional independent channels of protection. All applications where
malfunction could cause injury or loss of life must be subject to a risk assessment, and further
protection provided where needed.
General warning
Failure to follow safe installation guidelines can cause death or serious injury. The
xi
Modular Drive System Installation Manual
voltages used in this unit can cause severe electric shock and/or burns, and could be lethal.
Extreme care is necessary at all times when working with or adjacent to this equipment.
The installation must comply with all relevant safety legislation in the country of use.
AC supply isolation device
The AC supply must be removed from the Power Module backplane using an approved
isolation device or disconnect before any servicing work is performed, removing and/or
installing the Power Module and/or Drive Module(s), other than adjustments to the
settings or parameters specified in the manual. The drive contains capacitors which
remain charged to a potentially lethal voltage after the supply has been removed. Allow
at least 3 minutes after removing the supply before carrying out any work which may
involve contact with electrical connections to the drive.
Grounding (Earthing, equipotential bonding)
The drive must be grounded by a conductor sufficient to carry all possible fault current in
the event of a fault. The ground connections shown in the manual must be followed.
Fuses
Fuses must be provided at the input in accordance with the instructions in the manual.
Isolation of control circuits
The installer must ensure that the external control circuits are isolated from human
contact by at least one layer of insulation rated for use at the applied AC supply voltage.
xii
Modular Drive System Installation Manual
Table of Contents
Safety Considerations
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup, Commissioning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety of Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
xi
xi
xi
xi
xi
1
Modular Drive System (MDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation
5
MDS Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Basic Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MDS Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Module Backplane Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Module Assembly Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Module Backplane Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Module Assembly Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 1: Power Module Backplane Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 2: Drive Module Backplane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 3: Power Module High Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
AC Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical AC Input Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Step 4: Drive Module High Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Step 5: Power Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Step 6: Drive Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Step 7: Power and Drive Module Low Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Logic and Digitial I/O Power Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Module I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drive Module I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motor Brake Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Command Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Step 9: Power Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Power up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Drive and Power Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Drive Module Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
xiii
Drive Module Backplane Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Status, Diagnostics and Troubleshooting
73
Power Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Module Diagnostic Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Watch Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
View Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications
73
73
74
78
80
81
82
83
85
MDS Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive and Motor Combination Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial/Radial Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IP Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MDS Power Module Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MDS Drive Module Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
90
91
91
91
92
94
96
99
Glossary
111
Index
117
xiv
Modular Drive System Installation Manual
Introduction
Modular Drive System (MDS)
The Modular Drive System (MDS) is a 480V servo system comprised of a common Power
Module and up to eight Drive Modules. The modular approach provides an optimum solution
for each application. The Power Module provides the AC rectification and provides DC bus
power for up to eight Drive Modules. The common power supply minimizes installation
space and cost because there is only one AC Input, one Contactor, one set of AC fuses and
one AC line Filter per system. Each Power and Drive Module mounts on an innovative
backplane that provides the connection for the DC Bus and Logic Power, this minimzes
installation time. A compact installation is possible because the backplanes mount next to
each other, removing the need for space between each axis. Fuses (included) are mounted
directly on each Drive Module backplane to provide individual protection for each axis.
The Drive Modules can operate as base drives providing Velocity, Torque and Pulse/
Direction operations. For positioning and more advanced applications with more
functionality add a FM module to that axis for control. FM modules give the MDS "snap-on"
functionality for indexing (FM-2), programming (FM-3) and advanced programming (FM4). For applications that require fieldbus, the FM-3 and FM-4 modules can be ordered with
DeviceNet or Profibus options. Regardless of the control needed commissioning and
programming is made easy with our FREE PowerTools FM and PowerTools Pro software.
PowerTools is a Windows® based software that makes extensive use of drag and drop
editing, tabbed and hierarchal views, and on-line help to create a "Motion Made Easy"
experience. Commissioning time is minimized because the tuning of the drives is completed
with system parameters, Inertia mismatch, Friction and Response. The State-Space algorithm
uses the system parameters and motor map (DDF files) to make a robust control system that
is capable of 10:1 inertia mismatch applications out of the box. For higher mismatches, up to
50:1, a simple adjustment to the Inertia and Response parameters will provide the desired
performance. PowerTools has complete diagnostics and status indicators for quick
troubleshooting. System problems can be quickly identified with the status indicators and
I/O on the Power and Drive Modules, along with fault logging stored in the non-volatile
memory, minimizing startup time.
The MDS is able to use Control Techniques motors as well as other manufacturers motors.
Setup with a Control Techniques’ motor is done by selecting the desired motor in
PowerTools. Control Techniques has two lines of motors, MH and Unimotor motors to
provide an optimal solution for each application.
1
Modular Drive System Installation Manual
342 - 528 VAC
3 Phase
Input Power
Mains
Contactor
AC Line
Filter
(Optional)
AC Line
Fuses
FM Module
Connection
MP
MD
MD
MD
RS-232
or
RS-485
Computer or
Operator
Interface Panel
+24 VDC
User
Supply
MLP-002,
MLP-005,
MLP-010
Shunt Resistor
Optional
MH or UNI Motors
Figure 1: Module Drive System Overview
Power Modules are available in three power ratings
Power Module
Continuous Power
Peak Power
MP-1250
12.5 KW
25.0 KW
MP-2500
25.0 KW
50.0 KW
MP-5000
50.0 KW
100.0 KW
Drive modules are available in five current ratings.
Switching Frequency
Power Rating
Drive Module
(At 5 KHz)
5 KHz
10 KHz
Continuous Current
Peak Current
Continuous Current
Peak Current
MD-404
2.6 KW
4 A RMS
8 A RMS
2.8 A RMS
5.6 A RMS
MD-407
4.5 KW
7 A RMS
14 A RMS
5 A RMS
10 A RMS
MD-410
6.5 KW
10 A RMS
20 A RMS
6.5 A RMS
13 A RMS
MD-420
13.0 KW
20 A RMS
40 A RMS
14 A RMS
28 A RMS
MD-434
22.0 KW
34 A RMS
68 A RMS
22 A RMS
44 A RMS
Note
Power ratings in the tables above are for 480 VAC line voltage. For lower input line
voltages de-rate output power proportionally.
2
Introduction
FM Modules
The MDS is designed to accept a line of function modules that further enhance its use in
various applications.
•
FM-2 Indexing Module enables the user to initiate up to 16 different indexes, jogging, and
a single home routine.
•
FM-3, FM-3DN and FM-3PB Programming Modules offer complex motion profiling. A
complex motion profile consists of two or more indexes that are executed in sequence
such that the final velocity of each index except the last is non-zero. Logical instructions
between index statements can provide a powerful tool for altering motion profiles ’on the
fly’. The FM-3 can be order with DeviceNet or Profibus for fieldbus applications.
•
FM-4, FM-4DN adn FM-4PB Programming Modules offer complex motion profiling,
along with multi-tasking user programs. A complex motion profile consists of two or
more indexes that are executed in sequence such that the final velocity of each index
except the last is non-zero. Logical instructions between index statements can provide a
powerful tool for altering motion profiles ’on the fly’. The FM-4 can be order with
DeviceNet or Profibus for fieldbus applications.
The FM Function modules define complex motion by a configuration file that includes setups
and function assignments. For the FM-3 and FM-4 modules, the configuration file also
includes programs. The configuration file is created using PowerTools FM or PowerTools
Pro. The FM-2 module uses PowerTools FM software, and all the FM-3 and FM-4 modules
use PowerTools Pro software. Setup views have the same look and feel as dialog boxes. The
assigning of input and output functions is done through assignments view in the software.
PowerTools software is an easy-to-use Microsoft® Windows® based setup and diagnostics
tool.
FM MODULE CONNECTOR
FM
MP
MD
MD
MD
Programming Module
1
2
Inputs
Exp. I/O
485+
3
4
5
6
485-
7
SHLD
8
Sync.
Output
Outputs 10-30
VDC
Sync.
Input
1
2
3
4
+
-
3
Modular Drive System Installation Manual
4
Modular Drive System Installation Manual
Installation
MDS Installation Overview
Installation of the MDS is completed by following a simple step-by-step process. The MDS
installation begins by mounting the backplanes of the modules to a metal mounting panel
(Steps 1and 2). Next, the high power connections are made to the backplanes (Steps 3 and 4).
Power and Drive Module(s) are mounted to the backplanes (Steps 5, 6, and 7). Once the
modules are secured the low power connections are made. After inspection and test, the
system is complete and can be powered up for commissioning (Step 8).
Step 1: Power Module Backplane Installation, page 19
Step 2: Drive Module Backplane Installation, page 20
Step 3: Power Module Backplane High Power Connections, page 23
• AC Input Power
• Transformer Sizing ( if required)
• External Shunt Connection (if required)
• Line Fusing and Wire Size
Step 4: Drive Module High Power Connections, page 33
• Motor Power Cable
Step 5: Power Module Installation, page 34
Step 6: Drive Module Installation, page 35
Step 7: Power and Drive Module Low Power Connections, page 36
• Logic Power Sizing
• Digital I/O and Logic Power (user supplied)
• AC Interlock
• Digital I/O
• Command Signals
• Motor Brake
• Feedback
• Communications
Step 8: Power Up, page 65
Before starting actual Installation it is recommended that mounting location, cable layout,
environmental and electromagnetic compatibility be considered to insure a proper
installation. Refer to “Basic Installation Notes” on page 6 for Control Techniques
recommended installation guidelines and requirements.
5
Modular Drive System Installation Manual
Basic Installation Notes
You are required to follow all safety precautions during start-up such as providing proper
equipment grounding, correctly fused power and an effective Emergency Stop circuit which
can immediately remove power in the case of a malfunction. See the "Safety Considerations"
section for more information.
Electromagnetic Compatibility (EMC)
Drives are designed to meet the requirements of EMC. Under extreme conditions a drive
might cause or suffer from disturbances due to electromagnetic interaction with other
equipment. It is the responsibility of the installer to ensure that the equipment or system into
which the drive is incorporated complies with the relevant EMC legislation in the country of
use.
The following instructions provide you with installation guidance designed to help you meet
the requirements of the EMC Directive 89/336/EEC.
Adhering to the following guidelines will greatly improve the electromagnetic compatibility
of your system, however, final responsibility for EMC compliance rests with the machine
builder, and Control Techniques cannot guarantee your system will meet tested emission or
immunity requirements.
If you need to meet EMC compliance requirements, EMI/RFI line filters must be used to
control conducted and radiated emissions as well as improve conducted immunity.
Physical location of these filters is very important in achieving these benefits. The filter
output wires should be kept as short as possible (12 inches is suggested) and routed away from
the filter input wires. In addition:
•
Choose an enclosure made of a conductive material such as steel, aluminum or stainless
steel.
•
Devices mounted to the enclosure mounting plate, which depend on their mounting
surfaces for grounding, must have the paint removed from their mounting surfaces and the
mating area on the mounting plate to ensure a good ground. See the, "Achieving Low
Impedance Connections" section for more information.
•
If grounding is required for cable grommets, connectors and/or conduit fittings at
locations where cables are mounted through the enclosure wall, paint must be removed
from the enclosure surface at the contact points.
•
AC line filter input and output wires and cables should be shielded.
Achieving Low Impedance Connections
Noise immunity can be improved and emissions reduced by making sure that all the
components have a low impedance connection to the same ground point. A low impedance
connection is one that conducts high frequency current with very little resistance. Impedance
cannot be accurately measured with a standard ohmmeter, because an ohmmeter measures
6
Installation
DC resistance. For example, a 12 inch long 8 gauge round wire has a significantly higher
impedance than a 12 inch long 12 gauge flat braided conductor. A short wire has less
impedance than a long one.
Low impedance connections can be achieved by bringing large areas of conductive surfaces
into direct contact with each other. In most cases this requires paint removal because a ground
connection through bolt threads is not sufficient. However, component materials should be
conductive, compatible and exhibit good atmospheric corrosion resistance to prevent loss
through corrosion which will hinder the low impedance connection. Enclosure manufacturers
offer corrosion resistant, unpainted mounting plates to help.
Bringing components into direct contact cannot always be achieved. In these situations a
conductor must be relied upon to provide a low impedance path between components.
Remember a flat braided wire has lower impedance than a round wire of a large gauge rating.
A low impedance connection should exist between the following components, but not limited
to:
•
Enclosure and mounting plate
•
Each Power and Drive Module PE grounding tab
•
EMI/RFI AC line filter chassis and mounting plate
•
Other interface equipment chassis and mounting plate
•
Other interface equipment chassis and electrical connectors
•
Enclosure and conduit fittings or electrical connectors
•
Enclosure mounting plate and earth ground
•
Motor frame to conduit fittings, electrical connectors and grounded machine frame
•
Encoder chassis and electrical connector
A good rule to follow when specifying conductors for high frequency applications is to use a
metal strap with a length to width ratio that is less than 3:1.
7
Modular Drive System Installation Manual
Cable to Enclosure Shielding
Shielded motor, feedback, serial communications and external encoder cables were used for
compliance testing and are necessary to meet the EMC requirements. Each cable shield was
grounded at the enclosure wall by the type of grommet shown in the Figure 2.
Figure 2:
Cable Type
Through Wall Shield Grommet
Cable
Model
Shielded Cable Grommet
Kit Part #
Conduit Dimension
Hole Size
Actual Hole Size
7/8"
Motor Cable, 16 Ga
CMDS
CGS-050
1/2" pipe
Motor Cable, 12 Ga
CMMS
CGS-050
1/2" pipe
7/8"
Motor Cable, 8 Ga
CMLS
CGS-100
1" pipe
1 3/4"
Feedback Cable
CFOS
CGS-050
1/2" pipe
7/8"
Flex Motor Cable, 16 Ga
CMDF
CGS-050
1/2" pipe
7/8"
Flex Motor Cable, 12 Ga
CMMF
CGS-075
3/4" pipe
1 1/16"
CFCF, CFOF
CGS-063
3/4" pipe
1 1/16"
ENCO
CGS-038
1/2" pipe
7/8"
user supplied
user supplied
user supplied
user supplied
Flex Feedback Cable
External Encoder
AC Power
8
Installation
AC Line Filters
The AC line filters are necessary to comply with CE emission standards. The MDS was tested
with the filters presented in the table below and recommended by Control Techniques*.
Power Module Model
Schaffner Part #
Control Techniques
Model #
MP-1250
*
*MFL-020-00
MP-2500
*
*MLF-035-00
MP-5000
FS6717-65-34
MLF-065-00
Rating
65A, 480V, 3 Phase
* Consult factory for availability of the MLF-020-00 and MLF-035-00. The filter
recommended for the MP-5000 can be used for smaller Power Modules.
Toroids
In applications using long cables additional measures to reduce EMI might be necessary, such
as toroids on the motor cable. Based on Control Techniques compliance test results, the
following guidelines should be used.
Total System Current
< 25A
> 25A
Switching Frequency
Maximum Motor Cable Length
(without toroids)
5 kHz
125 Ft
10 kHz
50 Ft
5 kHz
75 Ft
10 kHz
75 Ft
Control Techniques recommends using Rasmi toroids in applications with motor cables
longer than in table above.
Motor Cable Model
Rasmi Toroid Part#
CT Model #
CMDS, CMDF
OC/2
MPF-OC2-00
CMMS, CMMF
OC/2
MPF-OC2-00
CMLS
OC/3
MPF-OC3-00
9
Modular Drive System Installation Manual
NEMA Enclosure
This wall must have
good continuity to
enclosure ground.
Through wall
shield grommets
Note: EMC testing was done with
surface paint removed from
the mounting panel area for
drive contact.
.
AC in
Bonded to mounting plate
and enclosure wall
PE Connection on
Drive Module
3-phase
filter
External Encoder
Loop R,S,T wires through toroid.
DO NOT loop PE wire through
toroid. More loops through toroid
helps reduce conducted emissions
PTB-16-23
CFCS Cable
CFOCS
Cable
Motor Power Cable routing should
be at least 12 inches away from
AC Input wiring or AC Line Filter.
CMDS, CMMS
OR CMLS Cable
Motor
Figure 3:
AC Filter and Cable Connections for MDS Series
Environmental Considerations
If the product will be subjected to atmospheric contaminants such as moisture, oils,
conductive dust, chemical contaminants and metallic particles, it must be mounted in a metal
NEMA type 12 enclosure.
If the ambient temperature inside the enclosure will exceed 40° C (104° F), you must consider
forced air cooling.
10
Installation
Note
It is necessary to maintain the MDS surrounding air ambient temperature at 40° C (104°
F) [50°C (122ºF) with derating of 3% per degree above 40° C].
The amount of cooling depends on the size of the enclosure, the thermal transfer of the
enclosure to the ambient air and the amount of power being dissipated inside the enclosure.
Consult your enclosure manufacturer for assistance with determining cooling requirements.
Wiring Notes
•
To avoid problems associated with EMI (electromagnetic interference), you should route
high power lines (AC input power and motor power) away from low power lines (encoder
feedback, serial communications, etc.).
•
If a neutral wire (not the same as Earth Ground), is supplied from the building distribution
panel it should never be bonded with PE wire in the enclosure.
•
You should consider future troubleshooting and repair when installing all wiring. All
wiring should be either color coded and/or tagged with industrial wire tabs.
•
As a general rule, the minimum cable bend radius is ten times the cable outer diameter.
•
All wiring and cables, stationary and moving, must be protected from abrasion.
•
Ground wires should not be shared with other equipment.
•
Ensure that metal to metal contact is made between the enclosure ground lug and the metal
enclosure, not simply through the mounting bolt and threads.
•
All inductive coils must be suppressed with appropriate devices, such as diodes or
resistor/capacitor (RC) networks.
•
All motor and feedback cables must have a continuous shield from the drive to the motor
(grounded at both ends).
•
Included with every Power and Drive Module is a Cable Strain Relief Bracket. It is a good
wiring practice to use the Strain Relief Bracket especially for heavy cables.
•
If using Toroids as motor power cable filter, mount them as close to the drive as possible.
Best results are obtained when the R, S, T wires are looped through the toroid 4 times.
•
Do Not route the motor PE wire through the toroid.
•
Keep all motor power cables at least 12 inches away from Incoming AC line on the input
side of the filter.
11
Modular Drive System Installation Manual
Panel Layout
High Power Cable Routing Only
Low
Power
Cable
Routing
Only
Wire Tie
Holddowns
High Power Cable Routing Only
Figure 4:
12
Recommended Layout
Installation
MDS Overview
The system must be back mounted vertically on a metal mounting panel such as a NEMA
enclosure. Additional space is necessary above and below the system for wiring and cable
connections. A MDS system is comprised of one Power Module and up to eight Drive
Modules. The Power Module is always the left most mounted module with the Drive Modules
mounted to the right. The Drive Modules are to be mounted from largest (highest current
rating) next to the Power Module to smallest (lowest current rating). Each module mounts to
an associated backplane which is mounted to a metal surface.For mounting dimensions refer
to Pages 14 - 18.
Backplane Installation Page 19
Drive Module
Installation - Page 35
Power Module Installation Page 34
Figure 5:
Modular Drive System
13
Modular Drive System Installation Manual
Power Module Backplane Dimensions
2.75
[69.85]
3.50
[88.90]
1.375
[34.925]
1.375
[34.925]
0.60 [15.24]
0.60 [15.24]
2.64
[67.04]
2.81 [71.37]
10.25
[260.35]
14.25
16.06
[361.95] [407.92]
2.64
[67.04]
2.81 [71.37]
14.25
16.06
[361.95] [407.92]
10.25
[260.35]
1.375
[34.925]
1.375
[34.925]
MP-1250 and MP-2500
Figure 6:
14
Power Module Backplane Dimensions
MP-5000
Installation
Power Module Assembly Dimensions
Power Module Model
DIM “A”
MP-1250 & MP-2500
2.75 [69.85]
MP-5000
3.50 [88.90]
16.06 [407.92]
9.00 [228.60]
14.25 [361.96]
Figure 7:
DIM “A”
Power Module Dimensions - MP-5000 Shown
15
Modular Drive System Installation Manual
Drive Module Backplane Dimensions
1.375
[34.925]
0.60
[15.24]
2.75
[69.85]
2.64
[67.056]
10.25
[260.35]
16.90
14.25
[361.95] [429.25]
2.81
[71.37]
MD-404, MD-407 and MD-410
Figure 8:
16
Drive Module Backplane Dimensions
Installation
1.375
[34.925]
0.60
[15.24]
2.75
[69.85]
3.50
[88.90]
7.0 [177.8]
1.375
[34.925]
0.60
[15.24]
2.64
[67.056]
2.64
[67.056]
14.25
16.90
[361.95] [429.25]
10.25
[260.35]
2.81
[71.37]
16.90
14.23
[361.442] [429.25]
10.25
[260.35]
2.81
[71.37]
MD-420
Figure 9:
MD-434
Drive Module Backplane Dimensions
17
Modular Drive System Installation Manual
Drive Module Assembly Dimensions
DIM "A"
Drive Module Model
MD-404
MD-407
MD-410
MD-420
MD-434
DIM "A"
2.75 [69.85]
2.75 [69.85]
2.75 [69.85]
3.50 [88.90]
5.49 [139.50]
14.25 [361.95]
9.00 [228.60]
14.25 [361.95]
Figure 10:
18
Drive Module Dimensions - MD-420 Shown
Installation
Step 1: Power Module Backplane Installation
Mount the Power Module in the left most position using #10 panhead screws. The optional
Cable Strain Relief bracket must be installed before tightening the screws holding the
backplane to the metal mounting panel. To install the Optional Cable Strain Relief bracket
simply slide the bracket behind the backplane, aligning the slot of the bracket with the screw
holding the backplane to the metal mounting panel. Push on the bracket until it stops. Secure
the Optional Cable Strain Relief bracket with a #10 panhead screw and tighten the backplane
screws.
Optional Cable
Strain Relief
Backplane
Figure 11:
Secure with
#10
panhead screw
MP-5000 Power Module Backplane shown with Optional Cable Strain Relief
Bracket Mounting
19
Modular Drive System Installation Manual
Step 2: Drive Module Backplane Installation
Note
Starting from the Power Module, the Drive Modules must be installed from largest
(highest current rating) to smallest (lowest current rating), with the largest size attached
to the Power Module.
Alignment
Tab
Snap
Tab
Slots
Bus bars
Bus
Screws
Logic connector
Snap
Tab
Slots
Alignment
Tab
MP-5000
Backplane
Figure 12:
20
MD-434
Backplane
Assembling the Drive Module Backplane to the Power Module Backplane.
Installation
1. Loosen the DC Bus screws on the Power Module backplane.
2. Align the DC Bus bars with the DC Bus screws, the Logic connector with the Power
Module board and all the tabs on the Drive Module backplane with the slots in the Power
Module backplane.
3. Push the Drive Module backplane firmly into the Power Module backplane until the
Bus bars are under the DC Bus screws and the backplanes snap together. The Power
Module backplane board is plugged into the Drive Module backplane Logic connector
and the tabs are secure in the slots. Backplane side walls of both modules are in contact
with each other.
4. Torque the bus screws to 8-10 in.lbs.
Secure with #10
panhead screw.
Torque Bus screws
to 8-10 lb-in.
Secure with #10
panhead screw.
Torque to 12 lb-in.
minimum.
Secure with #10
panhead screw.
Secure with #10
panhead screw.
Figure 13:
Securing the Drive Module backplane to the Power Module backplane.
5. To install the Optional Cable Strain Relief bracket, slide the bracket behind the
backplane, aligning the slot with the backplane screw, push until it stops then secure with
a #10 panhead screw.
21
Modular Drive System Installation Manual
6. Secure the Drive Module backplane to enclosure mounting panel with #10 panhead
screws.
The paint must be removed from behind each PE Ground Tab to ensure proper ground
connection.
7. Secure the Power and Drive Module PE ground tabs with #10 panhead screws, torque
to 12 in.lb.
8. Continue adding Drive Modules, largest to smallest, by repeating step 1 through step 7.
The Power Module and Drive Module backplanes can be assembled as described above,
where one backplane is assembled and secured to the enclosure at a time. Another method is
to assemble all the backplanes together (Steps 1-4) and then secure them to the enclosure
mounting panel.
Figure 14:
22
Installing the Optional Cable Strain Relief Bracket
Installation
Step 3: Power Module High Power Connections
System Grounding
To insure a safe and quiet electrical installation, good system grounding is imperative. The
figure below is an overview of the recommended system grounding. For more information on
achieving an electrically quiet installation refer to “Basic Installation Notes” on page 6.
Enclosure Wall
Ground
Mains Contactor
L1
L2
L3
Single Point Ground
3 Phase
Line
Power
Ground connection rail and enclosure panel should
have a low impedance connection. Paint must be
removed from panel mounting surface.
AC Line Fuses
DC
Power Supply
+
+24 VDC
User
Supply
Control
Voltage
Transformer
PE
PE
PE
PE
PE
Secure to panel with
#10 screw.
Paint must be removed
from mounting surface
to assure these tabs are
connected to the
single point
ground.
AC Filter
+ N
Shunt Module
MS-500-XX-00
Optional
MP
MD
MD
MD
Paint
must be
removed
at least
from
behind
the
mounting
tab
PE
MH or UNI Motors
Figure 15:
System Grounding Overview
23
Modular Drive System Installation Manual
PE is not distributed through the backplanes. A separate PE connection is required for
each Power and Drive Module.
Fixed Protective Earth (PE) connections are mandatory for human safety and proper
operation. These connections must not be fused or interrupted by any means. Failure to
follow proper PE wiring can cause death or serious injury.
AC Input Power Connection
The following examples show AC Input power connections for three phase drives. These
examples are shown for reference only. Local electrical codes should be consulted before
installation.
If the continuous power required by the system is greater than 35 KW an AC Line Reactor
needs to be installed. Minimum requirements for the Line Reactor is 250 mH and 80A
continuous. Control Techniques offers a Line Reactor, MLR02580-00. See the CT-MMEPOWER-CD for drawings.
The maximum voltage applied to the Power Module AC Input terminals must not exceed
528VAC phase to phase and phase to PE ground. This can be accomplished by
referencing the AC supply to earth ground.
AC Supplies NOT Requiring Transformers
If the distribution transformer is configured as shown in the figures below, the AC power
supply can be connected directly to the amplifier terminals.
24
Installation
DISTRIBUTION PANEL
L3
L2
SECONDARY
To Fusing and
Power Module
342 to 528 VAC
L1
PE
EARTH
GROUND
Figure 16:
(Protective Earth)
Earth Grounded WYE Distribution Transformer
DISTRIBUTION PANEL
L3
SECONDARY
L2
342 to 528 VAC
L1
To Fusing and
Power Module
PE
EARTH
GROUND
Figure 17:
(Protective Earth)
Earth Grounded Delta Distribution Transformer
AC Supplies Requiring Transformers
If the distribution transformer is configured as shown in the figures below, an isolation
transformer is required. For sizing of isolation transformer See “Transformer Sizing” on
page 27.
If an isolation transformer is used between the power distribution point and the Power
Module, the isolation transformer secondary must be grounded for safety reasons as shown
in the figures below.
25
Modular Drive System Installation Manual
DISTRIBUTION PANEL
3 O ISOLATION TRANSFORMER
L3
L2
342 to 528 VAC
To Fusing and
Power Module
L1
PE
EARTH
GROUND
Figure 18:
(Protective Earth)
Three Phase Delta (with mid-phase GND) Distribution to a Three-Phase
WYE/WYE Isolation Transformer
D IS T R IB U T IO N P A N E L
3 O IS O L A T IO N T R A N S F O R M E R
L3
L2
3 4 2 to 5 2 4 V A C
T o F u s in g a n d
P o w e r M o d u le
L1
PE
EARTH
GROUND
Figure 19:
(P ro te c tiv e E a rth )
Three Phase WYE (ungrounded) Distribution to a Three-Phase Delta/WYE
Isolation Transformer
DISTRIBUTION PANEL
3O ISOLATION TRANSFORMER
L3
L2
342 to 528 VAC
L1
EARTH
GROUND
Figure 20:
26
To Fusing and
Power Module
PE
(Protective Earth)
Three Phase Delta Distribution to a Three Phase Delta/Delta Isolation
Transformer
Installation
Transformer Sizing
If your application requires a transformer, use the following table for sizing the KVA rating.
The values in the table are based on “worst case” power usage and can be considered a
conservative recommendation. You can down-size the values only if the maximum power
usage is less than the transformer continuous power rating. Other factors that may influence
the required KVA rating are high transformer ambient temperatures (>40° C or >104° F) and
MDS operation near the maximum speeds.
Power Module
Suggested KVA Rating
MP-1250
25
MP-2500
50
MP-5000
100
Transformer output voltage drop may become a limiting factor at motor speeds and loads near
maximum ratings. Typically, higher KVA transformers have lower voltage drop due to lower
impedance.
Line Fusing and Wire Size
You must incorporate over current protection for the AC Input power with the minimum
rating shown here. Refer to the table below for recommended fuses and wiring of other
uqeivalent fast blow fuses.
Recommended Minimum
AC/PE Line Wire Gauge
Power Module Model
External AC Line Fuse
MP-1250
KTK-R 20A, JKS 20A or JJS 20A
16 GA
MP-2500
JKS 40A or JJS 40 A
10 GA
MP-5000
JJS 70A
4 GA
The MDS has an internal relay that is required to be wired into the control logic of the
installation. The AC Interlock relay contact should be wired in series with the coil of the
Mains contactor. The relay contact is rated at +24VDC at 5A. To protect the Modules the
AC Interlock will open during a High AC Input or Shunt Fault Condition.
27
Modular Drive System Installation Manual
Electrical AC Input Power Connections
Torque:
5 - 8 LB IN.
Figure 21:
L1 L2 L3 PE
Power Module AC Power Wiring Diagram
Do Not apply power to the backplanes before the modules are attached. The backplanes
have exposed high voltage conductors.
28
Installation
External Shunt Electrical Installation
Shunt Wire Size
Power Module Model
Recommended Minimum Shunt Wire Gauge
MP-1250
16 GA
MP-2500
16 GA
MP-5000
16 GA
Shunt Resistor Connection
Connect the Shunt Resistor to B+ and Shunt terminals on the Shunt connector.
Shunt Output
Torque:
5 - 8 LB IN.
Figure 22:
Power Module Shunt Wiring Diagram
Access to Bus- (B-) is given for measurement purposes only (i.e. oscilloscope or voltage
meter). Do Not make any connections to B-.
Shunt connections are at main voltage potential. Components connected must be rated for
the voltage and selected for safety.
29
Modular Drive System Installation Manual
Logic Power
+24VDC
M
Shunt
Thermal Switch
(if available)
AC Mains
Contactor
Coil
AC Mains
Contactor
Single Point
Ground
Fuse Required
See Note below
Thermal Switch
Shunt
Output
External
Shunt
Resistor
Figure 23:
Power Module Shunt Wiring
Note
For proper fuse size refer to table below. Fast blow semiconductor fused rated 700 VDC
or higher are recommended (such as Shawmut A70Q). If using Control Techniques’
shunt, MS-510-00 or MS-530-00 , refer to Figure 24 for proper connections.
30
Power Module
Shunt Output Fuse Size
External Shunt Minimum
Resistance (Ohms)
MP-1250
4A
30
MP-2500
8A
30
MP-5000
16A
9
Installation
Logic Power
+24VDC
M
Shunt
AC Interlock
AC Mains
Contactor
Coil
AC Mains
Contactor
Single Point
Ground
MS-5XX-00
Thermal Switch
Internal
Control
Circuitry
Shunt
Output
+24 24 RTN
Figure 24:
Power Module Shunt to Control Techniques’ MS-5XX-00 Wiring Diagram.
Figure 24 shows the high power connections only. For a complete wiring diagram to a MS5XX-00 see the Option and Accessories section in this manual.
31
Modular Drive System Installation Manual
+
AC INTERLOCK
B+
Figure 25:
SHUNT
24 VDC
The MS-5XX-00 Connections
The MS-5XX-00 has integral control circuitry for protection of the shunt resistor. In order to
protect the installation the shunt interlock must be placed in series with the AC Mains
Contactor.
32
Installation
Step 4: Drive Module High Power Connections
Motor Power Cable Wiring to the Drive Module
The Motors are equipped with up to three male MS (Military Standard) connectors, one for
motor power connections, one for encoder connections and one for the brake (if so equipped).
Motor power connections from the Drive Module to the motor can be made with cables which
have a female MS style connector on the motor end and four individual wires and shield that
connect to the motor power connector on the bottom of the Drive Module.
Motor Model
Standard Cable Model#
MH or HT 3" frame
CMDS
Flex Cable Model # Wire Gauge
CMDF
16
MH 4" and 6^ frame
CMMS
CMMF
12
MH 8" frame
CMLS
N/A
8
Note
The motor ground wire and shields must be run all the way back to the amplifier terminal
and must not be connected to any other conductor, shield of ground.
Drive Module Motor
Connections
Motor Power Cable Model Color Code
CMDS, CMMS,and
CMLS
CMDF and CMMF
PE
Green/Yellow
Green/Yellow
T
Blue
Red 3
S
Black
Red 2
R
Brown
Red 1
PE T S R
Torque:
5 - 8 LB IN.
Figure 26:
Drive Module Motor Power Wiring Diagram
33
Modular Drive System Installation Manual
Step 5: Power Module Installation
After all the backplanes are secured with AC Input Power and Motor Power cable connections
made, the Power Module must be installed into the backplane.
Make sure all power is off before installing any of the modules.
Orient the Power Module so the top of the module is up and the alignment bars in the Module
aligns with the alignment tabs in the backplane. The sheet metal of the Power Module will
be on the outside of the alignment tabs.
Improper alignment of the module can cause damage to the module or the backplane.
Firmly press the Power Module into the backplane to insure good backplane connection.
When the Module is completely seated to the backplane, torque the top and bottom retaining
screws to 6 - 8 LB IN.
Retaining Screw
Alignment Tab
Alignment Bars
Alignment Tab
Retaining Screw
Figure 27:
34
Power Module Assembly Diagram
Installation
Step 6: Drive Module Installation
After the Power Module is installed to its backplane the Drive Modules can be installed to
their respective backplanes.
Make sure all power is off before installing any of the modules.
Orient the Drive Module so the top of the module is up and the alignment bars in the Module
aligns with the alignment tabs in the backplane. The sheet metal of the Drive Module will be
on the outside of the alignment tabs.
Improper alignment of the module can cause damage to the module or the backplane.
Firmly press the Drive Module into the backplane to insure good backplane connection.
When the Module is completely seated to the backplane, torque the top and bottom retaining
screws to 6 - 8 LB IN.
Retaining Screw
Alignment Tab
Alignment Bars
Alignment Tab
Retaining Screw
Figure 28:
Drive Module Assembly Diagram
35
Modular Drive System Installation Manual
Step 7: Power and Drive Module Low Power Connections
Logic and Digitial I/O Power Sizing
The MDS requires a user supplied logic power supply, 24 VDC +/- 10%, to power the internal
logic of the Power Module and Drive Modules. Use the table below to determine the current
requirements of the application.
Module
Model Number
RMS Current (A)
MP-1250
Power Module
MP-2500
0.30
MP-5000
MD-404
MD-407
Drive Module
MD-410
0.60/Module
MD-420
MD-434
0.80/Module
FM Module
All
0.40/FM Module
Synchronization
Feedback Encoder
*
0.07/Encoder
* Control Techniques supplies external master synchronization feedback encoders (Model#
SCSLD-XXX) or user supplied synchronization feedback encoders can be used. The current
required to power the synchronization feedback encoder can not exceed 250 mA @ 5 VDC/
Axis.
The user supply connected to the Power Module provides power for the internal logic of the
MDS. The Logic Power is carried through the backplane from the Power Module to the Drive
Modules.
A user supply is also required for the Digital I/O power on the Power Module, Drive Modules,
and FM Modules. The user supply for Logic Power and Digital I/O Power can be the same
supply if desired. However, the input tolerances for Logic Power and Digital I/O are different
and may require that the I/O and Logic Power supply be separated. Reference the following
Figures for connections.
36
Installation
Logic and Digitial I/O Power Connections
In Figures 29 and 30 the MDS is being powered by one power supply. The supply needs to
be wired into the Power Module Logic Power Input and Digital I/O Input. Each Drive Module
and FM module also require Digital I/O power. The Power Module’s Logic Power Input
range is +24VDC +/-10%. The Digital I/O power for all the modules is +10 to 30 VDC. For
applications that require Digital I/O power outside the Logic Power Input range refer to
Figure 31 and 32.
Programming Module
1
2
SHLD
3
4
5
6
7
8
Sync.
Output
+
-
485+
485SHLD
Outputs 10-30
VDC
3
4
Sync.
Input
Sync.
Output
Outputs 10-30
VDC
Sync.
Input
1
2
Exp. I/O
485+
485-
4
5
6
7
SHLD
8
1
2
3
4
+
-
1
Inputs
Exp. I/O
AC Interlock
Inputs
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
Sync.
Output
1
2
3
485-
Outputs 10-30
VDC
Sync.
Input
Programming Module
Inputs
Exp. I/O
Programming Module
485+
2
3
4
5
6
7
8
1
2
3
4
+
-
Power Module Status
Logic Power
System Ready
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
+
-
Shunt Active
Shunt Fault
Over Temp
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
+24 VDC
User Logic
and I/O
Supply
(+24 VDC +/-10%)
+
-
+24VDC
24V rtn
Single
Point
Ground
Figure 29:
One Power Supply for the Logic and I/O Power Wiring Diagram.
37
Modular Drive System Installation Manual
Drive Module 1
J6
10-30
VDC
+ -
Drive Module 2 . . . . . . . . . .Drive Module 8
J6
10-30
VDC
+ -
J6
10-30
VDC
+ -
Power Module
Logic
Power
+24VDC
24V rtn
PE
I/O 10-30 VDC
+
-
+24 VDC
Function Module 1
24 RTN
Function Module 2 . . . . . . . . Function Module 8
PE Ground
Figure 30:
One Power Supply for the Logic and I/O Power Wiring Diagram.
Drive Module 1
J6
10-30
VDC
+ -
Drive Module 2 . . . . . . . . . .Drive Module 8
J6
10-30
VDC
+ -
J6
10-30
VDC
+ -
Power Module
Logic
Power
+24VDC
24V rtn
PE
I/O 10-30 VDC
+
-
+24 VDC
Function Module 1
24 RTN
Function Module 2 . . . . . . . . Function Module 8
PE Ground
+10-30 VDC
10-30 RTN
Figure 31:
38
Separate Power Supplies for the Logic and I/O Power Wiring Diagram
Installation
In Figures 31 and 32 the MDS Logic and I/O power are separated for applications that have
Digital I/O power (+10 to 30VDC) that is out of the Logic Power Range (+24VDC +/-10 %).
Programming Module
1
2
Sync.
Output
Inputs
5
6
7
8
3
+
-
Sync.
Output
4
485+
6
7
SHLD
8
1
2
3
4
+
-
3
4
5
6
485-
7
SHLD
8
Outputs 10-30
VDC
2
Sync.
Input
Sync.
Output
Outputs 10-30
VDC
Sync.
Input
1
Exp. I/O
Exp. I/O
Inputs
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
4
SHLD
5
2
3
485-
4
1
2
485+
3
485-
Outputs 10-30
VDC
Sync.
Input
Programming Module
1
Inputs
Exp. I/O
Programming Module
485+
1
2
3
4
+
-
Power Module Status
Logic Power
AC Interlock
System Ready
Shunt Active
Shunt Fault
Over Temp
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
+
-
I/O 10-30 VDC
+24 VDC
User Logic
Supply
+
-
+24VDC
24V rtn
(+24 VDC +/-10%)
+ VDC
User I/O
Supply
V rtn
(+10 to 30 VDC )
Single
Point
Ground
Figure 32:
Separate Power Supplies for the Logic and I/O Power Wiring Diagram.
39
Modular Drive System Installation Manual
Power Module I/O Connections
Status I/O,
Logic Power
and I/O
Power, See
Page 43
Status Indicators,
See Page 41
Status I/O, Logic
Power and I/O Power,
See Page 43
ISO View
Figure 33:
Bottom View
Power Module Operation and Features
The function of the Power Module is to rectify the AC input and provide the DC bus for the
Drive Modules. The Power Module has an integral soft-start circuit to limit the in-rush current
when powering up the system. Once the DC bus is charged the Power Module passes a logic
signal (System Ready) to the Drive Modules across the backplane allowing the Drive
Modules to draw power from the bus. For deceleration of loads that generate more energy
than the DC Bus capacitance can store, the Power Module has an integral shunt transistor that
can be connected to an external shunt resistor through the shunt connector on the bottom of
the backplane.
The Power Module has a built in processor providing system soft-start control, shunt control
and basic self-protection and diagnostic functions such as:
•
40
Excessive AC input voltage
Installation
•
Loss of AC input voltage phase (single phase operation)
•
Over temperature of the rectifier bridge and shunt transistor
•
Improper shunt circuit operation or wiring error
Six diagnostic display LEDs controlled by the microprocessor are located on the Power
Module front panel as well as the I/O connector with 4 digital outputs, 2 digital inputs, and
AC Interlock Relay contacts. The function of these signals can be found on the following
pages.
Power Module Status Indicators (LEDs)
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
Figure 34:
+
-
Power Module Status Indicator location
Logic Power
The Logic Power status indicator (green) is illuminated when the +24VDC logic Power is
correctly supplied to the Power Module. If the status indicator is not illuminated verify that
the user supply is providing between +21.6 VDC and +26.4 VDC.
System Ready
The System Ready status indicator (green) is illuminated when the system power-up sequence
is properly completed. See “Power up Sequence” on page 66.
The System Ready status indicator will blink if one of the AC Input Phases is lost. The system
will remain functional in single phase condition. However, it’s strongly undesirable to run the
system in single phase mode that can cause severe over heating of the power module
components.
41
Modular Drive System Installation Manual
If AC power is on and the System Ready status indicator is not illuminated, one of the
following has occurred: Shunt fault, Over-temperature or High VAC Input. These faults are
described below.
Shunt Fault
The Shunt Fault status indicator (red) will be illuminated in the case of shunt resistor wiring
error or a short circuit condition.
Over Temp
The Over Temp status indicator (red) will be illuminated if continuous RMS power rating of
the Power Module is exceeded creating an over temperature condition. The Power Module
needs to be shut down to allow for cooling before the Over Temp condition is not present.
This fault may also occur if ambient temperature exceeds 40oC.
High VAC Input
The High VAC Input status indicator (red) will be illuminated if the AC input Voltage
exceeds 528 VAC.
Shunt Active
The Shunt Active status indicator (green) will be illuminated when the Shunt Transistor is on.
The Shunt Transistor will turn on under two conditions:
42
•
The Bus voltage exceeds 830 VDC due to regenerative energy during motor deceleration.
Shunt Transistor turn off level is 780 VDC.
•
The External Shunt Control Input is active in case of emergency stop.
Installation
Power Module I/O
A highspeed diode
(such as a 1N4000) is
required for inductive
loads such as a relay,
solenoid or contactor.
I/O Supply
+10 to 30 VDC
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
System Ready
2.8 k
Shunt Active
Shunt Fault
Over Temp
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Load
Load
Load
Load
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
Load
AC Interlock
Power Module Status
Logic Power
Load
+
-
+
-
Torque to
4 - 6 lb in.
V rtn
+ VDC
Single point
PE ground.
I/O Supply
(+10 to 30 VDC)
Figure 35:
Power Module I/O Wiring Diagram
System Ready
The System Ready output is active (high) when the Power Module has completed the powerup sequence properly.
(See Figure 38) Once this signal is active the Drive Module can be
enabled. The System Ready output remains high during normal system operation and turns
low in case of system fault.
If AC power is on and System Ready output is low, one of the following has occurred:
Shunt fault,
Over-temperature fault or
High VAC Input. These faults are described
below.
Shunt Fault
The Shunt Fault output
short circuit condition.
will be active (high) in the case of shunt resistor wiring error or a
43
Modular Drive System Installation Manual
Over Temp
The Over Temp fault will be active (high) if continuous RMS power rating of the Power
Module is exceeded creating an over temperature condition.
High VAC Input
The High VAC output will be active (high) if the AC input Voltage exceeds 528 VAC.
Drive Module Fault
The Drive Module Fault output will be active (high) if at least one of the Drive Modules is in
over current or short circuit condition. In this case a ’Z’ fault will be displayed on the Drive
Module display indicator. The System Ready signal will not be affected by the status of this
signal.
Shunt Active
The Shunt Active Output will be active (high) when the Shunt Transistor is on. The Shunt
Transistor will turn on under two conditions:
•
The Bus voltage exceeds 830 VDC due to regenerative energy during motor deceleration.
Shunt Transistor turn off level is 780 VDC.
•
The External Shunt Control Input is active in case of emergency stop.
AC Interlock
The AC Interlock relay contacts are closed if +24 VDC Logic Power is supplied to the
system. This relay is intended to remove AC power from the system (contacts are open)
when one of the faults below occur:
44
•
High VAC Input
•
Shunt Fault
or
Installation
AC Interlock Connections
The MDS has an internal relay that is required to be wired into the control logic of the
installation. The AC Interlock relay contact should be wired in series with the coil of the
Mains contactor. The relay contact is rated at +24VDC at 5A. To protect the Modules the
AC Interlock will open during a High AC Input or Shunt Fault Condition.
Ground
L1
3 Phase
Line
Power
L2
L3
M
AC Mains
Contactor
AC Line
Fuses
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
+24 VDC
User Supply
(+24 VDC +/- 10%)
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
24V RTN
+ 24VDC
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
Logic
Power
+24VDC
+
-
AC Mains
Contactor Coil
M
AC Mains
Contactor
Figure 36:
AC Interlock wiring with +24VDC Mains Contactor Coil
45
Modular Drive System Installation Manual
Ground
L1
3 Phase
Line
Power
L2
L3
M
AC Mains
Contactor
AC Line
Fuses
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
+24 VDC
User Supply
(+24 VDC +/- 10%)
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
24V RTN
+ 24VDC
I/O 10-30 VDC
+
-
Logic
Power
+24VDC
CR
120/240
VAC
Control
Voltage
M
AC Mains
Contactor Coil
Figure 37:
AC Interlock with 120/240VAC Mains Contactor
Ext Shunt Control
The External Shunt Control Input (active high) gives the user control of the shunt transistor
in case of an emergency stop. When this input is active the shunt transistor will turn on and
bleed the bus down through an external shut resistor.
This Input is disabled when AC Power is supplied to the system.
46
Installation
Fault Reset
The Faults Reset Input (active high) allows the user to reset any of three faults without
removing +24 VDC Logic Power from the system.
Figure 38:
Power Module Logic Timing Diagram
Logic Power
The Logic Power is necessary for all internal logic operation of the Power and Drive Modules.
The Logic Power input is +24 VDC +/- 10 %. See “Logic and Digitial I/O Power
Connections” on page 37 for wiring diagrams.
PE (SHIELD)
The PE connection is a convenient place to connect I/O cable shield. It is the same electrical
point as all other PE connections of the MDS. See “System Grounding” on page 23.
47
Modular Drive System Installation Manual
I/O
The I/O supply input is used to power the user side of the Power Module I/O. The I/O supply
supports +10 to 30 VDC input. See “Logic and Digitial I/O Power Connections” on page 37
for wiring diagrams.
Drive Module I/O Connections
FM Module Connection See Page vi
Analog Output Test
Points - See Page 78
Reset Button
I/O Connector See Page 49
Motor
Feedback
Connector See Page 61
Serial Connector See Page 62
Command Connector See Page 52
Diagnostic Display
- See Page 73
Iso View
Figure 39:
Bottom View
Drive Module Operations and Features
The Drive Module draws power from the DC Bus and controls the current flow to the motor.
Each Drive Module is configured using PowerTools FM or PowerTools PRO. The Drive
Module contains a diagnostic display that provides visible feedback to the current status of
the Drive Module. The Drive Module has connections for Digital I/O, Analog I/O, Encoder
Feedback, Sync Encoder and the ability to connect FM modules for more functionality.
48
Installation
Input/Output Connector Wiring
Drive Modules are equipped with five optically isolated input lines (one is dedicated to a drive
enable function) and three optically isolated output lines. They are designed to operate from
a +10 to 30 VDC source. All inputs and outputs are configured as sourcing.
Each output is capable of providing 150mA and must be protected from over current
conditions by a user supplied fuse.
Highly inductive loads such as relays must be suppressed with a diode.
Front View
A highspeed diode
(such as a 1N5819) is
required for inductive
loads such as a relay,
solenoid or contactor.
I/O Supply
+10 to 30 VDC
OUTPUT
1 2 3
Load
INPUT
2 3 4
Load
1
2.8 k
Load
Drive
Enable
10-30
VDC
RESET
SERIAL
COMMAND
10-30
VDC
+ -
DRIVE
ENABLE
J6
INPUT
1
2 3
J4
1 Amp Fuse
J5
OUTPUT
4 1 2 3
J6
Single point
PE ground.
Figure 40:
- +
24 VDC
MDS Drive Module Input/Output Wiring Diagram
The I/O connector is a 10-pin removable terminal block. It is recommended that #18 to 24
AWG stranded wire be used and torque to 4 - 5 lb.-in.
49
Modular Drive System Installation Manual
Front View
Internal to Drive Module
Input #4
Input #3
Input #2
Input #1
Drive Enable Input
Output #3
Output #2
Output #1
I/O Common I/O Common I/O Supply +
I/O Supply +
4
3
2
1
16
17
2.8 k
18
19
31
32
33
34
GND
3
J5
1
2
OUTPUT
RESET
2 3
4
3
J5
INPUT
1
J4
OUTPUT
4 1 2 3
1
+ -
DRIVE
ENABLE
J6
INPUT
2
SERIAL
COMMAND
10-30
VDC
J6
Figure 41:
10-30
VDC
+ --
DRIVE
ENABLE
MDS Drive Module I/O Connector to Command Connector Internal
Connections
Note
If loads are applied to the same output signal on both Command Connector and I/O
Connector, the sum total current loading must be limited to 150 mA per output signal.
Motor Brake Wiring
HT and MH motors equipped with brakes have a separate three-pin MS style connector for
brake power. The brake power cable (model CBMS-XXX) has an MS style connector on the
motor end and three wire leads on the Drive Module end (see Figures 42 and 43). For
Unimotors equipped with brakes the brake wiring is contained in the motor power cable.
You must provide a DC power supply rated at +24 VDC with a 2 amp minimum current
capacity for the brake. If you use this voltage source to power other accessories such as I/O
or more than one brake, you must increase its current capability.
50
Installation
Front View
CBMS-XXX Cable
Black A2
Motor Brake
Connection
INPUT
1 2 3 4
OUTPUT
1 2 3
A1
RESET
+ -
DRIVE
ENABLE
10-30
VDC
INPUT
1
2
3
Customer
Supplied Drive
Enable Contact
Internal
to Brake
Motor
J4
J5
OUTPUT
4 1 2 3
Drive
Enable
14
10-30
VDC
SERIAL
COMMAND
J6
C
B
A
K1
2 Amp Fuse
1 Amp Fuse
11
Relay:
Model: BRM-1
Red +
J6
- +
Single point
PE ground.
Figure 42:
Motor
P/N PT06A-8-3SSR
Motor Brake Connector
(HT and MH Motors Only)
Connected to
Single point PE ground
24 VDC
MDS Drive Module Brake Wiring Diagram using the I/O Connector
51
Modular Drive System Installation Manual
Front View
CBMS-XXX Cable
Black A2
A1
Output #3
RESET
SERIAL
COMMAND
10-30
VDC
+ -
DRIVE
ENABLE
J6
INPUT
1
2
OUTPUT
3 4 1 2 3
J4
J5
Drive Enable
I/O Common
I/O Common
I/O Supply
I/O Supply
17
16
32
31
34
33
Customer
Supplied Drive
Enable Contact
14
2 Amp
Fuse
J5
- +
Figure 43:
C
B
A
K1
1 Amp
Fuse
Single point
PE ground.
Motor Brake
Connection
11
Relay:
Model: BRM-1
Red +
Internal
To Motor
Brake
Motor
P/N PT06A-8-3SSR
Motor Brake Connector
(Ht and MH Motors Only)
Connected to
Single point PE ground
24 VDC
MDS Drive Module Brake Wiring Diagram using the Command Connector
Command Connector Wiring
All command and digital I/O signals are available using the 44-pin Command Connector (J5).
If you are interfacing your MDS to an AXIMA 2000 or 4000 multi-axis controller, simply
connect the 44-pin connector of your AX4-CEN-XXX cable to the Drive Module and the 25pin connector to the AXIMA multi-axis controller.
If you are interfacing your MDS to an AXIMA Classic or any other motion controller, you
may use either the CDRO-XXX or CMDO-XXX cables or the optional External Connection
Interface (ECI-44) which provides a convenient screw terminal connection strip. Connect one
end of the CMDX command cable to your Drive Module and the other end to the ECI-44.
52
Installation
Shield
Connected to
Connector Shell
Command Connector
(RED/BRN)
1
(BRN/RED)
(BLK/BLU)
(BLU/BLK)
(WHT/ORG)
2
3
4
6
(ORG/WHT)
(PRP/BLU)
21
8
(BLU/PRP)
(RED/BLU)
9
11
(BLU/RED)
(BLK/GRN)
12
16
(GRN/BLK)
(BLK/BRN)
17
18
(BRN/BLK)
(PRP/ORG)
19
(ORG/PRP)
(BLK/RED)
(RED/BLK)
(PRP/GRN)
(GRN/PRP)
(YEL/BLU)
(BLU/YEL)
(YEL/BRN)
23
24
25
39
27
41
34
32
33
31
37
38
40
(BRN/YEL)
(PRP/BRN)
(BRN/PRP)
(PRP/GRY)
26
14
15
43
44
(GRY/PRP)
(WHT/BLU)
(BLU/WHT)
(WHT/GRN)
(GRN/WHT)
(WHT/RED)
29
28
(RED/WHT)
(GRY/YEL)
(YEL/GRY)
36
20
35
7
10
13
5
22
30
= Twisted Pair
Figure 44:
42
PE
Input #1
Input #2
Input #3
Input #4
RS 485+
RS 485-
10 Ohm
Encoder Output Channel A
Encoder Output Channel A/
Encoder Supply +5 Volts - Output. 200 mA
Encoder Common
Drive Enable Input
Output #3
Output #2
Output #1
Encoder Output Channel B
Encoder Output Channel B/
Pulse Input Z
Pulse Input Z/
Pulse Input A
Pulse Input A/
I/O Supply +
I/O Common I/O Supply +
I/O Common Encoder Output Channel Z
Encoder Output Channel Z/
Pulse Input B/
Pulse Input B
- Analog Command In
+ Analog Command In
Diagnostics Output Channel 1
Diagnostics Output Channel 2
Diagnostic Output Common
+15 Out (Test Only)
Pulse In B Single-ended
Pulse In A Single-ended
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Command Connector (J5) Pinout and CMDO-XXX Wire Colors
For information about Command Connector pinout and CMDO-XXX cable wire colors, see
the "Specifications" section.
Function
Pin Numbers
Electrical Characteristics
Inputs and Drive Enable
1, 2, 3, 4, 16
10-30 V (“On”) 0-3 V (“Off”) optically isolated
Outputs
17, 18, 19
10-30 VDC sourcing 150 mA
I/O Supply
33, 34
10 - 30 VDC @ 1 Amp maximum
I/O Common
31, 32
I/O return
Pulse Inputs Differential
25, 26, 27, 39, 40, 41
5 V, 200 mV differential, 60 mV hysteresis, RS-422 compatible
53
Modular Drive System Installation Manual
Function
Pulse Inputs Single Ended
Pin Numbers
20, 36
Electrical Characteristics
TTL, 330 ohm pull-ups to internal 5 V, 1.5 V = low, 3.5 V = high
Encoder Supply Output +5 V
11
+5 V (200mA) output self-resetting fused internally
Encoder Common 0 V
12
0.0 V, 10 ohms away from PE
Encoder Out
8, 9, 23, 24, 37, 38
Differential line driver output (RS 422)
Analog In
14, 15
± 10 VDC differential command
Diagnostic Output
43, 44
± 10 VDC 10 mA maximum. Analog diagnostic output, ref. to pin
29
Diagnostic Output Common
29
0.0 V, 10 ohms away from PE
0 ohms away from Encoder Common 0V (pin 12)
RS 485 ±
6, 21
Same signals as the Serial Connector
+15 out
28
10 mA supply. ref. pin 29 (for test purposes only.)
Command Cables
The CMDO, CMDX and CDRO cables are all cables that plug into the Command Connector.
The CMDO and CMDX cables both use the same straight connector style, same color code
and carry the full complement of signals available from the Command Connector. The
difference is the CMDO cable has a male connector on one end with open wires on the other
while the CMDX cable has male connectors on both ends.
For information about CMDO-XXX and CMDX-XXX (18 pair cable) cable wire colors see
the "Specifications" section.
Note
Some CMDO and CMDX cables may have White/Yellow and Yellow/White wires in
place of the White/Orange and Orange/White shown in the figure above (pins 6 and 21).
The CDRO cable includes only the most commonly used signals to reduce the cable outer
dimension and has a connector at only one end. The 45 degree connector design used on the
CDRO cable also reduces the enclosure spacing requirement below the Drive Module.
For information about the CDRO-XXX (13 pair) cable wire colors, see the "Specifications"
section.
54
Installation
- Analog In
Command Connector
+ Analog In
Analog Command Wiring
(Internal)
10 Ohm
Logic
Common
PE
15 14
Single Point
Panel Ground
External
Controller
VDC
CW Rotation
+ Command = CW
With positive direction = CW
Controller Logic
Common
Single Point
Panel Ground
Figure 45:
Analog Command, Differential Wiring Diagram
Drive
Command Connector
Figure 46:
Analog Command, Single Ended Wiring Diagram
55
Modular Drive System Installation Manual
Encoder Output Signal Wiring
The encoder outputs meet RS-422 line driver specifications and can drive up to ten RS-422
signal receivers.
The default encoder output scaling is set to output the actual motor encoder resolutions. The
standard MH and HT motors have 2048 lines per revolution. With PowerTools this resolution
is adjustable in one line per revolution increments up to the density of the encoder in the
motor.
Figure 47:
Command Connector (J5) Encoder Output Wiring
CW Rotation
+ Command = CW
With positive direction = CW
Figure 48:
56
Direction Convention Diagram
Installation
Pulse Mode Wiring, Differential Inputs
Figure 49:
Pulse Mode, Differential Output to Differential Input
Figure 50:
Pulse Mode, Single Ended Output to Differential Input
57
Modular Drive System Installation Manual
Pulse Mode Wiring, Single Ended Inputs
+5
Logic
Power
Pulse
A/
Direct
B
Sinking
Outputs (typ)
Common isolated
from other sources
Figure 51:
Pulse Mode, Single Ended Output to Single Ended Input (twisted pair cable)
+5
Logic
Power
Pulse
A/
Direct
B
Sinking
Outputs (typ)
Common isolated
from other sources
Figure 52:
58
Pulse Mode, Single Ended Output to Single Ended Input (non-twisted pair
cable)
Installation
+5
Logic
Power
CW Pulse
CCW Pulse
Sinking
Outputs (typ)
CW Pulse
CCW Pulse
Common isolated
from other sources
Figure 53:
Pulse/Pulse Mode, Single Ended Output to Single Ended Input (non-twisted
pair cable)
Figure 54:
Master/Slave Encoder Connections
Note
Encoder outputs meet RS-422 driver specifications and can drive up to 10 RS-422 signal
receivers. Each differential pulse input is an RS-422 line receivers. The default encoder
59
Modular Drive System Installation Manual
output resolution is 2048 lines per motor revolution. This resolution is adjustable in one
line per revolution increments with PowerTools software. The range is between 200 and
the actual motor encoder density.
60
Installation
Motor Feedback Wiring
Encoder feedback connections are made with the CFCS cable. This cable has an MS style
connector on the motor end and a 26-pin high density “D” connector on the Drive Module
end. For more information about all feedback cables see the "Specifications" section.
For A, A, B, B and Z, Z pairs, the CFCS cable uses low capacitance (~10 pf/ft) wire to get a
characteristic impedance of 120 ohms. This impedance match is important to minimize signal
loss and ringing.
Figure 55:
Motor Feedback Connector Pinout
The MDS drive can accept differential or single ended commutation signals: U, V, and W. It
the commutation signals are single-ended connect the appropriate signals to U, V, and W. The
compliment signals U\, V\ and W\ do not need to be grounded for operation. The signals are
pulled to ground internally.
61
Modular Drive System Installation Manual
Serial Communications
Serial communications with the MDS is provided through the female DB-9 connector located
on the front of the Drive Module. The serial interface is either three wire non-isolated RS232C or two wire non-isolated RS-485. RS-485 is also available through the 44-pin
Command Connector.
The MDS serial port on the drive contains connection for RS-232 and RS-485 in the same
9-pin connector. With this dual communications support a 9[pin to 9-pin straight through
cable can not be used. The Control Techniques’ TIA-XXX cable is recommended.
When connecting the serial port of your PC to the serial port of the Drive Module, verify
that your PC’s ground is the same as the MDS PE ground. Failure to do so can result in
damage to your PC and/or your Drive Module.
Note
Communication errors can usually be avoided by powering the computer or host device
off of a convenience outlet that is mounted in the enclosure and whose neutral and ground
are wired to the same single ended point ground that the MDSs and controllers are using.
This is sometimes beneficial even with battery powered computers.
Modbus Communications
The Drive Module’s serial communication protocol is Modbus RTU slave with a 32 bit data
extension. The Modbus protocol is available on most operator interface panels and PLC’s.
Serial Communications Specifications
Max baud rate
19.2k
Start bit
1
Stop bit
2
Parity
none
Data
8
Motion Interface panels are supplied with a Modbus master communications driver.
62
Installation
Multi-Drop Communications
The RS-485 option (pins 4 and 9) is provided for multi-drop configurations of up to 32 Drive
Modules. A multi-drop serial cable, is available, which allows you to easily connect two or
more MDS Drive Modules.
Grounded to enclosure ground with screw.
TIA-XXX
Serial Cable
Term-T
Note:
The terminating resistor packs, Term-H
and Term-T, should be installed on the first
(Term-H) and last (Term-T) MDS Drive Modules
in the string if the total cable length is over
50 feet.
*If the user device (PC, Operator Interface, PLC, etc)
is communicating RS-485, the Term-H or equivalent
terminating resistor (120 Ohm) must be placed at
the user device and not on the first MDS module.
Figure 56:
Term-H*
DDS-XXX
Serial Cables
MDS Multi-Drop Wiring Diagram, RS-232 to RS-485 communications
63
Modular Drive System Installation Manual
TIA Cable
DDS Cable
DDS Cable
TERM-T
TERM-H
RX (232)
TX (232)
Ground
1
2
3
4
5
6
1
2
1
2
1
2
1
2
3
4
5
6
3
4
5
6
3
4
5
6
3
4
5
6
1
2
3
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
Drive
Serial Port
Drive
Serial Port
Drive
Serial Port
120
Ohm
Computer
Computer Serial
Port
Drive Serial Port
0V
+5
Drive Serial Port
576
Ohm
485 +
120
Ohm
485 -
576
Ohm
Drive Serial Port
TERM-H
TERM-T
TIA Cable
DDS Cable
DDS Cable
Top View of Multi-drop Cabling
Figure 57:
Multi-Drop Wiring Pinout with RS-232 Communications to PC
User Cable
DDS Cable
DDS Cable
TERM-T
TERM-H
RS-485 +
RS-485 -
1
2
1
2
1
2
1
2
3
4
5
6
3
4
5
6
3
4
5
6
3
4
5
6
1
2
3
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
Drive
Serial Port
Drive
Serial Port
Drive
Serial Port
120
Ohm
User Device
User Device
Port
Drive Serial Port
Drive Serial Port
0V
+5
120
Ohm
485 -
576
Ohm
Drive Serial Port
TERM-H
User Cable
576
Ohm
485 +
TERM-T
DDS Cable
DDS Cable
Top View of Multi-drop Cabling
Figure 58:
64
Multi-Drop Wiring Pinout with RS-485 Communications to User Device
Installation
Step 9: Power Up Sequence
Verify that all Power and Drive Modules are installed and secured to their respective
backplanes.
Powering up and running the system without all Modules installed to their backplanes in
NOT SAFE and could result in serious injury or death.
Verify proper wiring of Incoming VAC and Motor Power. Verify that the AC Interlock Relay
is correctly wired to protect the system. Verify that the Logic Power supply and/or I/O Power
supply are wired properly. After installation use the following flow chart to verify the correct
Power Up sequence.
65
Modular Drive System Installation Manual
Power up Sequence
Turn on 24VDC Logic Power Supply
Ÿ
Ÿ
Logic Power Status
Indicator ON
AC Disconnect Relay
Closed
Check +24VDC Supply
Connector to Power
Module
NO
YES
"u" or "d"
Displayed on all
Drive Modules
Status Display
NO
Make sure
Drive Modules with
no display are
properly seated
To verify that
backplanes are
connected properly the
+24VDC bus can be
measured on the last
Drive Module Backplane
YES
Turn on AC Input Power
(342 to 528 VAC)
After Soft Start has been completed
(approx. 2 seconds)
Ÿ
Ÿ
YES
System Ready Status Indicator ON
The "." decimal on all Drive Module
Status Displays are ON
Startup sequence has been
completed properly. System is
ready for operatoin
NO
Ÿ System Ready status Indicator ON
Ÿ "." The decimal point is OFF
Verify that the Drive Module is
seated properly and the Drive
Module fuse is not blown.
See Power and Fuse Replacement
section.
Figure 59:
66
Ÿ System Ready status Indicator OFF
Ÿ "." The decimal point is OFF
To next
page
Power Up Sequence Flow Chart - Part 1
Ÿ System Ready status Indicator OFF
Ÿ "." The decimal point is ON
Power Module does not function
properly
Installation
From
previous
page
Power Module
Faults?
No
Drive module(s) do
not fuction
properly and need
to be replaced
Yes
Over Temp
High VAC Input
Shunt Fault
Power Module
exceeded it's max
temperature and
needs cool down
time.
AC Input line
voltage exceeded
528 VAC
Shunt transistor
failed, due to short
in wiring or module
If none of these conditions have been found it means the Power Module does not function properly
Figure 60:
Power Up Sequence Flow Chart - Part 2
67
Modular Drive System Installation Manual
The MDS is able to handle short drops (glitch) on the AC Input Power without interruption
to system operation. If the DC Bus voltage drop is greater than 250 VDC the System Ready
Signal will go Low (not Active). If AC Input Power is applied before the DC Bus voltage
drops to 60VDC the Power Module will re-enter Soft Start and the Ready Signal will go High
(Active) when the Soft Start is complete. If the DC Bus voltage drops below 60VDC the
system will need to be reset for the Modules to power-up.
+24 VDC
VAC
Short AC Drop
Bus Voltage
Medium AC Drop
Large AC Drop
250 VDC
Drive Module
“u” Fault
60 VDC
Ready Signal
and I/O
Sof-Start Relay
AC Disconnect Relay
Figure 61:
AC Glitch Handling Diagram
Motor Mounting
Motors should be mounted firmly to a metal mounting surface to ensure maximum heat
transfer for maximum power output. The mounting surface should be bonded to the single
point ground.
For motor dimensions, weights and mounting specifications, see the "Specifications" section.
68
Installation
Drive and Power Module Removal
DO NOT remove Power or Drive Modules until at least 3 minutes after AC Power has
been removed from the system.
1.
Unplug all I/O and/or cable connections to the Power and Drive Modules.
2.
Loosen the Retaining Screws of the module being removed
3.
Grasp the top and bottom Integrated Removal Tab of the module.
4.
Pull the module from the backplane.
Integrated
Removal Tab
Integrated
Removal Tab
Retaining Screw
Retaining Screw
Pull Drive or
Power Module
off the backplane
Retaining Screw
Retaining Screw
Integrated
Removal Tab
Figure 62:
Integrated
Removal Tab
Power and Drive Module Removal Diagram
69
Modular Drive System Installation Manual
Drive Module Fuse Replacement
Fuse
locations
Figure 63:
Fuse Location in a Drive Module Backplane - MP-2500/MD-434 Shown
The Drive Module backplane is equipped with two over current protection fuses with the
ratings shown here. Control Techniques recommends fuse type: SHAWMUT® A70QS.
70
Drive Module
Fuse Rating
MD-404
10 A
MD-407
16 A
MD-410
20 A
MD-420
32 A
MD-434
50 A
Installation
Drive Module Backplane Disassembly
These instructions are to remove a Drive Module backplane from another Module backplane.
Shown in the figure below is a Power and Drive Module Backplane assembly.
PE Ground Tab
Snap Tab
Remove the #10
panhead screw.
Insert
screwdriver
here.
Loosen the
Bus screws.
Remove the #10
panhead screw.
Logic Connector
Insert
screwdriver
here.
Snap Tab
Remove the #10
panhead screw.
Optional Cable Strain Relief
Figure 64:
Drive Module Backplane Disassembly Diagram
DO NOT remove Power or Drive Modules until at least 3 minutes after AC Power has
been remove from the system.
71
Modular Drive System Installation Manual
72
1.
Remove the Drive Module and the Power Module from their backplanes. For details see
“Drive and Power Module Removal” on page 69.
2.
Remove the PE ground tab screw and if applicable the Optional Cable Strain Relief screw
of the backplane being removed.
3.
Remove the screws that secure the backplane to the metal mounting panel. If applicable
the Optional Cable Strain Relief can be removed now.
4.
Loosen the Bus screws.
5.
Insert a flat tipped screwdriver into the slot between backplanes as shown in Fig 64. Push
on the screwdriver with enough force to depress the snap tab, at the same time carefully
pull the backplane away from the other backplane. The backplanes only need to be
separated far enough so the snap tab is unlocked from the other backplane.
6.
Insert the screwdriver in the slot on the other end of the backplane and depress the snap
tab, carefully pull the backplane away, unplugging the Logic connector from the other
backplane.
Modular Drive System Installation Manual
Status, Diagnostics and
Troubleshooting
Power Module Status Indicators
The Power Module status indicators on the front of the Power Module shows system and
Power Module status. When the condition is met the indicators will be illuminated.
Status Function
Logic Power
Condition
The +24VDC Logic Power is correctly supplied to the Power Module.
Everything in the Power Module is properly connected:
System Ready
• +24VDC Logic Power
• AC Input has all three phases
• No Power Module Faults
and soft start is completed.
The System Ready indicator will blink in the condition that one of the AC input phases is
lost. The system will continue to operate in this condition.
The shunt transistor is on. The shunt transistor will turn on under two conditions;
Shunt Active
•
The Bus voltage exceeds 830 VDC
•
The External shunt control input is active.
Fault Function
Condiltion
Shunt Fault
Shunt resistor is shorted or wired incorrectly,
Over Temp
The Power Module RMS power is exceeded creating an over temperature condition in
the Power Module or ambient temperature is higher than 40oC.
High VAC Input
The AC Input voltage exceeds 528 VAC.
Drive Module Diagnostic Display
The diagnostic display on the front of the Drive Module shows Drive Module status and fault
codes. When a fault condition occurs, the Drive Module will display the fault code, overriding
the status code. The decimal point is “On” when the Drive Module is enabled and the Stop
input is not active. This indicates that the Drive Module is ready to run and will respond to
motion commands. Commands will not cause motion unless the decimal point is “On”.
Display Indication
Status
Brake Engaged (Output "Off")
Description
Motor brake is mechanically engaged. This character
will only appear if the Brake output function is
assigned to an output line.
See Brake Operation section for detailed description of
Brake Output function.
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Modular Drive System Installation Manual
Display Indication
Status
Description
Disabled
Power Stage is disabled.
Position
Pulse mode operation.
Velocity
Velocity mode operation.
Torque
Torque mode operation.
Summation
Summation mode operation.
RMS Foldback
Motor torque is limited to 80 percent.
Stall Foldback
Drive output current is limited to 80 percent of drive
stall current.
Ready to Run
Drive enabled, no Stop input.
Fault Codes
A number of diagnostic and fault detection circuits are incorporated to protect the Drive
Module. Some faults, like High DC bus and Motor Over Temperature, can be reset with the
Reset button on the front of the Drive Module or the Reset input function. Other faults, such
as encoder faults, can only be reset by cycling logic power “Off” (wait until the status display
turns “Off”), then power “On”.
The drive accurately tracks motor position during fault conditions. For example, if there is a
"Low DC Bus" fault where the power stage is disabled, the drive will continue to track the
motor’s position provided the logic power is not interrupted.
74
Status, Diagnostics and Troubleshooting
The +/- Travel Limit faults are automatically cleared when the fault condition is removed.
The table below lists all the fault codes in priority order from highest to lowest. This means
that if two faults are active, only the higher priority fault will be displayed.
Display
Fault
Action to Reset
Bridge Disabled
Power Up Test
Cycle Logic Power
Yes
NVM Invalid
Reset Button or Input Line
Yes
Drive Overtemp
Allow Drive to cool down,
Cycle Logic Power
Yes
Reset Button or Input Line
Yes
Power Module
Cycle Logic Power
Yes
High DC Bus
Reset Button or Input Line
Yes
Low DC Bus
Reset Button or Input Line
Yes
Encoder State
Cycle Logic Power
Yes
Encoder Hardware
Cycle Logic Power
Yes
Motor Overtemp
Allow Motor to cool down,
Reset Button or Input Line
Yes
Invalid Configuration
75
Modular Drive System Installation Manual
Display
Fault
Action to Reset
Bridge Disabled
Overspeed
Reset Button or Input Line
Yes
Following Error
(Pulse mode only)
Reset Button or Input Line
Yes
Travel Limit +/-
Auto
No
All "On"
Normally "On" for one
second during power-up
Yes
Fault Descriptions
Power Up Test
This fault indicates that the power-up self-test has failed. This fault cannot be reset with the
reset command or reset button.
NVM Invalid
At power-up the drive tests the integrity of the non-volatile memory. This fault is generated
if the contents of the non-volatile memory are invalid.
Invalid Configuration
A function module was attached to the drive on its previous power-up. To clear, press and
hold the Reset button for 10 seconds.
Drive Overtemp
Indicates the drive IGBT temperature has reached its limit.
Power Module
This fault indicates either IGBT module failure or over current/short circuit condition as a
result of phase to phase or phase to ground short in the motor or cable.
76
Status, Diagnostics and Troubleshooting
High DC Bus
This fault will occur whenever the voltage on the DC bus exceeds the High DC Bus threshold.
The most likely cause of this fault would be an open external shunt fuse, a high AC line
condition or an application that requires an external shunt (e.g., a large load with rapid
deceleration).
High DC Bus Threshold
MDS
880 VDC
Low DC Bus
This fault will occur whenever the voltage on the DC bus drops below the Low DC Bus
threshold. The most likely cause of this fault is a reduction (or loss) of AC power. A 50 ms
debounce time is used with this fault to avoid faults caused by intermittent power disruption.
With and Epsilon drive, the low DC bus monitoring can be disabled with PowerTools
software in the Advanced tab.
Low DC Bus Threshold
MDS
60 VDC
Encoder State
Certain encoder states and state transitions are invalid and will cause the drive to report an
encoder state fault. This is usually the result of noisy encoder feedback caused by poor
shielding. For some types of custom motors it may be necessary to disable this fault. Refer to
the Advanced Tab section of Setting Up Parameters for more information.
Encoder Hardware
If any pair of complementary encoder lines are in the same state, an encoder line fault is
generated. The most likely cause is a missing or bad encoder connection.
Motor Overtemp
This fault is generated when the motor thermal switch is open due to motor over-temperature
or incorrect wiring.
Overspeed
This fault occurs in one of two circumstances:
77
Modular Drive System Installation Manual
1.
When the actual motor speed exceeds the Overspeed Velocity Limit parameter or 150%
of motor maximum operating speed. This parameter can be accessed with PowerTools
software.
2.
If the combination of command pulse frequency and Pulse Ratio can generate a motor
command speed in excess of the fixed limit of 13000 RPM, an Overspeed Fault will be
activated. In Pulse mode operation and any Summation mode which uses Pulse mode,
the input pulse command frequency is monitored and this calculation is made. For
example, with a Pulse Ratio of 10 pulses per motor revolution, the first pulse received
will cause an Overspeed fault even before there is any motor motion.
Following Error
This fault is generated when the following error exceeds the following error limit (default
following error limit is .2 revs). With PowerTools you can change the Following Error Limit
value or disable in the Position tab. The Following Error Limit is functional in Pulse mode
only.
Travel Limit +/This fault is caused when either the + or - Travel Limit input function is active.
All "On"
This is a normal condition during power up of the drive. It will last for less than 1 second. If
this display persists, call Control Techniques for service advice.
Normally, All "On" for less than one second during power-up. All segments dimly lit when
power is "Off" is normal when an external signal is applied to the encoder inputs (motor or
master) or serial port from an externally powered device. The signals applied to the inputs
cannot exceed 5.5V level required to drive logic common or drive damage will occur.
Diagnostic Analog Output Test Points
The drive has two 8-bit real-time Analog Outputs which may be used for diagnostics,
monitoring or control purposes. These outputs are referred to as Channel 1 and Channel 2.
They can be accessed from the Command Connector on the drive or from the Diagnostics
Analog Output Pins located on the front of the drive.
Each Channel provides a programmable Analog Output Source.
Analog Output Source options are:
78
•
Velocity Command
•
Velocity Feedback
Status, Diagnostics and Troubleshooting
•
Torque Command (equates to Torque Command Actual parameter)
•
Torque Feedback
•
Following Error
Default Analog Output Source:
•
Channel 1 = Velocity Feedback
•
Channel 2 = Torque Command
Channel
Output Source
Offset
Scale
1
Velocity Feedback
0
600 RPM/volt
2
Torque Command
0
30 percent/volt for selected
motor
Channel #2
Analog GND
Channel #1
RESET
SERIAL
COMMAND
10-30
VDC
+ -
DRIVE
ENABLE
J6
INPUT
1
2
3
J4
J5
OUTPUT
4 1 2 3
RESET
SERIAL
COMMAND
MDS Drive Module
Figure 65:
Diagnostic Analog Output Test Points
The DGNE cable was designed to be used with either an oscilloscope or a meter. The wires
are different lengths to avoid shorting to each other. However, if signals do get shorted to
GND, the drive will not be damaged because the circuitry is protected.
79
Modular Drive System Installation Manual
D/A
Black
(GND)
D/A
Yellow
Blue
10 Ohm
2
10 Ohm
2
GND
DGNE Cable
DGNE Cable
Figure 66:
GND 1
1
44
29
43
Command Connector
Pin #'s
Diagnostic Cable (DGNE) Diagram
Drive Faults
The Active Drive Faults dialog box is automatically displayed whenever a fault occurs. There
are two options in this dialog box: Reset Faults and Ignore Faults.
Figure 67:
Active Drive Faults Detected Dialog Box
Resetting Faults
Some drive faults are automatically reset when the fault condition is cleared. Other faults
require drive power to be cycled or the drive to be “rebooted”. If you wish to continue
working in the PowerTools FM software without resetting the fault, click the Ignore Fault
button.
To reset faults that can be reset with the Reset Faults button, simply click the Reset Faults
button in the Drive Faults Detected dialog box or push the Reset button on the front of the
drive where the fault occurred.
80
Status, Diagnostics and Troubleshooting
Viewing Active Drive Faults
To view all active drive faults, select the View Faults command from the Device menu or by
clicking on the View Faults icon on the toolbar. The dialog box displayed is the same as
Active Drive Faults Detected dialog box described above.
Rebooting the Drive
To reboot the drive, cycle power or select the Reboot Drive command from the Device menu.
This command reboots the drive attached to the active Configuration Window.
Watch Window
This feature allows you to customize a window to monitor drive parameters which you select
from a complete list of drive parameters. From this window you can watch the parameters you
selected in real time. This feature is only available when you are online with the drive.
Note
You cannot change the values of the parameters while they are being displayed in the
Watch Window. The parameter in the setup screens will look like they have been changed
when they actually have not. To update a parameter, delete it from the Watch Window
selection.
Note
It is normal to have the Watch Window show up with the three motor parameters already
selected if the motor parameters window has been accessed previously. If you do not need
to view them, simply push the Clear All button and select the parameters you wish to
view.
Figure 68:
Watch Window
The Watch Window is accessed by selecting Watch Drive Parameters from the Tools menu
or by clicking on the Watch Window icon on the toolbar.
The Watch Window will automatically appear as soon as you select a parameter from the
Select Drive Parameters dialog box. After you have selected the parameters you wish to
81
Modular Drive System Installation Manual
watch, click the Close button. The Select Drive Parameters dialog box will close and the
Watch Window will remain open.
Figure 69:
Select Drive Parameters Dialog Box
Group
This list box enables you to view the complete list of parameters or just a group of parameters
you are interested in. The groups include: Analog In, Analog Out, Communication, Digital
Inputs, Execution, Fault Counts, Fault Log, ID, Input Functions, Motor, Output Functions,
Position, Setup, Status, Torque, Tuning, User Defined Motor, and Velocity.
Clear All Button
This button is used to clear all the parameter selections that were previously selected.
Save Selections Button
This button saves the parameter selections. This enables you to restore the same list of
parameters for use in future online sessions.
Restore Selections Button
This button restores the parameter selections previously saved. This enables you to restore the
list of parameters you created in a previous online session.
View Motor Parameters
When online with the drive this feature allows you to display a pre-defined Watch Window
to monitor three motor parameters. These parameters are normally used when testing the
setup of a User Defined Motor for commutation accuracy.
82
Status, Diagnostics and Troubleshooting
Figure 70:
View Motor Parameters Window
The View Motor Parameters window is accessed by selecting View Motor Parameters from
the Tools menu.
Error Messages
PowerTools will pop-up an error message box to alert you to any errors it encounters. These
message boxes will describe the error and offer a possible solution.
The table below list the of common problems you might encounter when working with
PowerTools software along with the error message displayed, the most likely cause and
solution.
Problem/Message
Cause
Solution
Time-out while waiting for device response.
The attempted operation has been cancelled.
(see fault: No device selected)
Loss of serial communications.
Check the serial connection to the device and
try operation again.
The attached device(s) do not have valid
revisions, or do not have matching revisions.
Attempting to broadcast to drive without
matching firmware revisions.
Program each drive individually.
Unable to communicate with device [Address
x]
The device that you are attempting to
communicate with is no longer available.
Check all connections and verify that you are
using the correct baud rate then try again.
The specified drive type (name) does not
match the actual drive type (name). Please
make necessary corrections.
The drive type you selected in the “Drive
Type” list box does not match the drive you
are downloading to.
Change the drive type selected in the “Drive
Type” list box to match the drive you are
downloading to.
Non-Control Techniques device attached
(address). When trying to program more than
one drive, only EMC drives of the same type
can be attached to the network.
This error is caused When you attempting to
perform an upload or download to multiple
drives and one or more of the drives are not
the same type.
Disconnect the device(s) that has been
specified and try the operation again or
program each device individually.
You have changed a parameter which will
not take affect until the drive has been
rebooted. Before you reboot the drive, you
will need to save your setup to NVM. Do you
wish to save your setup to drive NVM now?
See message.
Yes/No.
(Operation Name) The attempted operation
has been cancelled.
Communication error.
Retry operation. Check connection to drive.
Invalid entry. The entry exceeds the precision
allowed by this field. The finest resolution
this field accepts is (value).
Entered a value out of range.
Enter a value within the range of that field.
The status bar displays information on the
currently selected object or action.
The device was disconnected during the
upload. The upload was not complete.
Connection to the device was lost (a time-out
occurred).
Check the connection to the device and try
again.
The device was disconnected during the
download. The download was not complete.
Connection to the device was lost (a time-out
occurred).
Check the connection to the device and try
again.
83
Modular Drive System Installation Manual
Problem/Message
Cause
Solution
No device selected.
No device selected during flash upgrade.
Select device(s) from list box.
The drive at address is use.
84
Close any other windows that are using the
same addresses and try again.
Modular Drive System Installation Manual
Specifications
MDS Specifications
Specifications
Power Requirements
AC Input Voltage
3 Ph, 342 to 528 VAC, 47 - 63 Hz (480 VAC for rated performance
AC Input Current
Output Continuous Current (5 kHz/10 kHz)
Output Peak Current (5 kHz/10 kHz)
Continuous Output Power
Model
Rating
MP-1250
17 Arms
MP-2500
35 Arms
MP-5000
70 Arms
MD-404
4 Arms / 2.8 Arms
MD-407
7 Arms / 5 Arms
MD-410
10 Arms / 6.5 Arms
MD-420
20 Arms / 14 Arms
MD-434
34 Arms / 22 Arms
MD-404
8 Arms / 5.6 Arms
MD-407
14 Arms / 10 Arms
MD-410
20 Arms / 13 Arms
MD-420
40 Arms / 28 Arms
MD-434
68 Arms / 44 Arms
MP-1250
12.5 kW
MP-2500
25 kW
MP-5000
50 kW
MD-404
3.3 kW
MD-407
5.8 kW
MD-410
8.3 kW
MD-420
16.7 kW
MD-434
28.3 kW
Switching Frequency
5 or 10 kHz ( Ratings based on 5 kHz performance)
Logic Power Supply (User Supplied)
21.6 to 26.4 VDC ( Current requirements based on system)
Encoder Supply Output
+5VDC, 250 mA maximum
System Efficiency
>90%
85
Modular Drive System Installation Manual
Specifications
Regeneration
Internal Energy Absorption (480V) System Bus Capacitance Drive Module and Power Module
Model
Rating
MP-1250
141 Joules
MP-2500
235 Joules
MP-5000
376 Joules
MD-404
10 Joules
MD-407
22 Joules
MD-410
33 Joules
MD-420
47 Joules
MD-434
47 Joules
Integral Transistor connected to External Resistor, 15 A continuous
I/O Power Supply (User Supplied)
Model
Rating
MP-1250
30 Ohm minimum, 6 kW max.
MP-2500
30 Ohm minimum, 6 kW max.
MP-5000
9 Ohm minimum, 12 kW max.
+ 10 to 30 VDC
Power Module Control Inputs
Digital (2)
+10 to 30 VDC, 2.8 kOhm, Sourcing, Optically Isolated
Power Module Control Outputs
Digital (6)
Relay Contact (1)
+10 to 30 VDC, 150 mA, Sourcing, Optically Isolated
AC Interlock, 24 VDC 5A
Drive Module Control Inputs
Analog (1)
Digital (5)
86
+/- 10 VDC, 14 bit, 100 kOhm, Differential
Analog Max Input Rating: Differential +/- 14 VDC
Each Input with reference to Analog Ground +/- 14 VDC
+10-30 VDC, 2.8 kOhm, Sourcing (active high) , Optically Isolated,
Max input response time is 500 µs, Input debounce: 0 - 2000 ms,
Software selectable
Specifications
Specifications
Software selectable Differential (RS422) or Single Ended (TTL Schmitt
Trigger)
Pulse (1)
Maximum input frequency:
Differential - 2 MHz per channel; 50% duty cycle (8 MHz count in
quadrature)
Single ended - 1 MHz per channel; 50% duty cycle (4 MHz count in
quadrature)
Ratio Capabilities: 20 to 163,840,000 PPR
Input Device = AM26C32
Vdiff = 0.1 - 0.2 V
V common mode max = +/- 7V
Input impedance each input to 0V = 12 - 17 kOhm
Drive Module Control Outputs
Analog (2)
+/- 10 VDC (single ended, 20 mA max) 10 bit software selectable output
signals
Digital (3)
+10-30 VDC 150 mA max, Sourcing, Optically Isolated, Input
debounce: Programmable range, 0 to 200 ms
Motor Over Temperature (1)
0 to +5 VDC, Single Ended, 10 kOhm
Differential line driver, RS-422 and TTL compatible
Scalable in one line increment resolution up to 2048 lines/rev of the
motor (MG and NT)
Pulse (1)
Output Device = AM26C31
20 ma per channel, sink and/or source
Vout Hi @ 20 ma = 3.8 - 4.5 V
Vout Lo @ 20 ma = 0.2 - 0.4 V
Vout diff w/100 ohm termination = 2.0 - 3.1 V
Vout common mode w/100 ohm termination = 0.0 - 3.0 V
Iout short circuit = 30 - 130 mA
Cooling Method
Model
Rating
MP-1250
Convection
MP-2500
Integral Fan
MP-5000
Integral Fan
MD-404
Convection
MD-407
Integral Fan
MD-410
Integral Fan
MD-420
Integral Fan
MD-434
Integral Fan
Environmental
Rated Ambient Temperature
32 to 104 F (0 to 40 C)
Maximum Ambient Temperature
32 to 122 F (0 to 50 C) with power derating of 3% / 1.8 F (1 C) above
104 F (40 C)
Rated Altitude
3280’ (1000 m)
87
Modular Drive System Installation Manual
Specifications
Maximum Altitude
For altitudes >3280’ (1000 m) derate output by 1% / 328’ (100m) not to
exceed 7560’ (2000 m)
Vibration
10 to 2000 Hz @ 2g
Humidity
10 to 95% non-condensing
Storage Temperature
-13 to 167F (-25 to 75 C)
Ingress Protection (IP) Rating
Power and Drive Module: IP20
MH motors: IP65
Molded motor and feedback cables: IP65
Serial Interface
RS-232 / RS-485
Internal RS-232 to RS-485 converter
Modbus protocol with 32 bit data extension 9600 or 19.2 k baud
Serial Communications
Max baud rate
19.2k
Start bit
1
Stop bit
2
Parity
none
Data
8
Weight
Model
MP-1250
Power Module
MP-2500
MP-5000
Rating
8.35 lbs
10.25 lbs
MD-404
MD-407
Drive Module
High Bus Voltage
880 VDC
Shunt Turn On
830 VDC
Shunt Turn Off (Hysteresis)
780 VDC
Nominal Bus Voltage 480 VAC
680 VDC
Transformer Sizing
KVA Rating at Max. Power (page 27)
88
8.35 lbs.
MD-410
MD-420
10.25 lbs
MD-434
12 lbs
Model
Size
MP-1250
25 KVA
MP-2500
50 KVA
MP-5000
100 KVA
Specifications
Specifications
AC Input Wire Gauge
Shunt Size
Logic and Digital I/O Power Sizing
Model
Gauge
MP-1250
16 GA
MP-2500
10 GA
MP-5000
4 GA
All Power Modules
16 GA
Model
Max. RMS Current (A)
MP-1250
Power Module
MP-2500
0.30
MP-5000
MD-404
MD-407
Drive Module
0.60/Module
MD-410
MD-420
MD-434
0.80/Module
All
0.40/FM Module
*
0.07/Encoder
FM Module
Synchronization Feedback Encoder
Specifications
Fuses
Power Module (page 27)
Drive Module (page 70)
Model
Type
Size
MP-1250
KTK-R, JKS or JJS
20A
MP-2500
JKSor JJS
40A
MP-5000
JJS
70A
MD-404
10 A
MD-407
16 A
MD-410
Shawmut A70QS
20 A
MD-420
32 A
MD-434
50 A
89
Modular Drive System Installation Manual
Drive and Motor Combination Specifications
Drive
MD-404
Motor
Cont.
Stall
Torque
lb-in
(Nm)
Peak
Stall
Torque
lb-in
(Nm)
Power
HP @
Rated
Speed
kWatts
Inertia
lb-in-sec2
(kg-cm2)
Max
speed
RPM
Encoder
resolution
lines/rev
Motor Ke
VRMS/
krpm
Motor Kt
lb-in/
ARMS
(Nm/
ARMS)
MH-316
21.5
(2.43)
58
(6.55)
0.83
0.0006725
(0.75987)
4000
2048
75
10.98
(1.24)
MH-340
46
(5.20)
135
(15.25)
1.31
0.0014275
(1.61296)
3000
2048
116
16.98
(1.92)
MH-455
65
(7.34)
140.56
(15.88)
1.8
0.003557
(4.01914)
3000
2048
120
17.57
(1.99)
MH-455
72.5
(8.19)
228.42
(25.81)
1.8
0.003557
(4.01914)
3000
2048
120
17.57
(1.99)
MH-490
105
(11.86)
225.4
(25.4)
1.78
0.006727
(7.60099)
3000
2048
110
16.1
(1.82)
MH-455
72.5
(8.19)
268.82
(30.37)
1.8
0.003557
(4.01914)
3000
2048
120
17.57
(1.99)
MH-490
105
(11.86)
322
(36.38)
1.78
0.006727
(7.60099)
3000
2048
110
16.1
(1.82)
MH-6120
119
(13.45)
336.8
(38.05)
3.25
0.010657
(12.04159)
3000
2048
115
16.84
(1.90)
MH-6120
119
(13.45)
353.64
(39.96)
3.25
0.010657
(12.04159)
3000
2048
115
16.84
(1.90)
MH-6200
234
(26.44)
673.6
(76.11)
3.41
0.018857
(21.30695)
3000
2048
115
16.84
(1.90)
MH-6300
299
(33.78)
673.6
(76.11)
3.74
0.027187
(30.71921)
3000
2048
115
16.84
(1.90)
MH-6200
234
(26.44)
729
(82.37)
3.41
0.018857
(21.30695)
3000
2048
115
16.84
(1.90)
MH-6300
299
(33.78)
932.09
(105.3)
3.74
0.027187
(30.71921)
3000
2048
115
16.84
(1.90)
MH-8500
530
(60.2)
997
(113.2)
9.95
0.078
(87.837)
3000
2048
121.6
17.8
(2.011)
748
(84.9)
1500
(170.3)
15.44
0.133
(150.24)
3000
2048
162
23.7
(2.68)
MD-407
MD-410
MD-420
MD-434
MH-8750
90
Specifications
Axial/Radial Loading
Figure 71:
Motor
Max Radial
Load (lb.)
Max. Axial
Load (lb.)
MH-316
40
25
MH-340
40
25
MH-455
100
50
MH-490
100
50
MH-6120
150
50
MH-6200
150
50
MH-6300
150
50
MH-8500
250
100
Axial/Radial Loading
IP Ratings
Motor
Rating
MH-316
MH-340
MH-455
MH-490
MH-6120
IP65
MH-6200
MH-6300
MH-8500
Encoder Specifications
Motor
Density
Output Type
Output Frequency
Output Signals
Power Supply
MH
2048 lines/rev
RS422 differential
driver
250 kHz per channel
A, B, Z, Comm U,
Comm W, Comm V
and all complements
5V, 150 mA ±10%
91
Modular Drive System Installation Manual
Power Dissipation
In general, the drive power stages are around 90 percent efficient depending on the actual
point of the torque speed curve the drive is operating. Logic power losses on the MDS Drive
Module is 11 W minimum to 21 W depending on external loading such as FM modules and
input voltages.
The values shown in the table below represent the typical dissipation that could occur with
the drive/motor combination specified at maximum output power.
Maximum Power Stage
Losses
(Pp) (Watts)
Total
Power Losses
(Watts)
MD-404 / MH-316
25
45
MD-404 / MH-340
36
56
MD-404 / MH-455
42
62
MD-407 / MH-455
48
68
MD-407 / MH-490
72
92
MD-410 / MH-455
60
80
MD-410 / MH-490
72
92
90
110
MD-420 / MH-6120
108
128
MD-420 / MH-6200
126
146
MD-420 / MH-6300
200
220
MD-434 / MH-6200
150
170
MD-434 / MH-6300
200
220
MD-434 / MH-8500
380
400
MD-434 / MH-8750
420
440
Drive Model
Logic Power Losses
(typ) Drive
(Pld) (Watts)
20
MD-410 / MH-6120
Power Dissipation Calculation
Calculating actual dissipation requirements in an application can help minimize enclosure
cooling requirements, especially in multi-axis systems. To calculate dissipation in a specific
application, use the following formula for each axis and then total them up. This formula is a
generalization and will result in a conservative estimate for power losses.
TPL =
TRMS · Vmax
+ Pld + Psr
1500
Where:
TPL = Total power losses (Watts)
TRMS = RMS torque for the application (lb-in)
Vmax = Maximum motor speed in application (RPM)
Pld = Logic Power Losses Drive (Watts)
92
Specifications
Psr = Shunt Regulation Losses (Watts)-(RSR-2 losses
or equivalent)
Note
TRMS * Vmax / 1500 = Power Stage Dissipation = Pp
A more accurate calculation would include even more specifics such as actual torque
delivered at each speed plus actual shunt regulator usage. For help in calculating these please
contact our Application Department with your system profiles and loads.
93
Modular Drive System Installation Manual
MDS Power Module Dimensions
2.75 [69.85]
1.75 [44.45]
1.38 [34.93]
.60 [15.24]
2.81
[71.37]
10.25
[260.35]
2.64
[67.04]
16.06
[407.92]
14.25 [361.95]
9.00 [228.60]
Figure 72:
94
MP-1250 and MP-2500 Dimensional Drawing
Specifications
3.50 [88.90]
1.75 [44.45]
1.38 [34.93]
0.60 [15.24]
PE
PE
2.64 [67.04]
2.83 [71.83]
16.08 [408.38]
14.25 [361.95]
10.25 [260.35]
9.00 [228.60]
Figure 73:
MP-5000 Dimensional Drawing
95
Modular Drive System Installation Manual
MDS Drive Module Dimensions
2.75 [69.85]
.55 [13.84]
.84 [21.32]
2.64 [67.04]
10.25 [260.35]
16.86 [428.23]
2.80 [71.12]
9.00 [228.60]
1.38 [34.93]
Figure 74:
96
11.80 [299.71]
MD-404, 407 and 410 Dimensional Drawing
Specifications
3.50 [88.90]
.55 [13.84]
.84 [21.32]
2.64 [67.04]
10.25 [260.35]
16.86 [428.36]
2.80 [71.12]
9.00 [228.60]
1.38 [34.92]
Figure 75:
11.80 [299.71]
MD-420 Dimensional Drawing
97
Modular Drive System Installation Manual
5.50 [139.70]
2.75 [69.85]
.55 [13.84]
.84 [21.32]
16.86 [428.16]
2.64 [67.04]
10.25 [260.35]
2.80 [71.12]
9.00 [228.60]
1.38 [34.93]
Figure 76:
98
11.80 [299.71]
MD-434 Dimensional Drawing
Specifications
Cable Diagrams
CMDX, CMDO, ECI-44
CDRO
AX4-CEN
Analog Command In +
Drive Signal
X
X
X
Analog Command In -
X
X
X
Encoder Out A
X
X
X
Encoder Out A/
X
X
X
Encoder Out B
X
X
X
Encoder Out B/
X
X
X
Encoder Out Z
X
X
X
Encoder Out Z/
X
X
X
Pulse In A
X
X
Pulse In A/
X
X
Pulse In B
X
X
Pulse In B/
X
X
Pulse In Z
X
Pulse In Z/
X
Pulse In A (single ended)
X
Pulse In B (single ended)
X
I/O Input Drive Enable
X
I/O Input #1
X
I/O Input #2
X
I/O Input #3
X
I/O Input #4
I/O Output #1
I/O Output #2
X
X
X
X
X
X
X
X
X
X
X
X
X
I/O Output #3
X
X
X
I/O Power + In (1st wire)
X
X
X
I/O Power + In (2nd wire)
X
X
X
I/O Power 0V In (1st wire)
X
X
X
I/O Power 0V In (2nd wire)
X
Analog Out 0V
X
X
X
Analog Out Channel #1 +
X
X
X
Analog Out Channel #2 +
X
X
X
External Encoder +5 Power Out (200
ma)
X
X
External Encoder Common
X
X
+15V Power Out (10 ma)
X
RS-485 +
X
RS-485 -
X
99
Modular Drive System Installation Manual
CMDX-XXX Cable
1
2
3
4
6
21
8
9
11
12
16
17
18
19
23
24
25
39
27
41
34
32
33
31
37
38
40
26
14
15
29
28
43
44
20
36
5
7
10
13
22
30
35
42
1
2
3
4
6
21
8
9
11
12
16
17
18
19
23
24
25
39
27
41
34
32
33
31
37
38
40
26
14
15
29
28
43
44
20
36
5
7
10
13
22
30
35
42
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
DRAIN
SHELL
COLOR CODE
FUNCTION
RED/BROWN STRIPE
INPUT I/O 1
BROWN/RED STRIPE
INPUT I/O 2
BLACK/BLUE STRIPE
INPUT I/O 3
BLUE/BLACK STRIPE
INPUT I/O 4
WHITE/ORANGE STRIPE
RS-485+
ORANGE/WHITE STRIPE
RS-485-
PURPLE/BLUE STRIPE*
MOTOR ENCODER OUTPUT A
BLUE/PURPLE STRIPE*
MOTOR ENCODER OUTPUT A/
RED/BLUE STRIPE
EXT ENCODER 200mA max +5V
BLUE/RED STRIPE
EXT ENCODER 200mA max COMMON
BLACK/GREEN STRIPE
DRIVE ENABLE INPUT
GREEN/BLACK STRIPE
OUTPUT I/O 3
BLACK/BROWN STRIPE
OUTPUT I/O 2
BROWN/BLACK STRIPE
OUTPUT I/O 1
PURPLE/ORANGE STRIPE*
MOTOR ENCODER OUTPUT B
ORANGE/PURPLE STRIPE*
MOTOR ENCODER OUTPUT B/
BLACK/RED STRIPE
SYNC ENCODER INPUT Z
RED/BLACK STRIPE
SYNC ENCODER INPUT Z/
PURPLE/GREEN STRIPE *
SYNC ENCODER INPUT A
GREEN/PURPLE STRIPE *
SYNC ENCODER INPUT A/
YELLOW/BLUE STRIPE
24V I/O
BLUE/YELLOW STRIPE
0V I/O
YELLOW/BROWN STRIPE
24V I/O
BROWN/YELLOW STRIPE
0V I/O
PURPLE/BROWN STRIPE*
MOTOR ENCODER OUTPUT Z
BROWN/PURPLE STRIPE*
MOTOR ENCODER OUTPUT Z/
PURPLE/GRAY STRIPE *
SYNC ENCODER INPUT B/
GRAY/PURPLE STRIPE *
WHITE/BLUE STRIPE
SYNC ENCODER INPUT B
COMMAND INPUT -
BLUE/WHITE STRIPE
COMMAND INPUT +
WHITE/RED STRIPE
ANALOG OUT AG 1 AND 2
RED/WHITE STRIPE
ENV+
WHITE/GREEN STRIPE
ANALOG OUT 1 +
GREEN/WHITE STRIPE
ANALOG OUT 2 +
YELLOW/GRAY STRIPE
NOT USED
GRAY/YELLOW STRIPE
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NC
NOT USED
NOT USED
NC
NOT CONNECTED
NC
NOT USED
SHELL
15
30
P1 MALE 44D
P2 MALE 44D
13 12
14
29
44
28 27
43
42 41
11
10
26 25
40
9
24
39
8
23
7
22
38 37
36
6
5
21 20
35 34
4
19
33
2
3
18
17
32
1
16
31
SOLDER SIDE
Note
Some CMDX cables may have White/Yellow and Yellow/White wires in place of the
White/Orange and Orange/White shown in the figure above (pins 6 and 21).
100
Specifications
CMDO-XXX Cable
PIN 1
2.10
COLOR CODE
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
DRAIN
1
2
3
4
6
21
8
9
11
12
16
17
18
19
23
24
25
39
27
41
34
32
33
31
37
38
40
26
14
15
29
28
43
44
20
36
5
7
10
13
22
30
35
42
FUNCTION
RED/BROWN STRIPE
INPUT I/O 1
BROWN/RED STRIPE
INPUT I/O 2
BLACK/BLUE STRIPE
INPUT I/O 3
BLUE/BLACK STRIPE
INPUT I/O 4
WHITE/ORANGE STRIPE
RS-485+
ORANGE/WHITE STRIPE
RS-485-
PURPLE/BLUE STRIPE*
MOTOR ENCODER OUTPUT A
BLUE/PURPLE STRIPE*
MOTOR ENCODER OUTPUT A/
RED/BLUE STRIPE
EXT ENCODER 200mA max +5V
BLUE/RED STRIPE
BLACK/GREEN STRIPE
EXT ENCODER 200mA max COMMON
DRIVE ENABLE INPUT
GREEN/BLACK STRIPE
OUTPUT I/O 3
BLACK/BROWN STRIPE
OUTPUT I/O 2
BROWN/BLACK STRIPE
OUTPUT I/O 1
PURPLE/ORANGE STRIPE*
MOTOR ENCODER OUTPUT B
ORANGE/PURPLE STRIPE*
BLACK/RED STRIPE
MOTOR ENCODER OUTPUT B/
SYNC ENCODER INPUT Z
RED/BLACK STRIPE
SYNC ENCODER INPUT Z/
PURPLE/GREEN STRIPE *
SYNC ENCODER INPUT A
GREEN/PURPLE STRIPE *
SYNC ENCODER INPUT A/
YELLOW/BLUE STRIPE
24V I/O
BLUE/YELLOW STRIPE
0V I/O
YELLOW/BROWN STRIPE
24V I/O
BROWN/YELLOW STRIPE
0V I/O
PURPLE/BROWN STRIPE*
MOTOR ENCODER OUTPUT Z
BROWN/PURPLE STRIPE*
PURPLE/GRAY STRIPE *
MOTOR ENCODER OUTPUT Z/
SYNC ENCODER INPUT B/
GRAY/PURPLE STRIPE *
SYNC ENCODER INPUT B
WHITE/BLUE STRIPE
COMMAND INPUT -
BLUE/WHITE STRIPE
COMMAND INPUT +
WHITE/RED STRIPE
ANALOG OUT AG 1 AND 2
RED/WHITE STRIPE
ENV+
WHITE/GREEN STRIPE
ANALOG OUT 1 +
GREEN/WHITE STRIPE
ANALOG OUT 2 +
YELLOW/GRAY STRIPE
NOT USED
GRAY/YELLOW STRIPE
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NC
NOT USED
NOT USED
NC
NOT USED
NC
NOT USED
SHELL
15
30
14
29
44
13 12
28 27
43
42 41
11 10
26 25
40
9
24
39
8
7
23 22
38 37
6
5
21 20
36
35 34
4
3
2
19 18 17
33
32
1
16
P1 MALE 44D
31
SOLDER SIDE
Note
Some CMDO cables may have White/Yellow and Yellow/White wires in place of the
White/Orange and Orange/White shown in the figure above (pins 6 and 21).
101
Modular Drive System Installation Manual
CDRO-XXX Cable
PIN 1
WIRE COLOR SOLID/STRIPE
BLU/PUR
P
PUR/BLU
ORG/PUR
P
PUR/ORG
BRN/PUR
P
PUR/BRN
RED/BLU
P
BLU/RED
GRN/BLK
P
BLK/GRN
WHT/BLU
P
BLU/WHT
WHT/RED
P
RED/WHT
YEL/GRY
GRY/PUR
P
PUR/GRY
BLK/BRN
P
BRN/BLK
BRN/YEL
P
YEL/BRN
WHT/GRN
P
GRN/WHT
GRN/PUR
P
ENCODER OUTPUT A/
ENCODER OUTPUT A
11
12
34
16
14
15
29
ENCODER +5VDC SUPPLY
ENCODER SUPPLY COMMON
I/O SUPPLY +
4
19
26
40
18
17
31
33
43
44
41
27
INPUT #4
OUTPUT #1
ENCODER OUTPUT B/
ENCODER OUTPUT B
ENCODER OUTPUT Z/
ENCODER OUTPUT Z
DRIVE ENABLE INPUT
ANALOG COMMAND INPUT ANALOG COMMAND INPUT +
DIAGNOSTIC OUTPUT COMMON
N/C
GRY/YEL
P
9
8
24
23
38
37
PUR/GRN
PULSE INPUT B
PULSE INPUT B/
OUTPUT #2
OUTPUT #3
I/O COMMON I/O SUPPLY +
DIAGNOSTIC OUTPUT 1
DIAGNOSTIC OUTPUT 2
PULSE INPUT A/
PULSE INPUT A
N/C
15 14 13 12
11 10 9
30 29 28 27
8
26 25 24
44 43 42 41 40
7
6
23 22
39 38 37
36
5
35 34
SOLDER SIDE
102
4
21 20
3
2
1
19 18 17
33
32
16
31
Specifications
AX4-CEN-XXX Cable
ENCODER OUTPUT A/
9
ENCODER OUTPUT A
8
ENCODER OUTPUT B/
24
ENCODER OUTPUT B
23
ENCODER OUTPUT Z/
38
ENCODER OUTPUT Z
37
BLU/PUR
PUR/BLU
ORG/PUR
PUR/ORG
PUR/BRN
N/C
34
DRIVE ENABLE INPUT
ANALOG COMMAND INPUT -
16
ANALOG COMMAND INPUT +
15
DIAGNOSTIC OUTPUT COMMON
29
BLU/WHT
N/C
I/O COMMON -
31
I/O SUPPLY +
33
DIAGNOSTIC OUTPUT 1
43
DIAGNOSTIC OUTPUT 2
44
OPEN COLLECTOR PULSE/
20
OPEN COLLECTOR DIRECTION
36
RED/WHT
P
P
P
P
P
P
WHT/GRN
GRN/WHT
P
GRN/PUR
PUR/GRN
N/C
DRAIN WIRES
ENCODER OUTPUT B/
12
ENCODER OUTPUT B
23
ENCODER OUTPUT Z/
11
ENCODER OUTPUT Z
21
ENABLE CONTACT
9
8
ENABLE CONTACT
ANALOG COMMAND OUTPUT -
20
ANALOG COMMAND OUTPUT +
6
ANALOG COMMON
15
DISCRETE INPUT (DRIVE STATUS)
N/C
N/C
N/C
YEL/BRN
BRN/YEL
ENCODER OUTPUT A
24
N/C
BLK/BRN
BRN/BLK
ENCODER OUTPUT A/
13
N/C
GRY/PUR
PUR/GRY
25
N/C
P
GRY/YEL
YEL/GRY
N/C
17
P
WHT/RED
N/C
OUTPUT #3
BLU/RED
WHT/BLU
19
18
RED/BLU
BLK/GRN
14
OUTPUT #2
P
GRN/BLK
N/C
OUTPUT #1
P
BRN/PUR
N/C
I/O SUPPLY+
P
P
16
DISCRETE INPUT (CW TRAVEL LIMIT)
3
DISCRETE INPUT (CCW TRAVEL LIMIT)
14
OV I/O SUPPLY COMMON
2
+24V I/O SUPPLY
7
ANALOG INPUT 1
19
ANALOG INPUT 2
5
PULSE/OUTPUT
17
DIRECTION OUTPUT
4
CHASSIS GROUND
103
Modular Drive System Installation Manual
TIA-XXX Cable
PIN 1
PIN 1
2.5 MAX (2X)
0.250
.63 MAX (2X)
END VIEW
FEMALE
END VIEW
MALE
(SOCKETS)
(PINS)
5
2
3
4
9
6
7
1
8
5
3
2
4
9
6
7
1
8
BRAID +
DRAIN
SHELL
BLACK
WHITE
BLUE
NC
NC
NC
NC
NC
NC
SHELL
MALE DB-9 CONN
FEMALE DB-9 CONN
DDS-XXX Cable
DDS
DDS
P3
SHELL
DRAIN
WIRE
DB-9 MALE
BLACK
5
GND
4
485+
9
485-
5
5
GND
2
2
RX
3
3
TX
4
4
485+
9
9
485-
6
6
7
7
1
1
WHITE
BLUE
8
DB-9 FEMALE
P2
104
8
DB-9 MALE
P1
Specifications
TERM-H (Head) Terminator
R.195
.78
1.22
.67
.66
TERM-H
PIN #1
.20
.110 MAX (2)
.090 MIN
.67 REF
5
5
GND
2
2
R1 IN (RX)
3
3
T1 OUT (TX)
4
485+
9
485-
4
R2
9
R4
6
6
+5V
7
7
NOT USED
1
1
NOT USED
8
8
NOT USED
SHELL
DB-9 FEMALE
SHELL
DB-9 MALE
TERM-T (Tail) Terminator
1.22
.78
R.195
.67
.66
.20
PIN #1
5
2
R1
3
4
9
.110 MAX (2)
.090 MIN
.67 REF
R3
R2
R4
5
GND
2
R1 IN (RX)
3
T1 OUT (TX)
4
485+
9
485-
6
6
+5V
7
7
NOT USED
1
1
NOT USED
8
8
NOT USED
SHELL
DB-9 MALE
SHELL
DB-9 FEMALE
Note
See the "Multi-drop Communications" section for resistor values.
105
Modular Drive System Installation Manual
CMDS-XXX Cable
3.23
1.20
3.0 +/- 0.25
GRN/YEL
BRN
D
A
B
C
BLK
BLU
SHELL
A
G
B
H
F
E
C
D
SOLDER SIDE
CMMS-XXX Cable
3.99
1.40
3.0 +/- 0.25
GRN/YEL
BRN
D
A
B
C
BLK
BLU
SHELL
F
A
B
G
E
D
C
SOLDER SIDE
106
Specifications
CFCS-XXX Cable
2.24
3.16
1.18
1.55
OVERALL TIN/COPPER BRAID
SHELL
LARGE 18GA PAIR
RED/GRN OR
BLU
ORN
GRN
BRN
BLK
YEL
WHT/BRN
BRN/WHT
WHT/GRY
GRY/WHT
RED/ORN
ORN/RED
RED/BLU
BLU/RED
RED/GRN
GRN/RED
N/C
N/C
N/C
N/C
N/C
1
10
2
11
3
12
4
13
5
14
6
15
7
17
9
16
8
18
19
20
21
22
23
24
25
26
B
C
N
P
M
U
E
R
F
S
G
H
K
T
A
V
L
D
J
W
X
Y
Z
N/C
DRAINS
BLU
ORN
GRN
BRN
BLK
YEL
WHT/BRN
BRN/WHT
WHT/GRY
GRY/WHT
RED/ORN
ORN/RED
RED/BLU
BLU/RED
RED/GRN
GRN/RED
N/C
N/C
N/C
N/C
N/C
A
A/
B
B/
Z
Z/
U
U/
V
V/
W
W/
+5 VDC
GND
MOTOR OVERTEMP
NOT USED
N/C
N/C
N/C
N/C
N/C
CASE
= TWISTED PAIR
PIN 1
P
N
Y
M
A
B
R
L X
Z
S
T
W
K
J
V
H
G
U
C
D
E
F
SOLDER SIDE
SOLDER SIDE
107
Modular Drive System Installation Manual
CFCO-XXX Cable
2.24
PIN 1
1.55
PLUGGING SIDE
OVERALL T/C BRAID
1
BLU
10
ORN
2
GRN
11
BRN
3
BLK
12
YEL
4
WHT/BRN
13
BRN/WHT
5
WHT/GRAY
P
P
P
P
P
14 GRAY/WHT
RED/GRN OR
LARGE 18 GA PAIR
6
RED/ORN
15
ORN/RED
7
RED/BLU
17
BLU/RED
9
RED/GRN
16
GRN/RED
8
N/C
18
N/C
19
N/C
20
N/C
21
N/C
22
N/C
23
N/C
24
N/C
25
N/C
26
N/C
CONNECTOR SHELL
PIN 1
SOLDER SIDE
108
P
P
P
P = TWISTED PAIR
Specifications
CFOS-XXX Cable
3.16
1.18
OVERALL TIN/COPPER BRAID
SHELL
LARGE 18GA PAIR
RED/GRN OR
BLU
ORN
GRN
BRN
BLK
YEL
WHT/BRN
BRN/WHT
WHT/GRY
GRY/WHT
RED/ORN
ORN/RED
RED/BLU
BLU/RED
RED/GRN
GRN/RED
N/C
N/C
N/C
N/C
N/C
N/C
DRAINS
P
N
L X
K
J
Z
B
S C
T
W
V
H
= TWISTED PAIR
A
R
Y
M
B
C
N
P
M
U
E
R
F
S
G
H
K
T
A
V
L
D
J
W
X
Y
Z
G
U
D
E
F
SOLDER SIDE
109
Modular Drive System Installation Manual
110
Modular Drive System Installation Manual
Glossary
µs
Microsecond, which is 0.000001 second.
A
Amps.
ARMS
Amps (RMS).
AWG
American Wire Gauge.
Baud Rate
The number of binary bits transmitted per second on a serial communications link such as RS232. (1 character is usually 10 bits.)
Check Box
In a dialog box, a check box is a small box that the user can turn “On” or “Off” with the
mouse. When “On” it displays an X in a square; when “Off” the square is blank. Unlike option
(radio) buttons, check boxes do not affect each other; any check box can be “On” or “Off”
independently of all the others.
CRC
Cyclical Redundancy Check.
Dialog Box
A dialog box is a window that appears in order to collect information from the user. When the
user has filled in the necessary information, the dialog box disappears.
DIN Rail
Deutsche Industrie Norm Rail
DLL
In Microsoft Windows, a Dynamic Link Library contains a library of machine-language
procedures that can be linked to programs as needed at run time.
111
Modular Drive System Installation Manual
Downloading
The transfer of a complete set of parameters from PowerTools or a Function Module to a
drive.
EEPROM
An EEPROM chip is an Electrically Erasable Programmable Read-Only Memory; that is, its
contents can be both recorded and erased by electrical signals, but they do not go blank when
power is removed.
EMC
Electromagnetic Compatibility
EMI - Electro-Magnetic Interference
EMI is noise which, when coupled into sensitive electronic circuits, may cause problems.
Firmware
The term firmware refers to software (i.e., computer programs) that are stored in some fixed
form, such as read-only memory (ROM).
FM
Function Module - device which is attached to the front of the drive to provide additional
functionality.
Hysteresis
For a system with an analog input, the output tends to maintain it’s current value until the
input level changes past the point that set the current output value. The difference in response
of a system to an increasing input signal versus a decreasing input signal.
I/O
Input/Output. The reception and transmission of information between control devices. In
modern control systems, I/O has two distinct forms: switches, relays, etc., which are in either
an on or off state, or analog signals that are continuous in nature generally depicting values
for speed, temperature, flow, etc.
Inertia
The property of an object to resist changes in rotary velocity unless acted upon by an outside
force. Higher inertia objects require larger torque to accelerate and decelerate. Inertia is
dependent upon the mass and shape of the object.
Input Function
A function (i.e., Stop, Preset) that may be attached to an input line.
112
Glossary
Input Line
The actual electrical input, a screw terminal.
Least Significant Bit
The bit in a binary number that is the least important or having the least weight.
LED
Light Emitting Diode.
List Box
In a dialog box, a list box is an area in which the user can choose among a list of items, such
as files, directories, printers or the like.
mA
Milliamp, which is 1/1000th of an Ampere.
MB
Mega-byte.
MDS
Modular Drive System
Most Significant Bit
The bit in a binary number that is the most important or that has the most weight.
ms
Millisecond, which is 1/1000th of a second.
NVM
Non-Volatile Memory.
NTC
Negative Temperature Resistor
Option Button
See Radio Button.
Opto-isolated
A method of sending a signal from one piece of equipment to another without the usual
requirement of common ground potentials. The signal is transmitted optically with a light
113
Modular Drive System Installation Manual
source (usually a Light Emitting Diode) and a light sensor (usually a photosensitive
transistor). These optical components provide electrical isolation.
Output Function
A function (i.e., Drive OK, Fault) that may be attached to an output line.
Output Line
The actual transistor or relay controlled output signal.
Parameters
User read only or read/write parameters that indicate and control the drive operation.
PE
Protective Earth.
PID
Proportional-Integral-Derivative. An acronym that describes the compensation structure that
can be used in many closed-loop systems.
PLC
Programmable Logic Controller. Also known as a programmable controller, these devices are
used for machine control and sequencing.
PowerTools-FM and -PRO
Windows®-based software to interface with the Modular Drive System and Function
Modules.
Radio Button
Also known as the Option Button. In a dialog box, radio buttons are small circles only one of
which can be chosen at a time. The chosen button is black and the others are white. Choosing
any button with the mouse causes all the other buttons in the set to be cleared.
RAM
RAM is an acronym for Random-Access Memory, which is a memory device whereby any
location in memory can be found, on average, as quickly as any other location.
RMS
Root Mean Squared. For an intermittent duty cycle application, the RMS is equal to the value
of steady state current which would produce the equivalent heating over a long period of time.
114
Glossary
ROM
ROM is an acronym for Read-Only Memory. A ROM contains computer instructions that do
not need to be changed, such as permanent parts of the operating system.
RPM
Revolutions Per Minute.
Serial Port
A digital data communications port configured with a minimum number of signal lines. This
is achieved by passing binary information signals as a time series of 1’s and Ø’s on a single
line.
Uploading
The transfer of a complete set of parameters from PowerTools or an FM-P.
VAC
Volts, Alternating Current.
VDC
Volts, Direct Current.
Windows, Microsoft
Microsoft Windows is an operating system that provides a graphical user interface, extended
memory and multi-tasking. The screen is divided into windows and the user uses a mouse to
start programs and make menu choices.
115
Modular Drive System Installation Manual
116
Modular Drive System Installation Manual
Index
A
AC Interlock Connections, 45
AC Power Line Fusing, 27
AC Power Wire Size, 27
AC Supplies NOT Requiring Transformers, 24
AC Supplies Requiring Transformers, 25
Achieving Low Impedance Connections, 6
Analog Command Wiring, 55
AX4-CEN-XXX Cable, 104
Axial/Radial Loading, 91
B
Backplane Installation, 19
C
Cable Diagrams, 99
Cable to Enclosure Shielding, 8
CDRO-XXX Cable, 103
CFCO-XXX Cable, 109
CFCS-XXX Cable, 108
CFOS-XXX Cable, 110
CMDO-XXX Cable, 101
CMDS-XXX Cable, 107
CMDX-XXX Cable, 100
CMMS-XXX Cable, 107
Command Cables, 54
Command Connector Wiring, 52
D
Declaration of Conformity, viii
Diagnostic Analog Output Test Points, 78
Diagnostic Cable (DGNE) Diagram, 80
Diagnostic Display, 73
Diagnostics and Troubleshooting, 73
Drive and Motor Combination Specifications, 90
Drive and Power Module Removal, 69
Drive Faults, 80
Drive Module Assembly Installation, 35
Drive Module Backplane Dimensions, 16
Drive Module Dimensions, 18
Drive Module I/O, 49
Drive Module I/O Connections, 48
Drive overload protection, vii
E
Electromagnetic Compatibility, 6
Encoder Output Signal Wiring, 56
Encoder Specifications, 91
Environmental Considerations, 10
Error Messages, 83
F
Fault Codes, 74
Fault Descriptions, 76
G
Glossary, 111
DDS-XXX Cable, 105
117
Modular Drive System Installation Manual
I
S
Installation, 5
Installation Notes, 6
Introduction, 1
IP Ratings, 91
Safety Considerations, xi
Safety of Machinery, xi
Safety Precautions, xi
Serial Communications, 62
Setup, Commissioning and Maintenance, xi
Specifications, 85
Speed Torque Curves, 94
System Grounding, 23
L
Logic and Digital I/O Power Connections, 37
M
MDS Overview, 13
Mechanical Installation, 12
Modbus Communications, 62
Motor Brake Wiring, 50
Motor Feedback Wiring, 61
Motor Mounting, 68
Multi-Drop Communications, 63
T
TERM-H (Head) Terminator, 106
Term-T (Tail) Terminator, 106
TIA-XXX Cable, 105
Transformer Sizing, 27
U
Underwriters Laboratories Recognition, vii
P
Power Dissipation, 92
Power Dissipation Calculation, 92
Power Module Assembly Installation, 34
Power Module Backplane Dimensions, 14
Power Module Dimensions, 15
Power Module I/O, 43
Power Module I/O Connections, 40
Power Module Status Indicators, 41
Pulse Mode Wiring, 57
R
Rebooting the Drive, 81
Resetting Faults, 80
118
V
Vendor Contact Information, 110
View Motor Parameters, 82
Viewing Active Drive Faults, 81
W
Watch Window, 81
Wiring Notes, 11
Since 1979, the “Motion Made Easy” products, designed and manufactured in
Minnesota U.S.A., are renowned in the motion control industry for their ease of
use, reliability and high performance.
For more information about Control Techniques “Motion Made Easy” products
and services, call (800) 397-3786 or contact our website at
www.emersonct.com.
Control Techniques Drives, Inc
Division of EMERSON Co.
12005 Technology Drive
Eden Prairie, Minnesota 55344
U.S.A.
Customer Service
Phone: (952) 995-8000 or (800) 397-3786
Fax: (952) 995-8129
Technical Support
Phone: (952) 995-8033 or (800) 397-3786
Fax (952) 9995-8020
Printed in U.S.A.
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