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Installation

2-23

IQ 2000/5000 Installation Manual

Bonding Your System

Bonding is the practice of connecting metal chassis, assemblies, frames, shields and enclosures
to reduce the effects of electromagnetic interference (EMI).

Unless specified, most paints are not conductive, and they act as insulators. To achieve a good
bond between modules and the sub panel, surfaces need to be paint-free or plated. Bonding
metal surfaces creates a low-impedance exit path for high-frequency energy.

Figure 2.18 illustrates recommended bonding practices for painted panels, enclosures and
mounting brackets. Improper bonding blocks that direct exit path and allows high-frequency
energy to travel elsewhere in the cabinet. Excessive high-frequency energy can effect the oper-
ation of other microprocessor controlled equipment.

F

IGURE

2.18

Recommended bonding practices

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Summary of Contents for IQ 2000

Page 1: ...M P A N Y T H E R I G H T S O L U T I O N IQ 2000 5000 Positioning Drive Modules Electro Craft 6950 Washington Avenue South Eden Prairie MN 55344 Instruction Manual Electro Craft S E R V O S Y S T E M S A Rockwell Business ...

Page 2: ... conducted from its power input terminals to the PDM The power connector must be suitably guarded to prevent a possible shock hazard Loose PDMs When running an unmounted PDM ensure that the cooling fan is adequately guarded and sufficient airflow is provided around the PDM to ensure adequate cooling The mounting surface of the PDM is a heatsink and its surface temperature may increase when the PDM...

Page 3: ...Q 2000 5000 Positioning Drive Modules Electro Craft 6950 Washington Avenue South Eden Prairie MN 55344 Instruction Manual P N 0013 1027 005 Rev A Electro Craft S E R V O S Y S T E M S A Rockwell Business ...

Page 4: ...oration All rights reserved Printed in the United States of America Information contained in this manual is subject to change without notice Electro Craft is a trademark of Rockwell Automation Other trademarks cited are the property of their respective owner ...

Page 5: ...Short Circuit Protection 2 2 IQ 5000 Short Circuit Protection 2 2 Personality Module Installation 2 3 Installing the Personality Module PM 2 4 System Firmware Installation 2 4 Installing the Firmware EPROMs 2 5 Jumper and DIP Switches 2 5 Option Card Installation 2 6 IQ 2000 2 6 IQ 5000 2 7 Mounting 2 8 Environment 2 8 Ventilation 2 8 Transformer Sizing 2 9 Mounting Requirements 2 9 IQ 5000 Positi...

Page 6: ...Monitor Output 3 13 Ready Relay Output 3 13 Enabled Relay Output 3 14 Encoders 3 14 Step and Direction Inputs 3 17 Serial Ports 3 18 Expansion I O and Memory 3 23 Cables 3 31 CHAPTER 4 Applying Power for the First Time Start up Procedure for IQ 2000 PDMs 4 1 Start up Procedure for IQ 5000 4 3 Power Supply Module 4 3 Start up Procedure for PDM 4 3 Motor Start up Procedure 4 5 Operator Terminal 4 5 ...

Page 7: ...2000 5000 Installation Manual Transformer Specifications 6 3 CHAPTER 7 Component Ordering Information Our Warranty Help 1 Documentation Improvement Help 2 EU Directives Help 3 Index of Topics Help 7 Product Support Help 13 ...

Page 8: ...Intro 6 Contents P N 0013 1027 005 Rev A ...

Page 9: ...r Brushless Servo Motors 2 22 Motor Power Winding Methods to Minimize Noise Emissions 2 22 Recommended bonding practices 2 23 Bonding Multiple Sub Panels and Cabinet 2 24 Recommended IQ 2000 Installation for EMC 2 25 Emergency Stop Contactor Wiring 2 28 IQ 5000 Transformer Outline Diagram 2 29 IQ 5000 Transformer Load Regulation Curve 2 30 PSM AUX Outline and Connection Diagram 2 31 IQ 2000 Transf...

Page 10: ... 3 22 RS 232C Daisy Chain Connections 3 22 IQ 5000 Power Wiring 3 25 PSM AUX Connections 3 26 IQ 2000 Power Wiring for PDM 10 20 and 30 3 27 IQ 2000 Power Wiring for PDM 75 3 28 IQ 2000 Power Wiring for PDM 150B 3 29 Expansion Card I O Connections 3 30 IQ P7 to Operator Terminal P N 9101 2025 3 31 IQ P6 to PC Serial Port 9 pin P N 9101 2024 3 31 IQ P4 or P5 to Auxiliary Encoder Unterminated P N 91...

Page 11: ...gnal Name 3 16 Step and Direction Inputs and Signal Name 3 17 Host Computer and Signal Name 3 18 P7 at Serial Port 1 on Operator Terminal 3 20 COM1 Connector on back of Operator Terminal 3 20 P1 and P2 on IQ and Expansion Board Connections 3 23 P3 Pins on Expansion Card 3 24 CHAPTER 4 Applying Power for the First Time CHAPTER 5 Diagnostics Troubleshooting Power Supply Module LEDs IQ 5000 systems o...

Page 12: ...tro 10 List of Tables P N 0013 1027 005 Rev A Part Numbers of Motor Mating Connector Kits 7 3 Part Numbers of Motor Shaft Seal Kits 7 4 Part Numbers of Transformers 7 4 Part Numbers of Interface Cards 7 4 ...

Page 13: ...DM It is intended for engineers or technicians directly involved in the installation oper ation and field maintenance of the IQ 2000 5000 PDM The IQ Master Instruction Manual describes the operation of the IQ Master executive software This software package is used to software configure the IQ 2000 5000 products which are shown in Figure 1 1 Refer to the IQ Master Instruction Manual for programming...

Page 14: ...tomation system or as a stand alone programmable motion controller Optically isolated I O and power supplies are integrated into the products The electronic gearing feature allows the closed loop axis to follow a second master encoder at a programmable ratio A multi axis addressing scheme multi drop operation allows mul tiple IQs to be controlled from a host computer over a single serial communica...

Page 15: ...150B are rated for 10 20 30 75 and 150 amp peak currents respectively These modules are packaged with an integral power supply to achieve a small size Input power to a PDM 10 PDM 20 or PDM 30 is single phase 115 or 230 VAC Input power to a PDM 75 or PDM 150B is three phase 115 or 230 VAC The input power may be optionally isolated through a transformer These PDMs have a built in solid state soft ch...

Page 16: ...perator Terminal is a rugged man machine interface device It allows the machine operator convenient access to status information program variables and control func tions plusmessagedisplaycapabilities TheOperatorTerminalhasabright4lineby20character vacuum fluorescent display and a sealed membrane keyboard with tactile feedback The Operator Terminal displays multiple status screens for monitoring a...

Page 17: ...hat connects the option card to the PDM powersupplies and microprocessor through a ribbon cable The option cards currently available include a combination Memory and I O Expansion Card and an I O Expansion Card Refer to Part Numbers of Interface Cards on page 7 4 Memory and I O Expansion Card Additional memory and I O may be added vwith a Memory and I O Expansion Card This board adds the following...

Page 18: ...single phase 115 VAC power as the input This option is only necessary for the IQ 5000 with the separate power supply module The IQ 2000 PDMs with an integral power supply include the auxiliary supply in the PDM The PSM AUX option is useful if PDM logic power must stay on even when the motor supply the PSM is off Absolute positioning is one example of when the PSM AUX would be useful since position...

Page 19: ...ents for locations where the machine may be brought into use In the U S these include but are not limited to UL and NEC requirements In Europe machines must comply with the Machinery Directive and the basic standards which this directive references TABLE 2 1 Mounting and Related Diagrams Figure Part Number Title Page 2 22 9101 0131 IQ 5000 Transformer Outline Diagram 2 29 2 23 9101 0132 IQ 5000 Tr...

Page 20: ...40 Volts maximum Short Circuit Current Rating with Fuse Restrictions Suitable for use on a circuit capable of delivering not more than 200 000 RMS symmetrical Amperes 240 Volts maximum when protected by high interrupting capacity current limiting fuses Class CC G J L R T Motor Overload Protection This drive utilizes solid state motor overload protection which operates within 8 minutes at 200 overl...

Page 21: ...ersonality Module needs to be changed for machine servicing Refer to Figure 2 1 for the location of the Personality Module on the IQ 2000 5000 logic board FIGURE 2 1 Location of Personality Module CAUTION Do not install or remove the personality module while power to the PDM is ON Static electricity can damage the per sonality module Wear a conductive wrist strap while handling or touch earth grou...

Page 22: ...hat incoming power is OFF 2 Remove PDM cover IQ 5000 only 3 Install Personality Module on PDM logic board in socket at location U10 The end of the Personality Module PM with the colored label must be toward the front of the PDM 4 Install the PDM cover IQ 5000 only System Firmware Installation All IQ 2000 5000 controllers come with the system firmware installed Therefore unless you are upgrading yo...

Page 23: ...d in sockets U57 U66 U67 and U87 The end of the EPROM with the notch must be toward the front of the PDM 4 Install the PDM cover Jumper and DIP Switches Jumpers W3 and W4 may be removed if an external 24 VDC power supply is used Removing these jumpers will disconnect the internal supply The jumpers do not need to be removed if only the 24 V common P1 pin 1 is connected to machine common but must b...

Page 24: ... cover by loosening the mounting screws and sliding cover off the unit 2 Install option card B on IQ 2000 logic board C using screws D Six screws are provided for mounting option cards on units built prior to January 1995 3 Install ribbon cable E between logic board and option card 4 Install side cover back onto unit FIGURE 2 4 IQ 2000 Option Card Installation 2 1 P10 1 1 1 P9 P8 B E D C not used ...

Page 25: ...ule From inside the cover remove the filler panel and its two mounting nuts 2 Install option card B onto IQ 5000 logic board C using screws D 3 Install ribbon cable E between logic board and option card 4 Install cover A back onto drive module FIGURE 2 5 IQ 5000 Option Card Installation NOTE Mating connectors are provided with the option card for customer connections to the option card connectors ...

Page 26: ...e and any required ventilation Typical heat losses can run approximately one half maximum power losses As an additional aid in sizing an enclosure with no active method of heat dissipation the following approximate equation is used T 4 08 Q A 1 1 Where T is temperature difference between inside air and outside ambient F Q is heat gen erated in enclosure Watts and A is enclosure surface area ft The...

Page 27: ...r 6 Specifications The following diagrams list dimensional mounting requirements Intro TIP Calculations are multiplied by a factor to compensate for the power and loss elements within a power system A factor of 2 0 is used with a single phase system and a factor of 1 5 is used with a three phase system This factor should minimize the effects of the secondary line voltage sagging in the transformer...

Page 28: ...4 ENCODER 2 AUXILIARY P5 ENCODER 1 MOTOR SERIAL 2 COMPUTER P6 AUXILIARY SERIAL 1 P7 TB2 3 1 2 EXTERNAL SHUNT INTERNAL R S T U10 CLEARANCE HOLES FOR 10 M5 MOUNTING SCREWS HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER 13 75 349 3 0 25 6 4 14 20 360 6 1 00 25 4 1 00 25 4 4 10 104 1 1 05 26 6 8 93 226 8 EXHAUST AIR AIR INTAKE WARNING 1 ALLOW 2 00 50 8mm CLEARANCE ABOVE BELOW UNIT FOR ...

Page 29: ... REMOVING POWER 5 10 P1 DIGITAL INPUTS 1 P2 1 10 DIGITAL INPUTS AND OUTPUTS P3 STATUS ANALOG I O 1 5 5 P4 ENCODER 2 AUXILIARY P5 ENCODER 1 MOTOR SERIAL 2 COMPUTER P6 AUXILIARY SERIAL 1 STATUS P7 14 20 360 7 8 84 224 5 0 27 7 0 13 75 349 3 1 99 50 5 5 97 151 7 AIR INTAKE AIR EXHAUST AIR INTAKE 1 00 25 4 1 00 25 4 WARNING FINAL INSPECTION 1 ALLOW 2 00 50 8mm CLEARANCE ABOVE BELOW UNIT FOR AIR FLOW 2...

Page 30: ...2 EXTERNAL SHUNT INTERNAL HIGH VOLTAGE MAY EXIST UP TO FIFTEEN MINUTES AFTER REMOVING POWER STATUS 5 10 P1 DIGITAL INPUTS 1 P2 1 10 DIGITAL INPUTS AND OUTPUTS P3 STATUS ANALOG I O 1 5 5 P4 ENCODER 2 AUXILIARY P5 ENCODER 1 MOTOR SERIAL 2 COMPUTER P6 AUXILIARY SERIAL 1 P7 WARNING 1 ALLOW 2 00 50 8mm CLEARANCE ABOVE BELOW UNIT FOR AIR FLOW 2 ALLOW 3 00 76 5mm CLEARANCE IN FRONT OF UNIT FOR CABLES NOT...

Page 31: ...PUTS GENERAL PURPOSE INPUTS AND OUTPUTS ANALOG I O AND STATUS INPUT 2 ENCODER ENCODER INPUT 1 PORT 1 SERIAL PORT 2 SERIAL P7 P6 P5 P4 P3 P2 P1 DO NOT APPLY POWER WITH COVER REMOVED DO NOT REMOVE COVER WITH POWER APPLIED DANGEROUS VOLTAGES MAY EXIST UP TO 5 MINUTES AFTER REMOVING POWER WARNING VIEW B A AIR INTAKE EXHAUST AIR SEE VIEW A B 0 50 13 0 MINIMUM FOR AIRFLOW BOTH SIDES OR BETWEEN ADJACENT ...

Page 32: ...n the BBS for Electro Craft products Do not run motors that are not properly mounted Attach all motor cables after motor is mounted Mount motor with connectors pointing downward and use a drip loop to keep liquids flow ing away from connectors Consider motor case temperature if necessary to safeguard operator and maintenance staff Maximum case temperature is approximately 100 C 212 F for a motor u...

Page 33: ... 100millimeters four inches clearance behind to allow for cable connectors Refer to Operator Terminal on page 6 2 for additional technical information FIGURE 2 11 Operator Terminal Dimensions 0 12 3 0 0 62 15 7 6 00 152 4 0 203 DIA 4 RADIUS MAX RECOMMENDED PANEL CUTOUT DIMENSIONS 9 60 243 8 10 00 254 0 0 20 5 1 0 20 5 1 5 10 129 5 5 50 139 7 GASKET SUPPLIED WITH UNIT 10 50 266 7 5 00 127 0 3 20 81...

Page 34: ...proximate conversions The conversion card must be mounted in the same enclosure as the IQ 2000 5000 PDM to comply with the EU LVD directive Refer to Figure 2 29 on page 2 35 and installation instructions 68 0060 available on request for additional technical information FIGURE 2 12 24VDC I O Conversion Card Mounting Dimensions 1 P1 P2 1 USER 26 26 77 0 1 9 77 0 1 9 169 0 6 7 47 0 1 9 7 5 0 3 25 1 0...

Page 35: ... as separate documents available from Rock well Automation Figure 2 13 shows the commonly used EMI model The model consists of an EMI source a coupling mechanism and an EMI victim Devices such as servo drives and computers which contain switching power supplies and microprocessors are EMI sources The mechanisms for the coupling of energy between the source and victim are conduction and radiation V...

Page 36: ...r sensitive circuits are powered off the same AC branch circuit The basic operating principle is to minimize the high frequency power transfer through the filter An effectivefilterachievesthisbyusingcapacitorsandinductorstomismatchthesourceimpedance AC line and the load impedance drive at high frequencies For Electro Craft drives brought into use in Europe the use of the correct filter is essentia...

Page 37: ...ing this is to mount the filter where the AC power enters the enclosure Figure 2 14 contrasts a good installation with a poor one When multiple power cables enter an enclosure an unfiltered line can contaminate a filtered line external to the enclosure Therefore all lines must be filtered to be effective The situation is similar to a leaky boat All the holes must be plugged to prevent sinking 3 If...

Page 38: ...e ground systems finite impedance In a sense ground systems are the sewer systems of electronics and as such are sometimes neglected The primary objective of a high frequency ground system is to provide a well defined path for HFcurrentsandto minimizetheloopareaoftheHFcurrentpaths Itisalso importantto separate HF grounds from sensitive circuit grounds A single point parallel connected ground syste...

Page 39: ... to 50 60 Hz currents while passing HF cur rents 2 Signal cables encoder serial analog should be routed away from the motor cable and power wiring Separate steel conduit can be used to provide shielding between the sig nal and power wiring Do not route signal and power wiring through common junc tions or raceways 3 Signal cables from other circuits should not pass within 300 mm 1 ft of the drive 4...

Page 40: ... with RC filters a 200 ohm 1 2 Watt resistor in series with a 1 2 microFarad 600 Volt capacitor is commonly used 5 Motor Power Windings can be grounded shielded and choked to minimize noise emis sions FIGURE 2 16 Torroid Encoder Shielding Method for Brushless Servo Motors FIGURE 2 17 Motor Power Winding Methods to Minimize Noise Emissions AMPLIFIER SHIELD ENCODER CABLE MOTOR CASE BRUSHLESS MOTOR B...

Page 41: ...between modules and the sub panel surfaces need to be paint free or plated Bonding metal surfaces creates a low impedance exit path for high frequency energy Figure 2 18 illustrates recommended bonding practices for painted panels enclosures and mounting brackets Improper bonding blocks that direct exit path and allows high frequency energy to travel elsewhere in the cabinet Excessive high frequen...

Page 42: ...This section specifies installation requirements for compliance to the Low Voltage Directive LVD and the Electromagnetic Compatibility EMC Directive for the IQ 2000 drive The infor mation below is based on successful testing using the specified installation methods Electromagnetic Compatibility Directive Although it is impossible to guarantee a specific installation will meet the EMC requirements ...

Page 43: ...and in the case of a motor with flying leads If there are any intermediate connectors in any of the screened cables the screen must connect through the backshells and not by routing a drain wire through a pin inside the connector Use of a drain wire virtually guarantees failure to meet the EMC requirements FIGURE 2 20 Recommended IQ 2000 Installation for EMC DANGER Large leakage currents exist in ...

Page 44: ...bles The shielded cables have a 0 5 portion of the cable jacket stripped off exposing the shield approximately 12 from the drive end of the cable This stripped area is to be clamped onto the chassis for shield termination when used with the IQ 2000 5000 drives Table 2 6 lists the part numbers of shielded cables TABLE 2 4 PDM Current Ratings and Suitable Supply Filters Drive Current Rating Schaffne...

Page 45: ...at stall Simply breaking the motor current can result in very high voltages due to motor inductance which will cause prolonged arcing in the contactor The contactor could catch fire in extreme cases A contactor was simulated in most EMC tests by breaking the motor lead and taking it through large rail mounted terminals This simulates a closed contactor which is acceptable as the con tactor would b...

Page 46: ...allation P N 0013 1027 005 Rev A FIGURE 2 21 Emergency Stop Contactor Wiring R S T Drive R S T Motor GND GND Isolated terminal Grounded terminal or stud Unbraided shield Enclosure wall Resistor Resistor Resistor ...

Page 47: ...Installation 2 29 IQ 2000 5000 Installation Manual 2Installation FIGURE 2 22 IQ 5000 Transformer Outline Diagram ...

Page 48: ...2 30 Installation P N 0013 1027 005 Rev A FIGURE 2 23 IQ 5000 Transformer Load Regulation Curve ...

Page 49: ...Installation 2 31 IQ 2000 5000 Installation Manual FIGURE 2 24 PSM AUX Outline and Connection Diagram ...

Page 50: ...5 200 9 10 MAX XXX 005 DECIMALS XX 010 FRACTIONS 1 64 DO NOT SCALE DRAWING UNLESS OTHERWISE SPECIFIED ANGLES 1ANGLES TOLERANCE ON FILLETS AND ROUNDS 02 R MAX BREAK ALL EDGES 02 MAX DIMENSIONS ARE IN INCHES 9101 1056 RELIANCE MOTION CONTROL Confidential Information of Eden Prairie MN 55344 DATE DATE 1 10 89 C PART NO DWG SIZE SHEET SCALE 1 1 1 1 of REV ECO CHKR DATE REVISION DESCRIPTION DIAGRAM OUT...

Page 51: ...Installation 2 33 IQ 2000 5000 Installation Manual FIGURE 2 26 IQ 2000 Transformer Load Regulation Curve ...

Page 52: ... 3 1X Shunt Resistance up to 200 Watts 300 Ohm 500 Watts TB2 1 TB2 3 4X Shunt Resistance up to 1000 Watts 9X Shunt Resistance up to 2 4 kWatts is factory available R1 R1 R2 R3 R4 TB2 1 TB2 3 R1 R3 R4 R6 R7 R9 R2 R5 R8 NOTES 1 A single resistor of equivalent total resistance may replace multiple resistors 2 Dissipation uses approximately 50 of total resistance value ...

Page 53: ...Installation 2 35 IQ 2000 5000 Installation Manual FIGURE 2 29 24V Sourcing I O Conversion Card ...

Page 54: ...2 36 Installation P N 0013 1027 005 Rev A ...

Page 55: ... drawings for complete power wiring details PDM 10 20 and 30 power wiring diagram Figure 3 27 on page 3 27 PDM 75 power wiring diagram Figure 3 28 on page 3 28 PDM 150B power wiring diagram Figure 3 29 on page 3 29 Figure Part Number Title Page 3 25 9101 0411 IQ 5000 Power Wiring 3 25 3 26 9101 0132 4 PSM AUX Connections 3 26 3 27 9101 2195 IQ 2000 Power Wiring for PDM 10 20 and 30 3 27 3 28 9101 ...

Page 56: ...nnection is required for safe and proper system operation Terminal block connections should be torqued to 11 lb in 1 25 Nm on the PSM 50 and 24 lb in 2 75 Nm on the PSM 125 The IQ 5000 does not contain supply fuses or disconnecting devices These must be supplied by the machine builder and connected externally for safety and maintenance purposes The Power Supply Modules will continue to operate wit...

Page 57: ...ned as long as logic power is on Another example would be maintaining PDM logic power so the PDM serial interface could be used for troubleshooting and diagnostics Refer to Figure 2 24 on page 2 31 for wiring information on the PSM AUX and optional PSM AUX isolation transformer PSM Interface Logic The Status signal and the Enable signal on the PSM are provided to interface the PSM with the PDM or ...

Page 58: ...F the PSM DC bus is turned OFF and the dissipative shunt is turned ON to quickly discharge the DC bus capacitors and dynamically brake synchronous motors This is to allow time for the PDMs to power up and apply the enable signal to the PSM if the PSM is to remain ON With the jumper in the enable input deactivated position standard Position B the enable input has no effect on the PSM operation and ...

Page 59: ... the shunt fuse and test with an ohmmeter 3 Replace the shunt fuse 4 Install the PSM cover FIGURE 3 3 Power Supply Module Jumper Location WARNING When replacing the PSM 50 and PSM 125 shunt fuse a DC rated fuse must be used FIGURE 3 4 Shunt Fuse Location ...

Page 60: ...h ground to ensure a safe installation and proper operation Refer to Figure 3 6 for connector pin and signal identification FIGURE 3 5 Operator Terminal Power Connections FIGURE 3 6 Motor Power Connections WARNING High voltage may be present on terminals of the IQ 2000 5000 Positioning Drive Module Remove power and dis connect the power cable before making or removing any connection NOTES 1 Do not...

Page 61: ...lamped at the left front of the drive chassis using the clamp provided near the bottom It is critical for EMC performance that the shield wires be clamped against the area of the chassis which is not painted This section of the chassis is labeled with the chassis ground symbol Drawings which illustrate the power connections for specific F Series H Series N Series S Series W Series and I Series mot...

Page 62: ...ers the control and interface connections between the PDM and the rest of the system This includes Digital I O Analog I O Relay Outputs Encoders Step and direction Inputs and Serial Ports Figure 3 8 illustrates all control connections to the PDM FIGURE 3 8 PDM Control Connections ...

Page 63: ... uses sinking NPN style inputs and outputs the most common interface used in the USA If a ground fault occurs on an input it can become active and may result in a potentially hazardous unanticipated machine state Contact Electro Craft for more information P2 P1 12 11 10 9 8 7 6 5 4 3 2 1 12 13 14 11 10 9 8 7 6 5 4 3 2 1 OUTPUT LOADS RESISTANCE IS 330 OHM MINIMUM INPUT SWITCHES RESISTANCE IS 3000 O...

Page 64: ...parameter can select the Pause input as active open or active closed The general purpose inputs on the PDM are referred to as I1 through I16 in program statements Inputs I1 through I10 can be assigned the predefined functions shown in the table below Inputs I11 and I12 may be used as Interrupt inputs Inputs I12 to I16 may be used as program select inputs Any of these input functions may be disable...

Page 65: ...lers the 24 VDC common P1 pin 1 also needs to be connected between each controller Multiple digital outputs may be wired together to form a wire OR connection If any one of the outputs turns on the line is pulled low on This is useful for connecting the Error outputs O8 from each axis of a system to a host PLC or machine controller to indicate an error in any of the axes Multiple digital inputs ma...

Page 66: ...P3 4 The Analog Common is tied to earth ground internally The 10 bit ADC has a resolution of approximately 20 mV This analog input may be used as a general purpose analog input or as the feedrate input Refer to the IQ Master Instruction Manual for information about the use of this input TABLE 3 4 Analog Inputs and Signal Name Connector Pin Signal Name P3 Analog I O and status 4 Analog Common 5 Ana...

Page 67: ...alog signal with 8 bit resolution Refer to the IQ Master Instruction Manual for information about the use of this output TABLE 3 6 Monitor Output and Signal Name Ready Relay Output Figure 3 11 illustrates theReady output P3 1 which is a normally open relay contact that closes when the PDM is powered up if no faults exist within the PDM Relay Common P3 3 is the common of this contact This contact i...

Page 68: ... input to the PDM on both the encoder 1 and encoder 2 inputs so four encoder counts is equivalent to one encoder line With a standard 2000 line encoder the PDM will count 8000 encoder pulses per revolution The PDM will accept differential line driver quadrature signals from a 5 volt incremental encoder As illustrated in Figure 3 12 the PDM accepts A B and I Index signals from the encoder with A le...

Page 69: ...Figure 3 14 illustrates the connections of Encoder 2 which provides an optional second encoder It can be used as position feedback directly from the load or as a master input for relative positioning master follower systems or for electronic gearing As an alternative the Encoder 2 port may also be used to output encoder 1 signals when only the motor mounted encoder is used The function of the Enco...

Page 70: ...tor P4 includes a separate pin Pin 15 for this purpose Refer to Figure 3 33 on page 3 32 TABLE 3 10 Encoder 2 and Signal Name Slaving One IQ to Another In applications where an IQ needs to follow another IQ 2000 5000 controller using electronic gearing theP4connectionsmaybeusedtoprovideasimplemethodofwiringthemotorencoder signals from the master IQ to the Encoder 2 input of the follower slave IQ T...

Page 71: ...rection Inputs and Signal Name The input resistance provides the proper current limit for a 5 VDC signal External resistance inseries with thestepanddirectionlinesto limitcurrentto10 mAallowsoperationwithvoltages greater than 5 Volts The step input is active low and will accept a square wave input with a maximum frequency of 800 kHz The direction input is high for motion in the forward direction T...

Page 72: ...n The default setup for the serial ports is Host Computer Serial Port 2 on connector P6 provides the communication interface between the PDM and the personal computer used for programming and configuration This is also the serial port that must be used for Host communications One or more IQs may be installed on an RS 422 multi drop network or an RS 232C daisy chain network If more than one IQ is i...

Page 73: ...log box 5 If you get an IQ not responding error message go to the Communications menu PC Setup and check your communications setup You should first verify that the communi cations port that you have selected is the one that your cable is connected to Then ver ify that the communications protocol matches the protocol in the PDM If this is not a new PDM any of these setting may have been changed by ...

Page 74: ...apter 2 Parameter menu Serial for more information TABLE 3 13 P7 at Serial Port 1 on Operator Terminal Networking the IQ Operator Terminal Figure 3 19 illustrates an additional option which is to connect one Operator Terminal to mul tiple PDMs This method requires RS 422 connections as shown in the following drawing A PDM may be selected from the terminal by using the NO key followed by the numeri...

Page 75: ... 6 are used to select the address Switch SW1 1 is the least significant bit and SW1 6 is the most sig nificant bit of the binary address If the address is set to anything other than 0 the PDM will not communicate until its address has been selected use Axis Select under the Communications menu Changing the address on the dip switch will not be recognized by the PDM until a Hard Reset is performed ...

Page 76: ...Drop Figure 3 23 illustrates the connections needed for multiple PDMs which can be linked with an RS 422 multi drop configuration Remember to set a different address on DIP switch SW1 for each PDM on the RS 422 network The cable used for these connections should be 22 AWG twisted pair with an overall shield grounded at one point RS 232C Daisy Chain The two serial ports can also operate as one port...

Page 77: ... board The last 16 positions of P1 and P2 are inputs and correspond to module positions 0 15 on a 24 channel expansion board TIP Firmware Version 2 00 or higher is required to use an Expansion I O card or a Memory and I O Expansion card TABLE 3 15 P1 and P2 on IQ and Expansion Board Connections Expansion I O Card Connector P1 and Pin IQ I O Type and Number 24 channel Expansion Board Module Positio...

Page 78: ...3 16 defines the relationship between P3 user crimped leads and the housing supplied with the kit The Monitor menu provides expanded I O status Refer to the IQ Master Instruction Manual for additional information about expanded I O display and status TABLE 3 16 P3 Pins on Expansion Card IQ Analog Input Number Expansion Memory and I O Card Connector and Pin ADC2 P3 1 ADC2 P3 2 ADC3 P3 3 ADC3 P3 4 A...

Page 79: ...Wiring 3 25 IQ 2000 5000 Installation Manual 3Wiring FIGURE 3 25 IQ 5000 Power Wiring ...

Page 80: ...3 26 Wiring P N 0013 1027 005 Rev A FIGURE 3 26 PSM AUX Connections ...

Page 81: ...Wiring 3 27 IQ 2000 5000 Installation Manual FIGURE 3 27 IQ 2000 Power Wiring for PDM 10 20 and 30 ...

Page 82: ...3 28 Wiring P N 0013 1027 005 Rev A FIGURE 3 28 IQ 2000 Power Wiring for PDM 75 ...

Page 83: ...Y POWER IS PRESENT OR A DRIVE FAULT WILL OCCUR DO NOT DAISY CHAIN DRIVE MODULE POWER CONNECTIONS MAKE SEPARATE CONNECTIONS DIRECTLY TO THE AC SUPPLY DRIVE RATED 100 240 VAC RMS 230 VAC STANDARD 6 CURRENT RATINGS ARE INDEPENDENT OF THE INPUT VOLTAGE REDUCED VOLTAGE WILL RESULT IN A REDUCTION IN SPEED BUT NOT TORQUE DRIVE RATED 65 150 AMPS PEAK FOR THREE PHASE INPUT A SUPPLY DISCONNECTING DEVICE IS ...

Page 84: ... 1 P1 P2 ARE DESIGNED TO CONNECT TO A 24 CHANNEL NOTES OPTO 22 GENERATION 4 I O MOUNTING RACK THROUGH A 50 PIN RIBBON CABLE THE FIRST EIGHT POSITIONS ARE WIRED AS OUTPUTS THE LAST 16 POSITIONS ARE WIRED AS INPUTS USE OPTO 22 GENERATION 4 I O MODULES OR EQUIVALENT DESIGNED FOR 5V LOGIC THE 5V LOGIC OPERATING VOLTAGE SHOULD BE TAKEN FROM PINS 6 7 OF P3 GENERATION 4 IS A REGISTERED 20777 JL __ __ D C...

Page 85: ...nstallation Manual 3Wiring Cables Refer to Table 7 3 on page 7 2 for ordering information about these and other cables FIGURE 3 31 IQ P7 to Operator Terminal P N 9101 2025 FIGURE 3 32 IQ P6 to PC Serial Port 9 pin P N 9101 2024 ...

Page 86: ... or P5 to Auxiliary Encoder Unterminated P N 9101 2031 Note This cable may be used on the P5 connector to motor feedback with the following differences Pin 8 is unused Pin 11 and 12 are TS and TS respectively Pin 13 is ABS Reference Encoder 1 on page 3 15 ...

Page 87: ...Wiring 3 33 IQ 2000 5000 Installation Manual FIGURE 3 34 IQ P4 to P4 2 foot P N 9101 2127 FIGURE 3 35 IQ P5 to S H or F Series Motor Encoder P N 9101 2027 ...

Page 88: ...3 34 Wiring P N 0013 1027 005 Rev A ...

Page 89: ... L2 N and L3 Ensure that a proper ground is connected also If auxiliary power is used ensure proper connections are made to terminals L1 AUX and L2 N AUX 3 With input power still off disconnect motor leads from PDM terminals R S and T Ver ify with an ohmmeter that the resistance between PDM terminals R to GND S to GND and T to GND is above 500k ohms If the resistance is acceptable reconnect the mo...

Page 90: ...e 3 18 4 If you have selected an address on the address dip switches verify that the same address is selected in the Communications menu Axis Select dialog box 5 Click Initialize PM from the File menu and continue with Step 7 above 11 Make sure that the motor is not connected to the load when applying power to prevent any mechanical damage in case of a fault Ensure the PDM is disabled turn the Ena...

Page 91: ... bus wires to the PSM terminals marked and ensuring that proper polarity is maintained Install the PSM cover Start up Procedure for PDM 1 Ensure input power to the PSM is OFF 2 Disconnect all interface cables P1 P7 from each PDM and remove all PDM covers Dis connect all motor leads from the PDM terminals marked R S and T Verify with an ohmmeter that the resistance between PDM terminals R to GND S ...

Page 92: ... is selected in the Communications menu Axis Select dialog box 11 Select Initialize PM from the File menu and continue with Step 7 above Make sure that the motor is not connected to the load when applying power to prevent any mechanical damage in case of a fault Ensure the PDM is disabled turn the Enable input off or select Disable from the Run menu of IQ Master after power is applied Apply input ...

Page 93: ...If motor does not turn clock wise then check that motor power wires and encoder wires are connected to the PDM properly 4 Disable all PDMs and turn off input power Measure the DC bus voltage to be sure that it is below 15 VDC 5 Now that the system installation is verified return the Ilimit parameter to a value to suit the application Operator Terminal The Operator Terminal requires no special star...

Page 94: ...4 6 Applying Power for the First Time P N 0013 1027 005 Rev A ...

Page 95: ...ve LEDs on the front These LEDs provide a first level of diagnostics Positioning Drive Module STATUS LED All PDMs have a STATUS LED on the top front right hand corner This LED may appear green red or opaque OFF Green The LED on the IQ 2000 5000 PDM indicates the present status of the PDM During normal operation when no fault conditions exist this LED is green This LED turns red to indicate that th...

Page 96: ...escription PHASE LOSS RED OFF OK Normal Operation ON Loss of one phase of incoming AC power The PSM will continue to run on two phases and the fault LED ON OVERTEMP RED OFF OK Normal Operation ON Excessive main heatsink temperature DISABLED RED OFF Not disabled Normal Operation ON DC bus disabled by external enable input PSM READY GREEN OFF No DC bus voltage ON DC bus charged Normal Operation Name...

Page 97: ...connected to the P6 connector the error message can be displayed in the Monitor menu Status dialog box The error messages are also displayed on the optional Operator Terminal The Error output may be disabled and used as a general purpose output Therefore this output may not be available for diagnostic purposes The remainder of the discussion about the Error output assumes that output 8 is assigned...

Page 98: ...er larger than 9 was read in as a BCD number in a BCD statement in a program Check the inputs that are being used for the BCD input 12 LOOP Count Out of Range Loop constant value is not within the range of 0 to 65535 13 Profile Calculation The move cannot be made based on the parameters for the move distance velocity acceleration or time Possible causes are variable values used for the move parame...

Page 99: ... power cables for shorts 44 Bus Overvoltage The DC bus voltage exceeded safe levels This error usually indicates that the power supply shunt is not operating properly Check the shunt fuse on the Power Supply Module IQ 5000 only See Figure 3 4 on page 3 5 45 46 Encoder 1 Fault Encoder 2 Fault Incorrect encoder signals were detected by the IQ circuitry The encoder signals may be out of quadrature or...

Page 100: ...gram directory Due to the unpredictable results of losing the direc tory information this error may cause the loss of some programs 69 Program File When programs are entered or changed the PDM computes and stores a check sum for the source program and a checksum for the executable program At power up and other times during PDM operation the checksums are recalculated and compared to the stored che...

Page 101: ... Electrical Characteristics Line Voltage Input 50 60 Hz 100 240 VAC 100 240 VAC 100 240 VAC 100 240 VAC 100 240 VAC Continuous Shunt Power 50 W 50 W 50 W 50 W 180W Peak Shunt Power 4 5 kW 4 5 kW 4 5 kW 10 kW 19 kW Continuous Shunt External 2 4 kW 2 4 kW 2 4 kW 4 kW 8 kW Peak Shunt External 6 kW 6 kW 6 kW 10 kW 19 kW Physical Characteristics Weight 15 lb 5 kg 15 lb 5 kg 15 lb 5 kg 21 lb 10 kg 31 lb...

Page 102: ...ect Class RK5 40 amps Class RK5 90 amps Output Bus Voltage 100 340 VDC 100 340 VDC Continuous Output Current 50 amps 100 amps Continuous Shunt Dissipation 600 W 1200 W Peak Shunt Power 20 kW 40 kW Terminal Block Torque 11 0 lb in 1 25 Nm 24 0 lb in 2 75 Nm Operator Terminal Characteristics Authority Input voltage Standard Optional 110 240 VAC 15 24 VDC or 24 VAC P N 9101 2017 P N 9101 2064 Input p...

Page 103: ...5 Three Phase Transformer Specifications Refer to Figure 2 22 on page 2 29 and Figure 2 23 on page 2 30 for transformer outline drawings and load regulation data Specification Value Rating 3 0 kVA Inputa a Single phase input and output 50 60 Hz 220 230 240 440 460 480 VAC RMS Outputa 115 230 VAC RMS Ambient temperature 32 122 F 0 50 C Specification Model TF 03 TF 06 TF 12 TF 18 Rating 3 kVA 6 kVA ...

Page 104: ...6 4 Specifications P N 0013 1027 005 Rev A ...

Page 105: ...C circuits Bussman MDL 1 or Littelfuse 313 001 9101 2005 Connector Kit Mating connectors for PDM P1 P7 9101 0098 DC Bus Connection Kit Pos Neg Gnd wires IQ 5000 only 9101 2036 IQ 2000 5000 Series Control Station 9101 2017 IQ 2000 5000 Operator Terminal 110 240 VAC 9101 2064 IQ 2000 5000 Operator Terminal 24 Volt 9101 2073 IQ 2000 5000 I O Expansion Card 9101 2038 IQ 2000 5000 Memory and I O Expans...

Page 106: ...er Cable 9101 1080 XXX1 IQ 2000 S or H 2000 S or H 3000 Motor Power Cable 9101 1081 XXX1 IQ 2000 S or H 4000 F 4000 Motor Power Cable 9101 1467 XXX1 IQ 2000 N Series Motor Power Cable 9101 2179 XXX1 IQ 2000 S or H 6000 F 6000 Motor Power Cable 44 0141 003 IQ 2000 5000 to I O Conversion Card 3 foot Cable 44 0141 010 IQ 2000 5000 to I O Conversion Card 10 foot Cable 1 Standard cable lengths are 010 ...

Page 107: ...RE EARTH MAGNET W WASH DOWN Not all line counts are available on all motors TABLE 7 6 Part Numbers of Motor Mating Connector Kits Part Number Description 9101 0325 Motor power connector kit All 2000 and 3000 motors MS3106F18 4S connector 9101 0326 Motor power connector kit All 4000 motors MS3106F208 4S connector 9101 0327 Motor power connector kit All 6000 motors MS3106F24 22S connector 9101 0328 ...

Page 108: ... seal kit F 4000 motor 1 437 in outside diameter 0 875 in inside diameter 0 25 in width 0041 5061 Shaft seal kit F 6000 motor 2 125 in outside diameter 1 438 in inside diameter 0 31 in width TABLE 7 8 Part Numbers of Transformers Part Number Description 0020 5097 3 KVA single phase transformer IQ 2000 0020 5091 001 3 KVA three phase transformer IQ 5000 0020 5091 002 6 KVA three phase transformer I...

Page 109: ...rned Goods and Field Service Policy Products that have been modified by the customer physically mishandled or otherwise abused through incorrect wiring inappropriate settings and so on are exempt from the warranty plan Return Procedure To ensure accurate processing and prompt return of any Electro Craft product the following procedure must be followed 1 Call your Electro Craft distributor to obtai...

Page 110: ...______________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ __________________________________...

Page 111: ...PDM 030 P N 9101 2143 16MHz Clock PDM 010 P N 9101 2161 20MHz Clock PDM 020 P N 9101 2162 20MHz Clock PDM 030 P N 9101 2163 20MHz Clock PDM 075 P N 9101 2164 20MHz Clock When operating any of the following motor families S H F and LD Series motors And when operated with or without the IF2 24V Sourcing Module P N 9103 0152 And when operated with or without the Operator Terminal P N 9101 2017 When i...

Page 112: ...Are intended to be incorporated into a drive or control system or to be assembled with other machinery to constitute machinery covered by directives listed above Do therefore not in every respect comply with the provisions of directive as supplied The manufacturer further declares that it is not allowed to put the product into service until the machinery into which any of the above products are to...

Page 113: ...ined in the document IQ 2000 Installation Requirements for Compliance to European Direc tives available by request from the manufacturer and the specific instructions in the product man ual Installation must be in a grounded metallic enclosure and all shields must be bonded to the enclosure wall where they pass through it An AC line filter of an approved type must be used for the supply to the amp...

Page 114: ...Help 6 EU Directives P N 0013 1027 005 Rev A ...

Page 115: ... 32 IQ 5000 Transformer Outline Diagram 2 29 PSM AUX Outline and Connection Diagram 2 31 Transformer Load Regulation Curve 2 30 2 33 Drive Not Ready 5 5 E Electrical Noise 2 17 EMC ElectroMagnetic Compatibility Defined 2 17 European Directive 2 24 System Installation 2 17 EMI ElectroMagnetic Interference Bonding 2 23 defined 2 17 Source Victim Model 2 17 Enable Output 3 4 Enabled Relay Output 3 14...

Page 116: ...quirements 2 2 Shunt 3 4 7 1 G Gear Out Of Range 5 4 Generic Operator Terminal 3 20 Grounding Types 2 20 H Heat Sink Overtemperature 5 5 High frequency energy 2 24 Home Not Defined 5 4 Home Sw Not Found 5 6 I I O Conversion Card Mounting 2 16 I O Expansion Card 1 5 1 6 I O Interface Card 1 6 Iavg Fault 5 4 Illegal Pgm Number 5 6 Indexer Inputs see Step and Direction Inputs Analog 3 12 Digital 3 10...

Page 117: ... 5 Installation 2 6 Memory 1 5 Outputs Analog 3 13 Digital 3 11 Enabled Relay Output 3 14 Monitor Output 3 13 Ready Relay Output 3 13 Overview 1 2 P Parameter Checksum 5 5 PDM see Positioning Drive Module Peak Overcurrent 5 5 Personal Computer PC 1 5 Personality Fault 5 5 Personality Module 1 4 Backing Up 4 5 Factory Default Initialization 5 3 Installation 2 3 POS Track Overflow 5 5 Positioning Dr...

Page 118: ... Types 2 20 Software 1 2 Sourcing I O Card Mounting Dimensions 2 16 Specifications IQ 2000 6 1 6 2 Operator Terminal 6 2 Start up Procedure 4 1 IQ 2000 PDM 4 1 IQ 5000 4 3 IQ 5000 PDM 4 3 IQ 5000 PSM 4 3 Step and Direction Inputs 3 17 Support Help 13 System Overview 1 2 System Power Connections 3 1 T Technical Assistance Help 13 TEXT Checksum 5 5 Transformer Sizing 2 9 Transformers 1 6 Troubleshoo...

Page 119: ...ro Craftfactorybasedsupportstaffbyphonebetween 7 30 AM and 5 00 PM CST Monday through Friday at 1 800 328 3983 The applications engi neers can assist you with programming difficulties as well as ideas for how to approach your automation task Should your problem require on site assistance field service is available The applications engineers can also be reached via fax at 1 612 942 3756 The fax mac...

Page 120: ... S A Rockwell Business IQ 2000 5000 Positioning Drive Modules Electro Craft 6950 Washington Avenue South Eden Prairie MN 55344 612 942 3600 main 612 942 3636 fax 800 328 3983 technical support P N 0013 1027 005 Rev A Installation Manual ...

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