Installation Instructions, PowerFlex DC Drive Resolver ... · board into connector XRE on the control board (identified in the previous ... Drive User Manual, publication 20P-UM001,

Installation Instructions

PowerFlex DC Drive Resolver Feedback Option Module

What This Kit Includes Resolver Feedback circuit board Resolver Interface circuit board Two stacker connectors Four 28 mm stand-offs and washers Three 14 mm stand-offs and washers Seven screws with captive lock washers Static strap

Tools That You Need Phillips screwdriver (PH2) Hexalobular screwdriver Nut driver or wrench Flathead screwdriver

Phillips is a registered trademark of Phillips Screw Company.

ATTENTION: Only qualified personnel familiar with DC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following.

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook.

IMPORTANT The Resolver Feedback option module can only be used with PowerFlex DC drives with firmware version 5.002 or higher.

20P-IN071B-EN-P


What You Need to Do To install the resolver feedback option module: Step 1: Remove power from the drive Step 2: Open the drive Step 3: Install the resolver interface board Step 4: Install the resolver feedback board Step 5: Wire the resolver interface and feedback boards Step 6: Replace the protective covers and configure the resolver feedback

option module

Step 1: Remove Power from the Drive

Remove and lock-out all incoming power to the drive.

Step 2: Open the Drive To open frame A drives see Frame A Drives on page 3.

To open frame B and C drives see Frame B and C Drives on page 4.

To open frame D drives see Frame D Drives on page 4.

ATTENTION: Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by:

sending an erroneous signal to your systems field devices, causing unintended machine motion

causing an explosion in a hazardous environmentElectrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance.

L1 L2 L3

O

I

2 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011


Frame A Drives

1. Disconnect the DPI cable from the HIM (if installed).

2. Loosen the captive screws that secure the bottom front cover to the drive, then slide the cover down and off the drive chassis.

3. Press in on the sides at the bottom edge of the cover and at the same time pull the cover toward you to pull it partially off the drive chassis. Next, at the top of the drive, pull the cover forward, away from the drive, until the pins fit in the keyhole in the top of the cover, then carefully lift the cover off of the drive chassis.

Continue with Disconnect the HIM Communication Cable on page 5.

IMPORTANT The HIM assembly is connected via a cable to the control board and therefore will not pull free from the drive until disconnected.

=

Disconnect DPI cable

Tightening torque:1.5 Nm (13.3 lbin)

Loosen screws

When metal pin fits in keyhole, lift cover off drive chassis.=

Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 3


Frame B and C Drives

1. Disconnect the DPI cable from the HIM (if installed).

2. Loosen, but do not remove, the screws that secure the top and bottom front cover to the drive, then slide the covers off the drive chassis.


Frame D Drives

1. Disconnect the DPI cable from the HIM assembly (if installed) (see Figure 1 on page 5).

2. Loosen, but do not remove, the four hexalobular screws that secure each of the three covers to the control pan on the drive, then slide the covers up and off the drive chassis (see Figure 1 on page 5). Tightening torque is noted in the illustration for reassembly.


IMPORTANT The HIM assembly is connected via a cable to the control board and therefore will not pull free from the drive until disconnected.

=

Disconnect DPI cable

Frame B shown

Tightening torque: 1.5 Nm (13.3 lbin)

Loosen screws

Loosenscrews

IMPORTANT A communication cable connects the HIM assembly to the control board mounted on the control pan. Therefore, the middle control pan cover and HIM assembly cannot be fully removed from the drive until the cable is disconnected.



Figure 1 - Frame D Cover Removal

Disconnect the HIM Communication Cable

Disconnect the HIM communication cable from the connector on the upper right corner of the Control board and remove the bottom cover.

DisconnectDPI cable

Tightening torque:1.5 Nm (13 lbin)

T15

=

Loosen screws

Loosenscrews

Pull tabs out to disconnect cable.

=

All Frames(Frame A shown)



Step 3: Install the Resolver Interface Board

1. Secure the four 28 mm (1.1 in.) (longer) stand-offs and washers to the control board. Tightening torque is 0.7 Nm (6.2 lbin).

S15

XR

XA

XP3

XRE

XFCD

S21

S4

Install stand-offsand washers

Install stand-offsand washers

Control board

Connector XRE



2. Carefully insert the stacker connector on the back of the resolver interface board into connector XRE on the control board (identified in the previous illustration).

IMPORTANT The two pins of the stacker connector that are capped should be to the right of connector XRE when installed on the control board.

Resolverinterface

board

Control board

XRE connector

Control board

Resolver interface board

Stacker connectorCapped pins to right

Bottom view

Side view

XRE connector



3. Secure the resolver interface board to the stand-offs using four screws with captive washers. Tightening torque is 0.7 Nm (6.2 lbin).

S15

XR

XA

XP3

P2 P3

S2

XRE

S1

TB1 TB2

Install screws

Install screws




Step 4: Install the Resolver Feedback Board

1. Secure the three 14 mm (0.6 in.) (shorter) stand-offs and washers to the resolver interface board. Tightening torque is 0.7 Nm (6.2 lbin).

S15

XR

XA

XP3

XFCD

P2 P3

S2

XRE

S1

TB1 TB2

Connectors P2 and P3

Install stand-offs andwashers



2. Carefully insert the long pins of the stacker connectors into connectors P2 and P3 on the back of the resolver feedback option board.

3. Carefully insert the stacker connectors on the back of the resolver feedback option board into connectors P2 and P3 (identified in the previous illustration) on the resolver interface board.

IMPORTANT The end of the stacker connectors with the long pins must connect to the mating connectors (P2 and P3) on the resolver feedback option board. The end of the stacker connectors with the short pins must connect to the mating connectors (P2 and P3) on the resolver interface board.

Resolver feedbackoption board

Long pins of stacker connector mate with resolver feedback option board

Side view


P2 and P3connectors

Short pins of stacker connector mate with resolver interface board connectors

P2 and P3 connectors



4. Secure the resolver feedback board to the stand-offs using three screws with captive washers. Tightening torque is 0.7 Nm (6.2 lbin).

Step 5: Wire the Resolver Interface and Feedback Boards

Wiring the Resolver Interface Board

Table 1 - Resolver Interface Board TB1 Wire Size and Tightening Torque

Terminal block TB1 on the resolver interface (bottom) board provides connection points for an external 24V DC power supply input, resolver feedback board voltage status output and resolver feedback board reset input. Table 2 on page 12 details the connections.

The resolver feedback module can be powered via an internal or external (customer-supplied) 24V supply. The voltage source is selected by switch S2 on the resolver interface board. See Figure 3 on page 13 for the location of switch S2. The customer-supplied, external 24V power supply is only needed when using the resolver interface board with a PowerFlex DC frame A drive or Stand-Alone Regulator under the following conditions.

A resolver is wired to the resolver feedback board (terminal block P1) A digital encoder is wired to the control board The frame A drive has a fan(s)

S15

XR

XA

XP3

P2 P3

S2

XRE

S1

TB1 TB2

P4 P2 P3

P1

S1

Install screws

Resolver feedback board

Wire Size and TypeTightening Torque Nm (lbin)Flexible (mm2) Multi-core (mm2) AWG

0.1401.500 0.1401.500 2616 0.4 (3.5)



Switch S2 on the resolver interface board must be set to the Ext position when using an external 24V DC power supply for the resolver feedback option module.

Table 2 - Resolver Interface Board TB1 Terminal Descriptions

Figure 2 - Resolver Feedback Board Voltage Status Wiring Example

Terminal block TB2 on the resolver interface board is used to send the signals from the primary digital encoder installed and wired to the encoder terminal block on the control board to a second follower drive/regulator. When the outputs on TB2 are used, switch S1 on the resolver interface board must be set to match the encoder power supply voltage set for the primary encoder on the follower drives control board (set via switch S21). See the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for details on installing a primary digital encoder and using switch S21 on the control board.

The S1 switch settings correspond to each of the three LEDs on the left side of the resolver interface board and indicate the selected supply voltage as follows:

Green LED indicates a 5V supply when lit (on) Yellow LED indicates a 12V supply when lit (on) Blue LED indicates a 24V supply when lit (on)

See Figure 3 on page 13 for the location of switch S1 and corresponding LEDs on the resolver interface board.

See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for encoder wiring recommendations.

Terminal Signal Description1 0V External power supply input common2 +24V External +24V DC power supply input3 OK- Resolver feedback board voltage status output common4 OK+ +524V Resolver feedback board voltage status output

Vcc OK = voltage present and within +524V range when connected to a digital input.Vcc not OK = voltage not present or below +5V when connected to a digital input. See Figure 2 below for wiring example.

5 R- Resolver feedback board reset input common6 R+ +24V Resolver feedback board reset input

23

45

1

6

11

12

13

14

15

16

17

18

19

20

1

2

3

4

5

6

Resolver InterfaceBoard TB1

Drive Control Board I/O TB2

Digital Input 2

Digital Input Common

24V Supply Common

+24V DC Supply

In this example digital input 2, on drive I/O TB2, is configured as an Enable input. When the signal from terminals 3 and 4 on TB1 of the Resolver Interface board = VCC not OK, the drive is disabled.


http://literature.rockwellautomation.com/idc/groups/literature/documents/um/20p-um001_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/um/20p-um001_-en-p.pdf


Table 3 - Resolver Interface Board TB2 Terminal Descriptions

Table 4 - TB2 Encoder Output Specifications

Figure 3 - Resolver Interface Board Switch and LED Locations

Terminal Signal Description1 A+ Encoder A2 A- Encoder A (NOT)3 B+ Encoder B4 B- Encoder B (NOT)5 Z+ Encoder Z6 Z- Encoder Z (NOT)7 Shield Connection point for encoder cable shield

Max. Output Current 20 mAMax. Output Low Voltage 0.5V @ 20 mAMin. Output High Voltage Vcc - 2.6V @ 20 mA (where Vcc = 5V or 30V)

23

45

1

76

TB1 TB2

S1

P2 P3

XRE

S2Switch S2 shown in

the Ext position

Switch S1 shown in the +24V selection position

Encoder output voltage LEDs(set with S1)

Green LED - 5V

Yellow LED - 12V

Blue LED - 24V

+5V position

+12V position

+24V position

Internal (Int) supply positionExternal (Ext) supply position



Wiring the Resolver Feedback Board

Terminal block P1 on the resolver feedback option (top) board provides the connection points for a single resolver. Table 5 details the connections.

Table 5 - Resolver Feedback Board P1 Terminal Descriptions

P1 terminal block part number: 1639300000 P1 terminal block material number: BL 3.50/08/90F SN BK BX

Recommended Resolver Cable

For the best results, Belden 9730 (or equivalent) cable is recommended. For retro-fit applications where Reliance Electric resolvers (800123-xxx), wiring (417900-207CG) or Automax systems were used, existing wiring may be used (assuming it is in good working condition).

Belden 9730 (or Equivalent) Cable Attributes 3 twisted pairs, 24 AWG, shielded, -20 to +80 C, 300V Inductance = 0.23 H/ft Capacitance = 12.5 pF/ft Resistance = 24 /1000 ft See Table 6 for maximum cable lengths

Reliance Electric 417900-207CG Cable Attributes 3 Twisted Pairs, 18 AWG, unshielded, 80C, 300V Chrome FPR Jacket, Plenum Rated Twists Per Inch: 2-3 twists per inch of wire lay per pair Inductance per 1000 Feet: 0.13 H 10% as read on a GEN_RAD Model

1658 RLC Digibridge or equivalent Capacitance Per Pair: not to exceed 30 pF/ft 0.3 pF as read on a

GEN_RAD Model 1658 RLC Digibridge or equivalent Capacitance Difference Pair to Pair: not to exceed 0.6 pF/foot as read on a

GEN_RAD Model 1658 RLC Digibridge or equivalent Resistance per 1000 Feet: 17.15 10% Insulation Thickness: 0.008 in. Conductor Stranding 16/30 Jacket Thickness: 0.018 in. See Table 6 for maximum cable lengths

Terminal Signal Description8 REF HIGH Positive Reference signal7 SHIELD Connection point for resolver cable shield6 REF LOW Negative Reference signal5 SIN HIGH Positive Sine signal4 SHIELD Connection point for resolver cable shield3 SIN LOW Negative Sine signal2 COS HIGH Positive Cosine signal1 COS LOW Negative Cosine signal

12

34

56

78



Table 6 - Maximum Resolver Cable Length

Resolver Feedback Option Board Specifications

Compatible Resolvers

The table below specifies which resolvers are compatible with the PowerFlex DC resolver feedback option module.

Cable

Maximum Cable Length

x1 and x2 Resolver Speed Ratio x5 Resolver Speed Ratio

Belden 9730 305 m (1000 ft) 183 m (600 ft)

417900-207CG 240 m (800 ft) 150 m (500 ft)

Consideration DescriptionExcitation Frequency 23819300 HzExcitation Voltage 826 VrmsResolver Feedback Voltage 2 Vrms +/- 300 mV

Manufacturer Manufacturer Model/Catalog NumberAdvanced Micro Controls Inc. R11X-C10/7Reliance Electric 800123-R

800123-1R800123-2R800123-S800123-1S800123-2S800123-T800123-1T800123-2T (flange mounted)

Tamagawa TS-2014N181E32TS-2014N182E32TS-2014N185E32TS-2087N1E9 TS-2087N2E9TS-2087N5E9TS-2087N11E9TS-2087N12E9



Resolver Wiring Diagrams

Figure 4 - Resolver Interface Connection Example for Clockwise Rotation - Count Up

Figure 5 - Resolver Interface Connection Examples for Clockwise Rotation - Count Down

IMPORTANT The shield connections must only be made at the drive end of the cable (resolver end of cable shield is unattached) as shown in the diagrams below. Grounding both ends of the shielded cable can result in ground loops that could damage the resolver and/or drive.

Also, the resolver connections are considered signal level wiring and MUST be run separate from control and power wiring (and at least 12 inches apart).

REF HIGH 8

SHIELD 7

REF LOW 6

SIN HIGH 5

SHIELD 4

SIN LOW 3

COS HIGH 2

COS LOW 1

REF

+-

SIN COS+

+-

-

-

+

-

+

-

+

-

+

-

+

-

+

Terminal Block P1 Resolver

REF HIGH 8

SHIELD 7

REF LOW 6

SIN HIGH 5

SHIELD 4

SIN LOW 3

COS HIGH 2

COS LOW 1

REF

+-

SIN COS+

+-

-

-

+

-

+

-

+

-

+

+

-

-

+

REF HIGH 8

SHIELD 7

REF LOW 6

SIN HIGH 5

SHIELD 4

SIN LOW 3

COS HIGH 2

COS LOW 1

REF

+-

SIN COS+

+-

--

+

-

+

-

+

+

-

-

+

-

+

Reverse Polarity of Sine or Cosine Signals

Terminal Block P1 Resolver



Step 6: Replace the Protective Covers and Configure the Resolver Feedback Option Module

1. Close the drive covers in the reverse order as described in Step 2: Open the Drive on page 2.

2. Configure the resolver feedback option module. See the PowerFlex Digital DC Drive User Manual, publication 20P-UM001.


http://literature.rockwellautomation.com/idc/groups/literature/documents/um/20p-um001_-en-p.pdf

1S7A72

Publication 20P-IN071B-EN-P June 2011Copyright 2011 Rockwell Automation, Inc. All rights reserved. Printed in USA.

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: [email protected], Online: www.ab.com/support/abdrives

www.rockwellautomation.com

Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444

Europe/Middle East/Africa: Rockwell Automation, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640

Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Power, Control and Information Solutions Headquarters

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Introduction_Catagory Types

This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards. It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printing.Find your publication type in the first section below. Use the assigned Printing Category information to determine the standard print specifications for that document type. The Printing Categories are defined below the Publication Type section. Note there may be slightly different print specifications for the categories, depending on the region (EMEA or Americas).For more information on Global Sales and Marketing Printing Standards, see publication RA-CO004 in DocMan.

Publication Type and Print Category

Publication TypeOff Set Print Category Spec. (See table below)JIT Spec. (See table below)DescriptionOrder Min **Order Max **Life Cycle Usage / Release Option

ADNA - PuttmanNAAdvertisement Reprint ColourNANAPresale / Internal

APA3D2Application Solution or Customer Success Story5100Presale / External

ARNANAArticle/Editorial/BylineNANAPresale / Internal

(press releases should not be checked into DocMan or printed)

ATB3, B4D5Application techniques5100Presale / External

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DSB3D5Dimensions Sheet15Post / External

DUB3D5Document Update15Post / External

GRB2D6Getting Results15Post / External

INB3 Primary, B2D5, D6Installation instructions15Post / External

LMNANALaunch Materials550Presale / Internal

PCB3D5Packaging Contents

PLE-only primary, B3E-onlyPrice List550Presale / Internal

PMB2D6Programming Manual15Post / External

PPA3D1Profile (Single Product or Service). NOTE: Application Solutions are to be assigned the AP pub type.5100Presale / External

QRB2 primary, B3, B5D5, D6Quick Reference15Post / External

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RMB2D5, D6Reference Manual15Post / External

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TGB2, B3D6Troubleshooting Guide15Post / External

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WDB3D5Wiring Diagrams / Dwgs15Post / Internal

WPB3 Primary, B5D5White Paper550Presale / External

** Minimum order quantities on all JIT items are based on the publication length. **

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77 or more pages1 (no shrink wrap required)

33 to 76 pages25

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CategoryColor OptionsAP, EMEA Paper RequirementsCanada, LA, US Paper Requirements

A14 color170 gsm 2pp100# gloss cover, 100# gloss text

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A74 color cover2 color textSelection GuideCategory being deleted10 Point Cover C2S50# matte sheet text

A84 color coverCategory being deleted50# matte sheet text, self cover

2 color text

Selection Guide

A92 color100gsm bond50# matte sheet text, self cover

Selection Guide

Gray shading indicates Obsolete Print Catagories

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B14 color cover270gsm Gloss 100gsm bond10 Point Cover C2S

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Catalogs


C14 color cover270gsm Gloss 90gsm silk10 Point Cover C2S

4 color text45# Coated Sheet

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D72 color160gsm tab90# index

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Gray shading indicates Obsolete Print Catagories

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Use these guidelines to determine if your publication should be JIT (just in time/print on demand) or if it would be more economical to print OS (offset/on a press). OS print jobs require an RFQ (Request For Quote) in US. If your job fits into the Either category, an RFQ is recommended, but not required. In the US, RA Strategic Sourcing will discourage or reject RFQs for jobs that fall within the JIT category. Guidelines differ for black & white and color printing, so be sure to check the correct tables.

Black & White Printing

Color Printing

Color Printing

Print Spec Sheet

JIT Printing SpecificationsRA-QR005G-EN-P - 3/29/2010

Printing SpecificationYOUR DATA HEREInstructionsNO

(required) Category:D5Select Print Category A,B,C or D from category list, on "Introduction_Catagory Types" tab11 x 17LOOSE -Loose LeafYESPre-sale / MarketingTOP

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(required) Publication Number :20P-IN071B-EN-PSample: 2030-SP001B-EN-P3 x 5SADDLE - Saddle StitchA2RIGHTCORNER

Use Legacy NumberNOYES or NO18 x 24 PosterPLASTCOIL - Plastic Coil (Coil Bound)A4BOTTOMSIDE

Legacy Number if applicable:Sample Legacy Number: 0160-5.3324 x 36 PosterSTAPLED1 -1 positionA3

Publication Title:PowerFlex DC Drive Resolver Feedback Option ModuleSample: ElectroGuard Selling Brief80 character limit - must match DocMan Title36 x 24 PosterSTAPLED1B - bottom 1 positionA5

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Binding/Stitching:STAPLED2 - 2 positionsReview key on right...Saddle-Stitch Items All page quantities must be divisible by 4.Note: Stitching is implied for Saddle-Stitch - no need to specify in Stitching Location.80 pgs max. on 20# (text and cover)76 pgs max. on 20# (text) and 24# (cover)72 pgs max. on 24# (text and cover)

Perfect Bound Items940 pgs max. w/cover (90# index unless indicated otherwise)70 pgs. min. for spine without words200 pgs min. for spine with words

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Tape Bound Items250 pgs max. on 20# no cover240 pgs max. w/cover (90# index unless indicated otherwise)4.75 x 7.75THERMALO - Thermal Bound (Tape bound - offline)A8

(required) Page Count of Publication:18Total page count including cover5.5 x 8.5 (half-size)A9

Paper Stock Color:White is assumed. For color options contact your vendor.6 x 4Post Sale / Technical Communication

Number of Tabs Needed:5 tab in stock at RR Donnelley7.385 x 9 (RSI Std)B1

Stitching Location:SIDEBlank, Corner or Side8.25 x 10.875B2

Drill Hole YES/NONOAll drilled publications use the 5-hole standard, 5/16 inch-size hole and a minimum of inch from the inner page border.8.25 x 11 (RA product profile std)B3None

Glue Location on Pad:Glue location on pads8.375 x 10.875B4Half or V or Single Fold

Number of Pages per Pad:Average sheets of paper.. 25, 50 75,100 Max9 x 12 (Folder)B5C or Tri-Fold

Ink ColorOne color assumes BLACK / 4 color assume CMYK / Indicate PMS number hereA4 (8 x 11 ) (210 x 297 mm)CatalogsDbleParll

Used in Manufacturing:NOA5 (5.83 x 8.26) (148 x 210 mm)C1Sample

Fold:NoneReview key on right...Short (must specify dimensions between folds in Comments)

Comments:C2Z or Accordian Fold

Part Number:JIT / PODMicrofold or French Fold - designate no. of folds in Comments - intended for single sheet only to be put in box for manufacturing

D1Double Gate

D2

FoldsHalf, V, Single C or Tri

Dble Parll

Z or Accordian Microfold or French

Double Gate

Short FoldD3

D4

D5

D6

D7

D8

D9

MBD000CCD74.bin

MBD000D141F.bin

MBD000E357A.bin

MBD000D05AE.bin

MBD000B37AA.bin

MBD000C2CF0.bin

MBD000CBFEF.bin

MBD000B71E5.bin

MBD000AB9B4.bin

MBD000AF7AA.bin

Documents

Installation Instructions, PowerFlex DC Drive Resolver ... · board into connector XRE on the control board (identified in the previous ... Drive User Manual, publication 20P-UM001,