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
PowerFlex DC Drive Resolver Feedback Option Module
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
PowerFlex DC Drive Resolver Feedback Option Module
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
PowerFlex DC Drive Resolver Feedback Option Module
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.
Continue with Disconnect the HIM Communication Cable on page 5.
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.
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
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.
4 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
PowerFlex DC Drive Resolver Feedback Option Module
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)
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 5
PowerFlex DC Drive Resolver Feedback Option Module
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
6 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
PowerFlex DC Drive Resolver Feedback Option Module
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
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 7
PowerFlex DC Drive Resolver Feedback Option Module
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
Resolver interface board
8 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
PowerFlex DC Drive Resolver Feedback Option Module
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
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 9
PowerFlex DC Drive Resolver Feedback Option Module
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
Resolver interface board
P2 and P3connectors
Short pins of stacker connector mate with resolver interface board connectors
P2 and P3 connectors
10 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
PowerFlex DC Drive Resolver Feedback Option Module
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)
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 11
PowerFlex DC Drive Resolver Feedback Option Module
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.
12 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
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PowerFlex DC Drive Resolver Feedback Option Module
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
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 13
PowerFlex DC Drive Resolver Feedback Option Module
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
14 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
PowerFlex DC Drive Resolver Feedback Option Module
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
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 15
PowerFlex DC Drive Resolver Feedback Option Module
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
16 Rockwell Automation Publication 20P-IN071B-EN-P - June 2011
PowerFlex DC Drive Resolver Feedback Option Module
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.
Rockwell Automation Publication 20P-IN071B-EN-P - June 2011 17
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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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Print Spec Sheet
JIT Printing SpecificationsRA-QR005G-EN-P - 3/29/2010
Printing SpecificationYOUR DATA HEREInstructionsNO
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(required) Business Group:Marketing CommercialAs entered in DocMan4 x 6STAPLED2 - 2 positionsA6
(required) Cost Center:19010As entered in DocMan - enter number only, no description. Example - 19021CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 191054.75 x 7 (slightly smaller half-size)THERMAL - Thermal bound (Tape bound)A7
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
Plastcoil Bound Items530 pgs max. of 20# (if adding cover deduct equivalent number of pages to equal cover thickness) (90# index unless indicated otherwise)
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
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