‘ALLEN-BRADLEY Bulletin 1388 DC PWM Servo Controller (Series A and B) Instruction Manual ee — — SE /Important User Information Because of the variety of uses for this equipment and because of the differences between this solid-state equipment and electromechanical equipment, the user of and those responsible for applying this equipment ‘must satisfy themselves as to the acceptability of each application and use of the equipment. In no event will Allen-Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment, ‘The illustrations shown in this manual are intended solely to illustrate the text of this manual. Because of the many variables and requirements associated with any particular installation, the Allen-Bradley Company cannot assume respoasibility or liability for actual use based upon the illustrative uses and applications. No patent lability is assumed by Allen-Bradley Company with respect to use of information, circuits or equipment described in this text. Reproduction of the content of this manual, in whole or in part, without ‘written permission oF the Allen-Bradley Company is prohibited. ‘The information in this manual is organized in numbered chapters. Read each chapter in sequence and perform procedures when you are instructed to do so. Do not proceed to the next chapter until you have completed all procedures, WARNING: tells readers about hazards and where people may be injured if procedures are not followed properly. CAUTION: tells readers where machinery may be damaged ‘or economic loss can occur if procedures are not followed. properly. ‘These reader-alerts help you identify: ‘The probability and severity of hazards. ‘The probability and severity of damage. ‘© The consequences of improper use. ‘¢ How to avoid these consequences.Page | Table of Contents Table of Contents Chapter! Title Page Section 1 Introduction 1.0 Manual Objectives 1.1 General Description 1.2 Bulletin 1388 Series B 13 Standard Controller Features 14 Accessories 15 Options . 116 Custom Options/ Modifications 2 Specifications 2.0 Chapter Objectives 24 21 Controller Specifications 24 22 Environmental Specifications 22 23 Controller Power Dissipation 22 2.4 Isolation Transformer Dissipation 22 3 Receiving, Unpacking and Inspection 3.0 Chapter Objectives .. 3H 3.1 Receiving BM 3.2 Unpacking . 34 3.3 Inspection : BM 34 Storing . 3M 4 Description of Operation 40 Chapter Objectives . 41 44 General .... at 42 150VDCPower Bus Supply... 4a 43 Transistorized Power Amplifier : at 4.4 Shunt Regulator + 43 45 LogicPower Supply - 44 46 — LogicControl Board... 44 47 Controller/System Fault Monitor and Detection 44 48 Isolated Current Sensing 46 49 Integral Circuit Breaker & Fuses 47 410 Line/DB Contactor ..........- a7 4.11 Dynamic Braking Resistor 47 4.12 Contingency Stop Circuitry 48 4.13 Power Up/Down Sequence 48 5 VO and Adjustment Descriptions 5.0 Chapter Objectives . 54 5.1, Signal Inputs/Outputs 54 5.2 Power Inputs/Outputs 54 5.3 Potentiometer Adjustments and Switches . 4 5.4 Plug Jumper Settings 58Title Page 6 Installation and Setup 6.0 Chapter Objectives 6.1 Mounting ..... 6.2 Wiring Recommendations 63 Wiring . 64 — Setupand Adjustment . 65 1388 Manual Operation 7 Transformers, Inductors and Shunt Regulators 7.0 Chapter Objectives ......++ ceaaeneesesnee 7.4 Bulletin 1388 Transformers . 7.2 NEMAType 1 Enclosure ... 7.3 External Shunt Regulators 74 Inductors eae 8 ‘Servomotor Operation and Maintenance 8.0 Chapter Objectives vee Bt 8.1 Receiving 8.2 Storage 83 Location . 8.4 Operation 85 Maintenance ae 86 Spare Parts en 9 ‘Troubleshooting and Maintenance 9.0 Chapter Objectives oo ceeeeee SH 9.1, System Troubleshooting ot 9.2 TestPoint Descriptions ... 96 9.3 Controller Maintenance 96 10 10.0 Chapter Objectives 10-1 10.1. Interconnect Diagrams . 10-1 " ‘Torque Block Operation 11.0 Chapter Objectives m4 11.1 Description 4 11.2 Installation and Setup 4 ‘Appendix A Dimensions . B Spare Parts List = © Motor and Controller Setup Data D ——-A-B 7900 Series Cross Reference E Machine/System Adjustment Record10 ‘Manual Objectives 1 General Description Chapter Introduction This manual is meant to guide the interface, installation, setup and troubleshooting of a Bulletin 1388 DC Pulse Width Modulated (PWM) Servo Controller. The contents are arranged in order from a general description of the controller to troubleshooting and maintenance. To censure success‘ul installation and operation, the material must be thoroughly read and understood before proceeding. Particular attention ‘must be directed to the Caution, Warning and Important statements, contained within. If additional information beyond the scope of this ‘manual is required, contact your local Allen-Bradley Sales Representative. Servo Controller and associated machinery should plan or implement the installation, start-up and subsequent ma.ntenance of the controller. Failure to comply may result in gersonal injury and/or equipment damage. p WARNING: Only personnel familiar with the Bulletin 1388 can result in component damage or a reduction in product life, Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the controller. p CAUTION: An incorrectly applied or installed controller 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. Ifyou are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook. p CAUTION: This controller may contain ESD (Electrostatic ‘The Bulletin 1388 is a transistorized servo controller which utilizes advances in power semiconductor technology to provide high performance ina modular package. Controller current ratings of 10, 20, 40 and 60 ampares are available, all with identical mounting dimensions. Each unit is self-contained and includes a number of standard features, required in anautomated machine or process. Installation, setup and system design time can be reduced with its modular package and flexible interface. The Bulletin 1388 will interface directly with Allen-Bradley numerical and programmable control products and with a variety of other eontrol equipment.Page 1-2 Introduction 1.4 General Description (Continued) 12 Bulletin 1388 Series B 13 ‘Standard Controller Features 14 Accessories The controller will handle most DC permanent magnet servomotors with simple on-site adjustments and setup. The controller contains a number of features which enhance servomotor operation including integral electronic Motor Thermal Overload Detection (MODR) and Torque Taper circuits (speed dependent current limit). The thermal overload detection trip and torque taper circuits are set simultaneously with the same potentiometer. ‘The Bulletin 1988 is offered with a line of complementary isolation trans- formers, inductors and Bulletin 1326 PM servomotors equipped with integral feedback packages and a variety of options. ‘The Bulletin 1988 Servo Controller exists in two versions; Series A and Series B. Except for minor enhancements and the addition of a 10 ampere controller, the two versions are identical in mounting and function. ‘The Series B version can be identified by the addition of a letter “B" in the catalog number, as shown in the example below. 1388B = Series B 1388 = Series A Differences between the two versions will be identified in the manual as necessary. ‘The major features and assemblies contained in the Bulletin 1388 Complete PWM Servo Amplifier RMS Armature Thermal Overload Detection Line/DB Contactor MOV Protected Input Input Line Circuit Breaker Integral 150V DC Power Bus Supply Dynamic Braking Resistor ‘Shunt Regulator and Power Bus Regeneration Circuit ‘Torque Taper Circuit (Speed Dependent Current Limit) Multiple Diagnostics and Test Points ‘Tachometer Voltage Input Range of 3to 135V DC Direct PLC? controller and CNC Interface Power Amplifier Inverse Time Overload Detection ‘Transistor Short Circuit and Thermal Overload Detection Power Bus Over and Under Voltage Detection Logic Supply Under Voltage Detection ‘The accessories available for the Bulletin 1388 Servo Controller are listed below. > Isolation Transformers (1.25, 2.6, 5.0 and 10.0kVA) » Armature Inductors (as required) » Bulletin 1326 Servomotors with multiple options including adapter kits to mount Allen-Bradley 845H or N Encoders. PLC ina rpictere trademark ofthe Allen-Bradley CompanyPage 1-3 Introduction 14 Accessories (Continued) 15 Options » Bulletin 1388-XB, Linear Accel/Decel Board. Converts step changes in the speed reference voltage to a ramp output, providing smooth accel/decel response. Used when the Bulletin 1388 will be operated ‘manually without a position controller. » Bulletin 1388-XC Velocity Reference Board. Provides a regulated velocity reference voltage of + 10V DC. Used when the Bulletin 1388 will be opercted manually without a position controller. The following standard options may be supplied with the Bulletin 1388 Servo Controller. Provisions have also been made for custom options. Contact your local Allen-Bradley Sales Representative to discuss application requirements not listed in this chapter. The options will be designated in the controller part number as described in Chapter 3. ~ Auxiliary Contact on Contactor (Option A) ‘A form C tye contact block will be mounted on the power line/DB contactor. All three terminals are brought out to power terminal block, A2TBI. A normally closed contact will be between terminals, A2TB1-10 aad 11 and a normally open contact between terminals A2TB1-11 and 12. The contacts are rated at 10A, 250V AC. ~ Current Rescaling of 20A Unit (Option B) ‘The 1388-AV20 motor overload detection and torque taper circuit can be adjusted to allow operation with a servomotor rated as low as 8 amperes. Below 8 amperes, circuit tolerances, drift, ete. affect the accuracy of these circuits. For applications where a DC motor with a continuous current rating from 4 to 10 amperes is used, the 1988-AV20 controller can be rescaled to provide 10 amperes continuous, 25 amperes peak. This allows the motor overload detection and torque taper circuits to work properly at the lower current ratings. IMPORTANT: The above description is included to define this option on the 1388-AV20. New applications use the 1388B-AV10. ~ Current or Torque Block Operation (Option C) ‘When the velocity loop circuitry is within the position controller, the Bulletin 1388 can be configured to operate asa current or torque amplifier. A current command can be applied to terminals ASTB1-6 and 7 or 6 and 8 instead of a velocity command (5V DC=250% current), To guard against DC motor damage, an analog signal proportional to motor speed must be supplied. This allows the torque taper circuit to be functional and operate the servomotor within its commutation limits. ~ External Shunt Regulator (Option D) ‘The Bulletin 1388 contains an internal power resistor that is part of the bus voltage shunt regulator circuit. Some applications such as an overhauling load cause excessive regenerative energy that must be dissipated. For these applications, an external shunt regulator resistor assembly rated for 625 to 675 watts continuous can be supplied for customer mounting. Refer to Chapter 7 for further information.Page 1-6 Introduction 16 Custom Options / Modifications ‘The Bulletin 1988 has a limited number of custom options/modifications available. The type of option can be identified by noting if the controller catalog number is followed by a three character alphanumeric code (ie. 1388-AV20-A03), This code is sequentially assigned at the factory as options are provided per customer specifications. ‘The Bulletin 1988 s available with custom modifications to meet varying application requirements. The custom modifications documented at the date of publicationare listed below. Some modifications are designed to supply additional outputs from the Logic Control Board via an optional connector (A3J2). When supplied, this connector is located on the middle, right side of the Logic Control Board (see Chapter 5) and can have up to four outputs as described. For options not listed or for other custom options'modifications, contact your local Allen-Bradley Sales Representative, A010 Logic supply output voltage for external use. 4: 12V 9¢ at Sma [8312-1 (minimum impedance = 2,500 ohms) Commen ‘4312-2 (minimum impedance = 2,500 oh) “TRV Cat sma, ‘4312-3 (minimum impedance = 2,500 ohms) SVC at 10ma ‘8312-4 (minimum impedance = 5,000 ohms) A0z Modified motor overload detection circuit for use with printed cireuit type DC servomotors. Causes the electronic motor overload (MODR) to trip within 2-3 seconds onan overload (normal time is 2-7 min.) A030 Current analog output (torque indication) and normalized tach voltage (motor speed indication) for external use. Current Feedback: SV DC=250% Rated Current 31210 Common 3122 Sealed Tach Output (15): +5V DC = Max Speed 31230 Butfered Speed Reference (VC): +5VDC=Max Speed 312-40) A04 (Obsolete)® Power transistor disable. This option is superseded by the AO6 option for all new installations. The A04 option must be used for replacement purposes only. Output Transistor Disable 312-1 Common 3122 Connecting and maintaining A3/2-1 to A312-2 will tur the power transistor output off to theservomotor. IMPORTANT: The power contactor and SOV DC bus supply willremain, ‘energized in this condition A05@ Anti-backlash/electronic counterbalance (use with 1388-XA). Preload Output ‘8312-1 (minimum impedance = 1 megohm) Preload Input ‘8312-2 (minimum impedance = 1 megohm) Velocity Error Output 312-3 (minimum impedance = 1 megohm) commen ‘A312-4 (minimum impedance = 1 megohm)Page 1-5 16 Custom Options / Modifications (Continued) 17 UtListing Introduction 06098 Power transistor enable (N.O. contact only) Output Enable a3 Output En 3122 0700 Power transister enable with current analog output. ‘Output Enab aan ‘Output Enable 3122 Current Feedback: +5V D¢=25086 Rated Current 231230 Common Perey © When the A06 ttodifcation installed, the Enable input (A3TBI-12.& A3TB1-13) ofthe Bulletin 1388 wl energize the Line/DB contactor ony, without enabling the power ‘output stage. Macing a contact across A312-1 and A3I2-2 and closing itwill enable the ‘output power sage providing the contactor has been energized fist. The contactor, Switch must be sapable of operating at 12V DC and 25mA. When the switch is opened {Glsable state) the power contactor and 150V DC bus remain energized, with no torque ‘being produced at the motor. if the contactor switch is opened while the motor rotating, the motor will coast (no dynamicbraking) toa stop. IMPORTANT: The Bulletin 1388 contains a definite purpose contactor thats not tobe ‘energized! de-energized more than twice an hour on a continuous basis. The contactor Iscycled everytime the Enable signal is applied to terminals A3TB1-12 and 13. The life ‘of the contactor may be reduced considerably if this ce is exceeded. Contact your local Allen-Bradley Sales Representative for addtional information. ‘© The AO7 option combines the functions of A06 with an analog output proportional to current (torqueindiation). See Note © for further information on the power transistor enabie function. @ Maximum current draw mA, Use ameter with at least 10 megohm impedance. © only one options available per controller. © tfinput power & to be cycled more than twice per hour, this option must be used ‘The Bulletin 1388-AV10, AV20 and AV40 Servo Controllers are now Listed by Underwriter's Laboratories Inc. as Industrial Control Equipment according to UL 508. In order to maintain this rating, the 1388 must be used in conjunction with a 1388 Isolation Transformer and ‘a motor that incorporates a thermal protector (1326D). The motor thermal protector must be connected to the user's control circuit in such a ‘way that if it opens, the controller will be disabled. Refer to the Interconnect Diagrams presented in Chapter 10 for further information.20 Chapter Objectives 24 Controller Specifications Chapter Specifications Chapter two contains the electrical and environmental specifications for the Bulletin 1388. Refer to Appendix A for Dimensions. ‘The general specifications of the Bulletin 1388 are provided in the listing below. The specifications are divided when necessary for the various controller ratings. 13888-AVI0 13888-AV20 73888 AVAO 7388-aveo © Wominal Output Voriage 150v DC 150v 0 T50vC 150vDC ‘Continuous Current TOA 2A A con Peak Current 25a SOA 7008 1500, ‘Continuous Power Output ‘O75 KW TSkW 30KW “45k Peak Power Output 3750 754W 15kW. 25kW Minimum Gireuit Inductance 09 mH OS mH ami 04 mH king Resistor 75 Ohms 15 Ohms 1.0 Ohm (075 0hms king Resistor Power Rating 100 Watts Too watts Too Watts sOWatts Internal Shunt Regulator Power Capacity, 51 Watts Si Watts St Watts ‘a5 watts ‘External Shunt Resistor NA Ohms ‘Ohm Ohms “External Shunt Resistor Power Capacity = swat GA 7S watts Tnput Greuit Greaker Rating BS AIRNS, T6AIRMS 25 AIRMS 35 ARMS “Grcuit Breaker Interrupt Rating 3500 ‘3500 5000 A 50008 StatieGain 25AImV, Amv TOA Inv. TSAmV 2@37) 231042) 2310-42) 34(15.40) ALL CONTROLLER RATINGS Form Factor (at minimum inductance) 103 or tess Peak Current Limit Adjust 10 to 250% of Rated Current ‘rive Efficiency (minimum atrated oad) 3% Modulation Frequency 5000 He (= 10%) Drift referred to input TORVITC, Input Voltage Power: 120V AG, Three Phase Control: 35.5V ACC. Single-Phase ‘Wax RMS Short Grault Current aammetvica 16008 Deadband Zero “Ambient Temperature tos C GF to a0" F) ‘Storage Temperature O10 65°C (BP to 149A) Relative Humidity 520959 Non-Condensing ‘Akitude 7000 Meters (3300 Feet) © Series acontroliers OnlyPage2-2 Specifications 22 Environmental Specifications 23 Controller Power Dissipation 24 Isolation Transformer Dissipation ‘The Bulletin 1388 must be mounted in an enclosure that is clean, dry and ventilated by filtered or cooled air. Enclosures vented with ambient air must have appropriate filtering to protect against contamination caused by oils, coolants, dust, condensation etc. The air temperature around the controller must be kept between 0 to 60°C (32° to 140°F) and the humidity between 5 and 95%, non-condensing. ‘The Bulletin 1388B-AV40 and 1388-AV60 are equipped with an integral cooling fan, while the 1988B-AV10 and 1388B-AV20 are convection cooled. The general flow of air through the unit must be maintained by following the recommended spacing guidelines found in Chapter 6. The Bulletin 1388 can operate at elevations to 3300 feet (1000 meters) without derating, hewever, the current rating must be derated by 3% for each additional 1000 feet (305 meters) up to 10,000 feet (3050 meters) Consult with your local Allen-Bradley Sales Representative prior to operation under these conditions. Table 2.A expresses power dissipation of the Bulletin 1388 Servo Controller, Table 2.8 Bulletin 1388 Power Dissipation (watts) Percent Current Drawn __1389B-AVI0__13858-AV20_—15888-AV40__1388-AV60 20 0 120) 210 300) 20 75 145) 250 350) 60 35 175) 310 a0 30 35 210 390 560) 700) Tio) 260 480 700 Note: Power Disipation figures shown ae fr estimation purposes only ‘The power dissipation characteristics of the Bulletin 1388 Isolation ‘Transformer are shown in Table 2.B. Table 2.8 Bulletin 1388 Isolation Transformer Power Dissipation (watts) Percent Power Drawn _125kVA_2.5kVA_S.0RVA__7.5RVA_10.08VA, as SCS SiO 0 35 50 700) 750) 200) 6 38 75 150) 225 300) 30 50 700) 200) 300 400. 700 0 725, 250) 375 500) Note: Power Disipation figures shown ae fr estimation purposes onyChapter Receiving, Unpacking and Inspection 30 Chapter Objectives Bt Receiving 32 Unpacking 33 Inspection 34 Storing Chapter 3 provides the information needed to unpack, properly inspect and if necessary, store the Bulletin 1388 and related equipment, The section entitled Inspection provides a complete explanation of the Bulletin 1388 catalog numbers. Itis the responsibility of the user to thoroughly inspect the equipment before accepting the shipment from the freight company. Check the item(s) received against the purchase order. Ifany items are obviously damaged, it is tae responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill. Should any concealed damage be found during unpacking, itis again the responsibility of the user to notify the freight agent. The shipping container mustbe left intact and the freight agent should be requested to make a visual inspection of the equipment. ‘Remove all packing material, wedges, or braces from within and around the controller. Remove all packing material from the cooling fans (if equipped), heatsink ete. IMPORTANT: Before the installation and startup of the controller, a general inspection of mechanical integrity (i.e. loose parts, wires, connections, packing materials, et.) should be made to guard against problems during start-up. After unpacking, check the item(s) nameplate catalog number against the purchase order. An explanation of the catalog numbering system is included as an aid for nameplate interpretation. Refer to the following pages for complete nomenclature, ‘The controller should remain in its shipping container prior to installation. Ifthe equipment is not to be used for a period of time, it must be stored according to the following instructions: ¢ Store ina clean, dry location, Store withinan ambient temperature range of 0 to 65° C (32 to 149°F). Store within a relative humidity range of 5% to 95%, non-condensing. ‘© Donot storeequipment where it could be exposed toa corrosive atmosphere, Donot store equipment in a construction area.Page 3-2 19, Unpacking and Inspection ISOLATION TRANSFORMER First Second Third Fourth Fifth Position Position Position Position Position Bulletin Primary Voltage | _ Secondary Number Type kVARating | & Frequency Voltage. Code Description | No, kVA | Code Input ode Description T Transformer | 012 125| 0 2aovasovac, | R 120VAC,3—ph. Opencore | or, 25 3-ph., OH ‘and 4Windings at Coil AG eae BB.SVAC 1p. CT 100 10.0 pest N 208/230/460 S7SV AG 3 ph 60 He NEMA TYPE 1 TRANSFORMER ENCLOSURE KIT 1388 - TA2 First Second Position Position Bulletin Accessory Number Module Letter Descrintion TA2 Fits allkVARatings on Bulletin 1388, 1389 and 1391 polation TransformersPage 3-3 Receiving, Unpacking and Inspection SERVO CONTROLLER 1388B- A Vv 40 - A - AOO 60 OACont./150A, Peak fit second | thie rourth rite sian pelt, | Sian | petty | —Featn | pon | posltbn Nominal utput standard Bulletin: ‘Type Voltage Under Continuous Options yecial rite | cormtcion | OMBEUT | Secs acting | mtn | modltations Code Description | Cade Description | Letter Voltage | No. Rating ' 3 character, 1 ‘sequentially numbered eae ne ci cece coltrane en (aca ra cica Re coal a 1 | Bletondignrc ian > mown | | ened 40 4ACont./100A ‘ a Letter Description ‘A Auxiliary Form CContacton Main Power Contactor (1.0. and N.C) © Controler Configured as Current or Torque Amplifier D External shunt Regulator Resistor (675W) ‘Always Order Resistor Package {1388 MOD-SRBEA when -D Option is ordered. ACCESSORIES - MODULES 1388 - X B First Second Third Position Position Position Bulletin Accessory Number Module | Accessory Letter Description BAccel/Decel Board w/Mounting Rack © Velocity Reference Board w/Mounting RackPage 3-4 Receiving, Unpacking and Inspection ACCESSORIES - INDUCTOR 1388 - L 5 20 First Second Third Fourth Position Position Position Position DC Continuous Inductance Bullet Typ% Current Rating at Number | Construction | (250% without sturatng) 5000 Hz Code besciption | code Description No, Inductance Applicable Controler L Inductor, | 10. 10Ampare 5 0SmH —13888-Av20 OpenCore | 20 20Ampare 2 02m —_13888-AV40, AVEO anacol 40 40Ampere 10 10mH — 33008-av10 60 60Ampere SERVOMOTOR First | Second | Third | Fourth Fifth Sixth Seventh Position | Position | Position | Position | Position Position Position Bulletin Factory Motor Motor | Factory Installed Number | Type Use | Series | Length Winding ‘Options Code Type Motor | sequentially | sequently i frameeries | numbered for | lettered foreach D oe reach motor | motorlength to Servo Sequentialy | fremeseriesto. | “designate the motor Tetteredto | "“indiate | specific motor PuType indeate | inceasing stack | winding motorirame | orframe length. | characteristics. Code Description ‘AL 72in-th, Holding Brake w/90V DC Coil ‘AQ 168.n-tb., Holding Brake w/S0V DC Coll AS B64intb,, Holding Brake w/90V DC CoilPage 3-5 Receiving, Unpacking and Inspection SHAFT OIL SEAL KIT First Second Third Fourth Fifth Sixth Position Position Position Position Position Position Bulletin Shaft Motor Motor Number Type Seal Material Series Mounting Code Description Letter Type | Letter For1326A8 | Number Description MOD Modifier v vin | ppAseries | 1 std.tnch tonkie averse cDPSSeries BRAKE POWER SUPPLY RECTIFIER 1326 - MOD - BPS First Second Third Position Position Position Bulletin Number Type Description ‘Code Description | Code Description MOD Modifica. | aps Single-Phase, ton Kit FulbWave, screw Mount Rectifier. TISVACInput, S0V DC OutputPage 3-6 Receiving, Unpacking and Inspection FEEDBACK OPTIONS - CABLES First Second Third Position Position Position Bulletin Cable No. Type Length Letter Type Code Description ceu aston | 1515 Encoder aw 100 100" FEEDBACK OPTIONS - 845H OR N ENCODER FEEDBACK MOUNTING ADAPTER KIT 1326DP-MOD - Mi - C1 First Second Third Fourth Position Position Position Position Mounting Bulletin Adapter Kit Coupling size No. Type For.. For.. Code Description | code MotorSeres | Code Motor Series size- Motor Stub Shafeto-Encoder Shaft MOD Modifies. | M1 DPA. DPC, tion kie™ PED, | C1 DPA, DPC.DPE, 3/8” 10 3/8" ew Pw M2 DPK,DPP, | C2 DPL,DPK,DPM, 1/4" t03/8" Ps, DPU, ‘PP, DPS, OPU. Pw. * Kit includes Servo Clamps, Motor Coupling and Mounting Adapter IMPORTANT: This Kit Does Not include an 84SN Encoder,Page 3-7 Receiving, Unpacking and Inspection FEEDBACK OPTIONS - FEEDBACK COUPLING (included in all Feedback Mounting Adapter Kits) 1326 -MOD- C1 First Second Third Position Position Position Bulletin No. Type Coupling size code Description | Code MotorSeries MoD Modifica | cy 3/8"t03/8" tionkit” | @ 38rt0 1/8" FEEDBACK OPTIONS - RESOLVER FEEDBACK PACKAGE 1326DP - MOD - M1 —RC 1:2.5 First Second Third Fourth Fifth Position Position Position | Position Position Bulletin Metor Resolver Gear Ratio No. Type Type Type Input:Resolver ode Description | code Motor Series MOD Modifica. [M1 — DPA.DPC, ode Description 1:1 1Tumof the MotorShaftto1 took ore or. : umof the Resover Dew | |a:2 1 Turn of the Motor Shaftto2 Ma DPK.o0P, i Tarn of the Resolver Dre bru, ! FU, | |xa5 1Tumaf te Motor shattto2.s ora ; Ture ofthe ResoWver *Kitincudes Resolver, Motor Mounting 1 [HS Hamat he Motor sheets Adopter Mating Connecter, Motor i Goepling and af Mourning Haraware i cody Typeluse Dexintion RC | Receiver-use with | 2 Pole Harowe ‘Ac Series #2008 | 11BRW-300-F-58A c120,123- | or equivalent RD | Transmitter-use | 2Pole Harowe with AB Series | 11BRCX-300-c10/6 ‘8600 and Creonies | oF equivalent REC4096 Board40 Chapter Objectives at General 42 150V DC Power Bus Supply 43 Transistorized Power Amplifier Chapter Description of Operation Chapter 4 is intended to familiarize you with the Bulletin 1388 circuitry in terms of function and operation. This will also help you to better understand and perform the installation and start-up procedures presented laterin this manual. ‘The Bulletin 1588 PWM Servo Controller is made up of the following: 150V DC power supply, transistorized power amplifier, shunt regulator circuit, logie power supply, Logic Control Board, (including fault monitoring ané protective circuits), isolated current sensing, circuit breaker, line/DB contactor and dynamic braking resistor. The intended use of the Bulletin 1388 is to control the speed and torque of a DC permanent magnet servomotor in a closed loop position system. A complete servo system can be configured with a Bulletin 1388 Servo Controller, Bulletin 1326 Servomotor with integral tachometer and Bulletin 1388 Isolation Transformer. ‘The controller contains an integral, unregulated, 150V DC nominal, full load, power sugply. It consists of the power transformer input (120V AC, three-phase, 5( or 60 He), three-phase input bridge rectifier and one power supply filter capacitor (1388B-AV10 and AV20) or two power supply filter capacitors (1388B-AV40 and AV60). The capacitors have been sized to minimize the need for additional armature circuit inductance and to provide an additional measure of regenerative energy storage, ‘The Bulletin 1388 utilizes integrated power Darlington transistor modules, including free-wheeling diodes, in an “H Bridge” configuration (see Figure 4.1). The Bulletin 1388B-AV10 and AV20 have two transistor modules, each containing one half of the “H Bridge.” The 1388B-AV40 and AV60 have four transistor modules, two in parallel on each half of the “H Bridge.” The power input, output and parallel connections are made with copper bus bars and the entire assembly is attached to the power heat sink. ‘The Bulletin 1988B-AV10 and AV20 are convection cooled. The 1388B-AV40 and AV60 have integral fan cooling. The integral fan forces air over the heat sink to help dissipate added heat generated at these current ratings. A permanent magnet DC motors speed varies proportionately with the voltage applied across its armature terminal connections. The Bulletin 1388 accomplishes this by switching a 150V DC fixed bus voltage across the armature terminals at 5,000 Hz.Page42 Description of Operation 43 Transistorized Power Amplifier (Continued) Figure 4.1 -"H- By varying the width of the pulses or the duty eycle (the ratio of pulse on- time to offtime) which occur every 200ps, the effective motor voltage varies from 0 to 150V DC (refer to Figure 4.2). Ata 50% duty eycle (pulse ison for 100s), the armature voltage will be 75V DC, which is 50% of the 150V DC bus. At an 80% duty cycle, the voltage will be 120V DC or 80% of the 150V DC bus. 50% DUTY CY. 80% DUTY CYCLE Average Average Motor Voltage Motor Voltage 7 VOC imp CL Time 2004s 200 us Figure 4.2 ~ Effects of Varying Duty Cycle ‘To rotate the motor ina forward (clockwise) direction, the upper left (FU) and lower right (FL) transistors are switched on. This applies a positive voltage across the armature, making motor terminal Al become positive (assume a 50% duty cycle, which gives an armature voltage of 75V DC). 100ps later, FL is switched off and RU is switched on. The stored energy in the motor now forces current to flow from terminal Al to A2 through the free-wheeling diode in the RU leg and transistor FU. This serves to ‘keep the motor curren: at a nearly constant level and therefore helps ‘minimize motor torque ripple. 100ys later, FU and FL are switched on again for another 100us. At the end of this 100ps period, FU is switched off, RL is switched on and the stored energy in the motor now forces current through transistor FL and the free-wheeling diode across RL. When FU and FL are turned on again at the beginning of the next cycle, this entire sequence repeats itself. Rotation of the motor in the reverse (counterclockwise) direction is accomplished by turning on RU and RL in a similar sequence. This switching method efficiently distributes the loading evenly among the power transistor blocks, reduces the ripple current through the motor and helps minimize the audible noise generated by the 5,000 He switching rate.Page 4-3 ion of Operation 43 Transistorized Power Amplifier (Continued) 44 Shunt Regulator When the command is reduced to 0 volts, transistor pairs FU and RU and FL and RLare alternately switched on. This will force the motor to 0 RPM. Upon removal ofthe controller Enable signal, all four transistors are turned off. If the servomotor was rotating at the time, its rotational and electrical energy would regenerate to the power bus through the free- wheeling diodes. This occurs because the switching. off of the motor current through the armature inductance forces the motor voltage to a level high enough to overcome the bus voltage and sustain current flow through it by regenerating energy back into the power bus. ‘The armature current through the motor will rise and fall with the application of tae 150V DC bus, creating a current ripple. The current rises and decays as the armature circuit L/R time constant. The 5,000 Hz switching rate, in conjunction with the armature circuit inductance, helps minimize this ripple and provide a smooth torque output at the servomotor shaft ‘This low ripple results in an extremely smooth rotation of the servomotor shaft and reduced motor heating which provides a significant increase in utilization of tke continuous torque of the motor. The Bulletin 1388 has low minimum inductance requirements which helps reduce the need for an external inductor to achieve this. Figure 4.3 shows a current waveform of a DC servomotor operated by a Bulletin 1388. Average Current 150 DC Bus Voltage 7 voc Figure 4.3 ~ Current Waveform ‘The controller as an integral shunt regulator circuit that reduces the power bus voltage if it exceeds 235V DC. This increase in power bus voltage above the 150V DC nominal is usually caused by excessive regenerative energy being returned to the bus. Upon sensing that this level has been exceeded, a power resistor is placed across the power bus until it decays :0 213V DC. The integral shunt regulator can help satisfy the majority of applications. Additional shunt regulating capability can be added in the form of an externally mounted power resistor. See Options in Chapter 1 for details. ‘The shunt regulator provides an additional function. Each time the Enable signal is removed or a fault occurs, the line contactor opens and the shunt regulator discharges the 150V DC power bus to less than 30V DC, usually in ess than 5 seconds. This reduces hazards of electrical shock during system maintenance and repair.Page 4-4 Description of Opers 44 Shunt Regulator (Continued) 45 Logic Power Supply 46 Logic contro! Board 47 Controller/System Fault Monitor and Detection (1388B-AVscx - D) will result in a slower than normal decay time of the 150V DC Power Bus. Hazardous voltages may be present on the external resistor package. A hazard of electrical shock exists if contact is made with the Power Bus. Prior to servicing the unit, verify that the Power Bus has decayed to 0V DC by connecting a voltmeter to test point “NB” and “COM” on the Logic Control Board p WARNING: Use of the External Shunt Regulator Option ‘The Bulletin 1988 control logic voltage is +12V DC and +5V DC. It is generated on the Logie Control Board and receives its input, 35.5V AC center-tapped, from a tertiary winding on the power input transformer. ‘The Logic Control Board is the printed circuit board that is readily accessible from the front of the controller. It contains all circuits, necessary to control the Bulletin 1388. These circuits include: the logic power supply regulators and capacitors, velocity and current loop, fault detection and annunciation circuits, power-up/power-down logic, PWM. generation and forward‘reverse controlling circuits. The Bulletin 1388 ‘System Block Diagram found in Figure 4.6, shows these circuits. The following section describes many of the functions and operations performed on the Logie Control Board. A number of fault menitor and detection functions exist on the Bulletin 1388 that guard the controller and help to minimize motor and system faults. The occurrence ofa fault will cause the controller to disable itself. In this condition, the power output stage is disabled and the line/DB contactor is de-energized. Fault conditions are latched in the fault, monitor detection circuitry. They are reset by removing and reapplying voltage to the isolation transformer. Overvoltage Protection - The controller continually monitors the 150V DC power supply voltage for an overvoltage condition. If the bus voltage exceeds 235V DC at any time, the integral shunt regulator becomes active and places a power resistor across the bus until it drops below 213V DC. Ifthe voltage exceeds 265V DC, the controller disables itself and indicates an overvoltage fault. ‘Undervoltage Protection - If the logic supply voltage drops to 90% of ‘nominal or the power bus voltage drops below 75V DC, the controller disables itself and indicates an undervoltage fault. Overtemperature Protection - The heat sink and internal shunt regulator resistor have overtemperature sensing devices attached to them. Ifthe 150° C (302° F) trip point of either is exceeded, the controller disables itself and indicates an overtemperature fault. Heat sink overtemperature may be due to either a continuous transistor overload or loss of power to the irtegral cooling fan. ‘Shunt regulator overtemperature would be caused by an excess amount of energy being retumed to the Power Bus. Additional shunt regulating capacity may be required if this condition occurs frequently.47 Controller/System Fault Monitor and Detection (Continued) IT Current Protection - A fixed time vs current monitoring circuit contains a model of the power transistor transient and continuous thermal capability. When current through the output transistors exceeds their continuous ratings, this circuit compares the duration of| the overload witha fixed value oftime. Ifit is exceeded, the circuitry begins to reduce the available peak current. Ifthe overload persists, the circuit will continue to reduce the current to 20% of the current setting, ultimately reaching the continuous rating of the controller. Removal or reduction of the overload will result in the peak current limit being restored. This action essentially maintains constant power to the power transistors. Figure 4.4 shows the time vs current ratings and relationships ofthe 1388 in a 60° C (140° F) ambient temperature. ‘Transistor Overload Protection - Every power transistor in the power amplifier is consinuously monitored for overeurrent. Ifthe current through any single device exceeds 400% of rated controller current, the controller disables itself and a fault indication is given. This protection is active on line-te-line shorts and will protect against line-to-ground faults ifthe transformer neutral point (Xo) is grounded. Servomotor Thermal Overload Detection -The Bulletin 1388, contains a circuit that has been designed to simulate an ambient insensitive heater element type thermal overload. It is adjusted by setting potentiometer MODR to a position that represents the continuous current rating of the servomotor. This circuit can be disabled by inserting jumper P2 ‘The MODR pothas ten graduations representing 10% increments of the controller's continuous rating. Motor continuous current is divided by controller contiauous current and multiplied by 100. This result is then rounded to the next lowest increment and the pot is set to this point. The pot has a usable range of 40 to 100% (+15%). Below 40%, circuit offsets, non-linearities, etc. increase the tolerance of the setting beyond 15%. Ifit is desired to operate a motor that has a rating below the 40% setting, an external thermal overload in series with the motor armature is recom- mended, The RMS thermal overload detection trip point and the current time relationship for a MODR setting of #4 to #10 is shown in Figure 4.4, JOUTPUT CURRENT VERSUS TIME | 200 \z HH | 8 z cl } | mt t Ct + 7 10 1 “00 "0000 seconos Figure 4.4- Time vs Current Ratings and MODR Circuit AdjustmentsPage 4-6 Description of Operation 47 Controller/System Fault Monitor and Detection (Continued) 48 Isolated Current Sensing capabilities (i. printed circuit armature DC motors) that ‘are measured in seconds instead of minutes. They may be damagec when subjected to excessive overloads. If motors of this type are used with the Bulletin 1388 Servo Controller, consult your local Allen-Bradley Sales Representative. Factory alterations can be made to the time vs current characteristics of the MODR Circuit (option A02) that will, place its operating range within the thermal limits of the motor. Servomotor damage may result if MODR circuit alterations are not made. p CAUTION: Certain servomotors have limited overload IMPORTANT: The MODR circuit has been designed to simulate a heater element type overload. Itallows a DC servomotor to be overloaded for various percentages of its continuous rating for varying amounts of time (in minutes). This has been implemented on the Bulletin 1388 tn take advantage of the short term overload capabilities of iron core servomotors, Torque Taper Circuit - A DC servomotor can be supplied with many times its rated current for short periods of time. As the speed of the servomator increases, its peak torque capability must be restricted so that its sparking or commutation limit is notexceeded. The Bulletin 1388 contains a Torque Taper Circuit that reduces the maximum current available to the motor as speed increases with a peak value that is 4.5 times its rated current. This function can be disabled by inserting jumper Ps. ‘The current is restricted as a percent of the motor’s continuous current (set by the MODR pot) and as a function of its speed (set by SW1, SW2 and SW3). Three ranges, each having a different peak to continuous reduction ratio are available by setting plug jumpers P3and P4, The values are listed in Table 5.E and are a percent of the motor’s continuous current rating. ‘The actual current value however is designed not to exceed the current rating ofthe Bulletin 1388 being used (ie. a 20A motor on a 1388-AV20 will have a peak current of 50A, not 20 X 4.5 = 90A). In addition, the Peak Current Limit Adjustment pot (ILIM) can lower the peak current allowed by the Torque Taper Circuit. This circuit is extremely useful when operating a low current servomotor on a larger servo controller (i 20A motor on a Bulletin 1388B-AV40). Armature current sensing is accomplished with a Hall Effect sensor. ‘The sensor is a semiconductor device which develops a precise, linear voltage as a functior of a magnetic field applied across it. A loop of wire (in the controller) in series with the motor armature generates this ‘magnetic field. The sensor is positioned in this field and its output is amplified and used for current monitoring and limiting on the Logic Control Board. Thisresults in an electrically isolated current feedback signal. The sensor has no user adjustments, is factory adjusted and set to a particular size of eontroller. Its output, regardless of controller power rating, will be 5V at 250% of continuous current.Description of Operation 49 Integral Circuit Breaker & Fuses 4.10 Line/DB Contactor (K1) 4m Dynamic Braking Resistor (R2) ‘The control logic and power circuitry are protected against overcurrents by two sets of fuses and a circuit breaker. The DC bus power supply and input rectifier utilizes a three pole magnetic circuit breaker (MCB) located in frontof the power input terminal block (A2TB1). The logic control circuitry uses two fuses located at the lower right hand portion of the Logic Control Board, The power contactor and fan (when used) are protected against overcurrents by two fuses located under the upper left corner of the Legie Control Board (Series A). On the Series B 1388-AV10, AV20 and AV40 these fuses are located adjacent to the input circuit breaker. Refer to Appendix B for specific locations. ‘The three-phase incoming AC line is opened by three of the four contactor poles whenever the Enable signal is removed or a fault occurs, This operation, in conjunction with the shunt regulator, discharges the 150V DC power supply to less than 30V DC. The logic supplies stay energized except when voltage is removed from the incoming power transformer, IMPORTANT: The Bulletin 1388 contains a definite purpose contactor that isnot to be energized /de-energized more than twice an hour on a continuous basis. The contactor is cycled every time the Enable signal is applied to terminals A3TB1-12 and 13. The life of the contactor may be reduced considerably if this cycle is exceeded. If input power must be cycled more than two times an hour, use option A06 as described in section 1.6. Contact your local Allen-Bradley Sales Representative for additional information. ‘The normally closed fourth pole of the line contactor places the integral dynamic braking resistor across the motor armature whenever the contactor is de-energized. The resistor is designed to stop a free wheeling motor with onetimes the reflected load inertia. The resistor values used on the Bulletin 1388B -AV10, AV20, AV40 and AV60 are 2.0, 1.5, 1.0 and 0.7 ohms, respectively.Page 4-8 Description of Operation 412 Contingency Stop Circuitry 413 Power-Up/Down Sequence ‘The Bulletin 1388 contains a definite purpose line/DB contactor which is controlled by the Enable logic circuitry. A hardwired “Contingency Stop” string breaking the three-phase power to the Bulletin 1388 is recommended. The motor will DB to a stop when the circuit is opened. Refer to Figures 6.4and 6.5 for recommended contingency stop circuitry. A A WARNING: The Enable control circuitry in the Bulletin 1388 includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of Tiquid, gas or solids exist, an additional hardwired contingency stop circuit may be required. Refer to the codes and standards applicable to your particular system for specific requirements and additional information. A device that removes AC input power when a contingency stop is initiated can be used. When AC power is removed, the motor will DB toa stop. WARNING: The usor has the ultimate responsibility to determine which stopping method is best suited to the application and will meet applicable standards for operator safety. Figure 4.5 describes the various steps involved in the power-upidown ‘sequence of the Bulletin 1388 controller.Page 49 Description of Operation POWER-UP SEQUENCE | POWER-DOWN SEQUENCE | [APPLICATION OF 120V ACBUS SUPPLY (oower-up) 2) Logicsupplies power-up. ») Shunt regulator discharges the power bus supply. ©) Hno fautsare encountered, the fault relay contact closes. The fait relay will audibly “click” on a power-up sequence. v (ONE(1) SECOND DELAY Vv ENABLE SIGNALS APPLIED 2) Shunt regulator becomes active, ») Line/D8 contactor closes and the 150V DC power busisenergized. © ©) Dynamic braking resistors removed from the ‘motor armature circuit <) Approximately 0.200 seconds ater, the output power transistors are enabled, (©) Fault contact remains closed Fault aul out ‘ 1 ENABLE SIGNAL REMOVED (powerdown) 2) Output power transistors are disabled. ) Line/D8 contactor coil and 150V DC power bus are de-energized. © ©) Dynamic braking resistor i placed across the motor armature 6) Faultrelay contact remains closed. ©) Shunt regulator discharges the power bus supply armature FAULT CONDITION OCCURS (See chapter 9) 2) Output power transistors are disabled, ) Line/03 contactor coilisde-energized and 150V OC power buts de-energzed. ‘@_ Dynamic braking resistors placed across the motor 6) Fault relay contact opens 2) Shunt regulator discharges the power bus supply. © IMPORTANT: The Bulletin 1388 contains a definite pursose contactor that isnot tobe energized/ de-energized ‘more than twice an hour on a continuous bass. The contactors eycled every time the Enable signals applied to terminals A3TB1-12 and 13. The life ofthe contactor may be reduced considerably if ths cel isexceeded. Contac your local Allen-Bradley Sales Representative for addtional information, Figure 4.5 - Power-Up/Down SequenceDescription of Operation Page 4-10 Figure 4.6 - Bulletin 1388 System Block Diagram50 Chapter Objectives 5a Signal Inputs/Outputs Chapter 1/0 and Adjustment Descriptions Chapter 5 contains descriptions of the various inputs and outputs available on the Bulletin 1388 Servo Controller. Additionally, a comprehensive listing and description of the potentiometer adjustments and plug jumpers is provided. This information is provided to help you understand some of the important aspects about the controller prior to the actual installation and start-up. In some cases, adjustment methods are provided fer use during start-up. ‘The signal inputs and outputs are located at terminal block A3TB1, which is located at the bottom of the controller (see Figure 5.1). Refer to the following paragraphs for the signal descriptions, ‘Tachometer Feedback Input (Terminals 1, 2) ‘The controller has the ability to accept and scale a DC tachometer voltage input from 3 tc 135V DC. The tachometer input is connected at A3TB1-1 and 2 and the tachometer shield to ASTBL-3, Programmable Current Limit (Terminals 4, 5) ‘The peak rating of the controller is 250% of its continuous capability. This peak current can be varied by applying 0 to 5V DC at ASTB1-4 and 5. A1V DC input will set the current limit of the controller to 50% ofits rated current, 2 volts will increase the current limit to 100%, ete. Leaving the terminals open will provide the controller with its full 250% peak available current. Jumpering the terminals will reduce the peak current to 25% of peak or less. An alternative to applying a voltage is to insert a fixed resistor across ASTBI-4 and 5, The resistors (1/2 Watt minimum) will limit the controller peak current to the values shown in Table 5.A. This input will not cause a peak current that exceeds the ILIM potentiometer setting. If LIM isset to allow 40% of the peak rating, applying a voltage that exceeds 2 volts or a resistor greater than 2kQ (greater than 40%) will have no effect.Page 5-2 NO and Adjustment Descriptions Ground stud ‘MODR Adjust —_| ——] 5w1,23, tum adjust | GAIN Adjust —_| TAC Scale Aust OFFSET Adjust | sre Signal inpur/Ourput Connector Figure 5.1 — Bulletin 1388 Input and Output Connectors aoe Power Input/Output, Connector aan Option Connector asre2Page 5-3 VO and Adjustment Descriptions St ‘Signal inputs/Outputs (Continued) Velocity Command Voltage Input (Terminals 6,7,8) ‘The Bulletin 1338 will accept up toa +10V DC velocity command signal toachieve maximum motor speed. The signal must be brought to the servo controller through an 18 gauge (minimum) shielded, twisted-pair cable, The signal can be terminated in either a differential or single ended input. Table 5.B details these connections. Refer to the Bulletin 1388 System Block Diagram in Chapter 4 and the Interconnection Diagrams in Chapter 10 for further information, Table 5.8 Velocity Command input Connection Velocity Command inputs Typeof Termination “Command High Command Low Shield Differentiat ASTBTS TASTBI-T Open & insulated “Single Ended ‘ASTBIS ASTBTS Open insulated Anverting input) ‘Single Ended ‘ASTI ASTBTSR Open insulated (Nonsinvertng Ingut) ASTBLS IMPORTANT: If the Bulletin 1388 is ordered as a current or torque block controller (1388-A V.xx-0), these contacts are used for the current command input, 5V DC=250% of the continuous rating of the controller. 35.5V AC Logic Supply Voltage (Terminals 9, 10, 11) ‘The power transformer contains 4 separate windings, each providing 35.5V AC with a center tap. This voltage is used by the servo controller to develop its internal +12 and +5V DC power supplies. Each Bulletin 1388 connected :o the isolation transformer must have its own separate 35.5V AC supply. The 35.5V AC leads are brought to A3TB1-10, ASTB1- 11 and the center tap to A3TB1-9 on the Bulletin 1388. Refer to Figures 64 and 7.1 for connection details. Controller Enable Input -CR2 (Terminals 12, 13 0r4, 13) Closure of a user supplied contact or solid state switch at ASTB1-12 and 13 (user does no: supply voltage at A3TB1) energizes the line/DB contactor and enables the power output stage. The contact or switch must be rated a minimum of 24V DC and 50mA. The controller can also 'be enabled by applying 15 to 30V DC from a remote power supply to A3TB1-4 and 13 (the 24V DC power supply of a single controller cannot be used to enable other controllers). One contact or open collector switch must be used for each controller. IMPORTANT: If this method is used, the 15-30V DC supply must be isolated so that a ground loop is not formed when using multiple controller common terminals, A3TB1-2, 3, 4 and 8. Refer to sections 6.2 and 6.3 for further information. IMPORTANT: The Bulletin 1388 contains a definite purpose contactor that is not to be energized /de-energized more than twice an hour ona continuous basis. The contactor is eycled every time the Enable signal is applied to terminals A3TB1-12 and 13. The life of the contactor may be reduced considerably if this eycle is exceeded. Contact your local Allen-Bradley Sales Representative for additional information,Page 5-4 1/0 and Adjustment Descriptions Sa Signal inputs/Outputs (Continued) 52 Power Inputs/Outputs 53 Potentiometer Adjustments and Switches Fault Output Contact (Terminals 14, 15) Application of power to the input isolation transformer energizes the logic supplies. Whea they achieve 90% of their rated voltage and no faults are detected, a contact closure occurs between ASTBI-14 and 15. This contact remains closed until a fault occurs or power is removed from the input isolation transformer. This contact is rated at 120V AC /250 mA, 24V DC/1A. Motor and Transformer Thermal Switches Both the transformer and servomotor have an integral thermal overload switch which is set to open when the rated maximum temperature of the device is exceeded. These contacts must be inserted in the hard wired machine or process stop circuit. Input and output power connections are performed at terminal block A2TB1. Refer to the following paragraphs for descriptions. External Shunt Regulator Resistor (Terminals 1. 2) The controller has provisions to accept an external shunt regulator resistor to supplemeat the integral unit. This is available for applications that recuire the dissipation of up to 675 watts of regenerative energy, The external resistor is connected to power terminals A2TBI-1 and 2. Refer to Chapter 7 for more information. Armature - Al and A2 (Terminals 4, 5) ‘The servomotor leads Al and A2 are connected to power terminals AQTBL-5 and 4 respectively. 120V AC Input (Terminals 7, 8, 9) ‘The controller requires a 120V AC, three-phase, 50 or 60 Hz input, This is supplied by the isolation transformer and is connected to power terminals A2TB1-7,8 and 9. ‘The Logic Control Board contains 5 potentiometers and 3 switches that ‘must be set to adjust the controller to the servomotor used. This section details how these adjustments can be determined. Ifan Allen-Bradley Bulletin 1326 DC Servomotor is being used, al settings and adjustments for a particular motor are listed in Appendix C. Potentiometer and switch locations are shown in Figure 6.3. Peak Current Limit (ILIM) This single turn potentiometer adjusts the maximum current available to the DC servomotor. It has ten graduations which represent 10% increments of the peak controller current capability. ‘The pot covers a range of 10 to 100% of the peak controller rating and can also be set at TP ILIM where 5V =250% continuous current. The torque taper circuit (speed dependent current limit) reduces the current available to the servomotor as speed increases. ILIM can lower the value set by this cireuit but not increase it.Page 5-5 VO and Adjustment Descriptions 53 Potentiometer Adjustments and Switches (Continued) ‘Velocity Loop Gain (GAIN) ‘The Velocity Loop Gain potentiometer is used to fine tune the response characteristics of the servo controlled system. Rotating this single turn pot clockwise increases the dynamic gain of the servo amplifier, while rotating it counterclockwise decreases the gain. It has ten graduated increments which are useful for referencing a particular setting. When used in conjunction with the velocity loop plug jumpers P6 and P7 (see section 5.4), the system response can be adjusted. Velocity Loop Offset Adjustment (OFFSET) OFFSET is a 20 turn potentiometer that provides an adjustment for velocity loop and system offset voltages, referred to the velocity input of up to 60mV. ‘Tachometer Sealing Adjustment (TACH) ‘TACHis a 20 turn potentiometer that scales the tachometer feedback signal with the velocity command signal. It is used in conjunction with tach scaling jumpers P8, 9 and 10 to allow the use of tachometer feedback voltages from to 195V DC. This adjustment can be monitored at test point TS. RMS Motor Overload Detection (MODR) [MODR sets the RMS motor thermal overload detection reference trip point and the torque taper profile simultaneously. The pot is single turn and has ten graduations representing 10% increments of the eontinuous controller rating, ‘The adjustment must be set to the increment that represents the servomotor’s full load, continuous current rating as a percent of the continuous current rating of the controller. On all Allen-Bradley Bulletin 1326 Servomotors, this value (full load current) is stamped on ‘the motor nameplate (see Figure 5.2). In addition, the continuous current ratings of all Allen-Bradley Bulletin 1326 Servomotors (available at the time of publication) are listed in Appendix C. MODR is adjustable from 40 to 100% of the controller's rating. A graph showing the time vs current relationship for each setting is shown in Figure 4.4. ‘The graduations on MODR have the following values for each size controller: 1988B-AV10 1 Ampere /Graduation 1388B-AV20 2 Ampere /Graduation 1988B-AV40 4 Ampere /Graduation 1388-AV60 6 Ampere /Graduation For example, on the 1388B-AV20, witha continuous rating of 20A, a servomotor witha 10A rating would have MODR set to graduation #5. ‘This represents 50% of the rating of the controller, which is 10A. ‘The MODR circuitry acts similar to a circuit breaker. If MODR causes the controller to trip because of an overcurrent or overload, there will be a time delay before a reset can occur. This length of time is determined by how long it takes the equipment to cool down. Other faults such as an over or under voltage can be reset immediately. See Caution statement ‘on following page.Page 5-6 VO and Adjustment Descriptions S.0.No. BULLETIN 1326 DC PM SERVO MOTOR @®) ALLEN-BRADLEY ‘The Allen-Bradley Sales Order Number willbe present here ifthe motor hat special options, Such as: shaft modifications, ete ‘The Allen-Bradley Catalog Number of the DC Servomotorislisted in this area, ‘The rated curent of the motor willbe ised caraLogno. fore, Ts value usedto determine the ‘Sttng ofthe potertiometer MOOR untoapeunment | en The suitch stings for SW 512853 willbe present here. The let digits for SW!, middle forsWi2 and the right for sW3. Any digitsto, the right ofthe decimal point should be ignored. itshould be noted that thi not the tachometer voltage constant, Bulletin 1326 DC Servomotors have tach voltage constant of 31.5V DC /T000 RPM with the exception of DPW series, which have 20V/1000 RPM: \ The manufacturers mode! number and serial umber ofthe sewomotor willbe printed Figure 5.2 - Bulletin 1326 Servomotor Nameplate Nomenclature 53 Potentiometer Adjustments and Switches (Continued) a heater element type overload. It allows DC servomotor to bbe overloaded for various percentages of its continuous rating for varying amounts of time (in minutes). This has been implemented on the Bulletin 1388 to take advantage of the short term overload capabilities of iron core servomotors. A CAUTION: The MODR circuit has been designed to simulate Certain servomotors have limited overload capabilities (i.e. printed circuit armature DC motors) that are measured in seconds instead of minutes. They may be damaged when subjected to excessive overloads. Ifmotors of this type are used with the Bulletin 1888 Servo Controller, consult your local Allen-Bradley Sales Representative. Factory alterations can be made to the time vs current characteristics of the MODR circuit that will place its operating range within the motor thermal limits. Servomotor damage may result if MODR circuit alterations are not made. Current Gain (GAIN) ‘When Option B (see Chapter 1, Options) is specified (1388-AV20-B), the Logie Control Board will contain an additional potentiometer. This single turn, calibrated potentiometer will control the current loop gain. It must be set to position “O” and rotated clockwise (CW) to reduce most current instabilities encountered during system set-up. When this potentiometer is set at position “0,” the Logic Control Board is, electrically identical to the boards used on the 1388-AV20, 40 and 60.Page 5-7 V0 and Adjustment Descr 53 Potentiometer Adjustments and Switches (Continued) Torque Taper Switches (SW1, SW2, SW3) ‘The current toa DC servomotor must be reduced as its speed increases. The voltage across its armature is proportional to this speed. When a DC servomotor has 150V DC on its armature (which is the nominal output voltage of the controller) it will rotate at a certain speed based on its, voltage constant. The DC tachometer will also output a voltage at this speed based on its own voltage constant. ‘The tachometer voltage is reduced in the controller with torque taper switches SW1, SW2 and SWS to a low voltage representing 0 to 150V DC. This voltage is shen used as a speed reference to the circuit that reduces the current to the servomotor. To simplify the setting of this reference, switches SW1, SW2 and SWS are set directly to the voltage the tachometer outputs when the motor is rotating with 150V DC on its armature. The switches are set left to right. For example, ifthe tach- ‘ometer voltageis 64V DC, then SW1 is set to 0, SW2 to 6 and SW3 to 4. ‘The range of the switches is 0 to 199V DC (setting SW1 above 1 will not result in any value except 1) when the maximum tachometer output voltage at maximum motor speed is less than 10V DC, plug jumper PLL ‘must be inserted as outlined in section 5.4. Note that when P11 is, inserted, the range of SW 1-3 is 0to 19.9 volts instead of 0 to 199. ‘The appropriate settings for the torque taper switches can be determined one of four ways: 1) The switch settings are stamped on the nameplate of all Bulletin 1926 Servomotors and are listed as “Tach Voltage at Rated Armature Voltage.” See Figure 5.2. 2) Refer to Appendix C fora listing ofthe switch settings for all Allen-Bradley Bulletin 1326 Servomotors. 38) Refer to Table 6.C for the various motor and tachometer voltage constants and appropriate switch settings. Table 5.C ‘Torque Taper Switch Settings WexorVatoge Tech Vltage constant (100080) ee ~~ os~—~OS*~«aSS*C«iSSC«SC om a a so i805) oad oad 7% 1s os 057 059 8 7 1307 032 003 0st % a % a oo a a 7 “oat aie 20 on or a 06908 017 0s 056 iz “tet owe aig taro = a a IMPORTANT: All Allen-Bradley Bulletin 1326 DC Servomotors have a tach voltage constant of 31.5V DC /1000 RPM.Page 5-8 VO and Adjustment Descriptions 53 Potentiometer Adjustments and Switches (Continued) 5a Plug Jumper Settings 4) Use the following formula to calculate the setting: Switch Seting a ‘Motor Voltage Constant x Tach Voltage Constant the motor isrunning at rated temperature (80°C) NOTE: The voltage constant at 40°C differs from the voltage constant at 25 ‘Asa generale, the value ofthe voltage constant will be: Vase) X0.85 Volts/1000 RPM ViascqX0.95 Volts/1000 RPM Ceramic Magnets KViarc) Rare Earth Magnets KVaocy 2. The DCTachometer Voltage Constants expressed in volts /1000 RPM, ‘The Bulletin 1388 has 11 points on the Logic Control Board that can be jumpered to adapt system compensation, scaling, and to defeat or enable various funetions. The plug jumpers and their functions are deseribed in Table 5.D and the paragraphs that follow. Table 5.D Logic Board Plug Jumper Settings (P1 - 11) Plug lumper Function Pr TT Current Fotaback Tip. RMS Thermal O.L Detection Defeat Torgue Taper Torque Taper Defeat ‘Velocity Loop Compensation Tachometer Sealing Toeated on the Logie Contra Tor customer we, 25pares IT Current Foldback Trip (PI) ‘The power amplifier protection circuit reduces (folds back) the amplifier peak current level as. fixed time/current relationship, if exceeded (see Figure 4.4). The removal of plug jumper P1 will cause a fault rather than a reduction in current limit whenever the fixed time/current relationship isexceeded. RMS Motor Thermal Overload Detection Defeat (P2) Ifan external motor thermal overload detection circuit is utilized, the electronic overload detection circuit can be defeated by inserting plug jumper P2. A CAUTION: Do not insert jumper P2 unless the servomotor has suitable thermal overload protection. Sustained overloads ean cause damage to the servomotor and other system components.Page 5-9 1/0 and Adjustment Descriptions 54 Plug Jumper Settings (Continued) Torque Taper Ranges (P3, 4) ‘The torque taper circuit jumpers will set control circuitry that restricts the peak currents (torque) to the servomotor as its speed increases. The circuitry has three different ranges that can be selected. The appropriate range will depend on the particular DC servomotor being used. The controller comes factory set with P3 and P4 inserted. The settings for Allen-Bradley Bulletin 1326 DC Servomotors are listed in Appendix C of this manual. If the motor is not listed, the correct jumpers will have to be determined by the following procedure: 1. Determine the maximum RPM of the servomotor in the system. the voltage required from the Bulletin 1988 to rotate it at, 3. Obtain a copy of the Speed/ Torque Performance Curve (commutation curve). The vertical axis will be speed and the horizontal axis is, torque. 4, Move in a horizontal direction from the RPM determined in step 1 to the center ofthe commutation/accel-decel zone. Move down vertically from this point to the torque axis and determine the torque value at this point. 5. Divide this torque by the continuous stall torque of the motor and multiply by 100 (.e. if torque value read is 80 in-Ibs and motor continuous torque is 100 in-Ibs, the final value would be 80). Ifthe DC servomotor is blower-cooled, the continuous stall torque rating with the blower must be used. The blower-cooled rating of a DC servomotor is typically twice its totally enclosed nonventilated (TENV) rating. ‘This value isthe peak torque the motor can supply at the maximum machine speed, expressed as a percent of its continuous output: 6, Determine the appropriate Torque Taper Range by using the voltage determined in step 2and the percent of continuous torque calculated in step 5 For example, in Table 5.E, ifthe motor voltage is 150V DC and the percent of continuous torque was 80%, then jumpers P3 and P4 would bbe inserted. This would restrict the current (torque) to the motor, at its maximum speed on the machine, to 80% ofits continuous torque. If you are uncertain as to what range to use, select P3=IN, P4=OUT. Table 5.E Torque Taper Range Settings % of Motor Continuous Current (Torque) Rating Motor Armature ~ Palaserted 'aPa P3 Removed —_P3E PS Woltage (VOC) P&Removed Inserted Pa inserted __ Removed 5 350) 50 450 450 30 SSCSOSSC«S 250 250 Ss s—STOC CCC 0 170) 300) 220) 220) 75 130) 225) 320) 320) 0 10S 105 sO 200 200) wm Om oO ss 3 a 150 Q 20 120) 720)Page 5-10 VO and Adjustment Deser ions 54 Plug Jumper Settings (Continued) 17. Ifthe peak torque value that the circuit allows is higher than desired, potentiometer ILIM can be used to reduce the peak value (refer to section 5.3 to adjust current limit), Ifinformation is not available on the servomotor to allow selection of an appropriate range, insert jumper P3 and remove P4. This range allows the least emount of current to the motor within its speed range. Consult your local Allen-Bradley Sales Representative if the correct range cannot be determined by the method described here or ifthe ‘motor requires special adjustments. ‘Torque Taper Defeat (P5) Ifitis desired to defeat the Torque Taper Circuit, plug jumper P5 must be inserted and the torque taper switches set to 999. This allows the servomotor maximum controller current as set by the peak current limit adjustment of the controller at any value of output voltage or motor speed. CAUTION: DO NOT insert jumper P35 if the servomotor maximum commutation limit will be exceeded. Damage to the servomotor can occur ifits limit is exceeded. Velocity Loop Dynamic Response (P6, 7) Three resistor and capacitor combinations can be shunted across the velocity loop amplifier. In conjunction with the Velocity Loop Gain potentiometer, inserting plug jumpers P6 and P7 will connect various sets of components which can accomodate the majority of machine systems with an inertia range of 0.03 to 1.0 in-Ibs-sec2, Ifnone of these ranges are sufficient, a set of component standoffs is available for insertion of custom components. The velocity loop small signal gain resistors are fixed on component standoffs to allow the insertion of custom components if necessary. An additional set of standoffs are available in the tachometer input circuit to provide a lead network ifrequired ‘Tachometer Sealing (P8, 9, 10, 11) Four plug jumper points are available to scale the tachometer feedback voltage tothe velocity command signal which is assumed to be a maximum of +10V DC. Plug jumper P10 is inserted for tachometers with a maximum veltage at maximum machine speed of 3 to 15V DC, P9 is for a range of9 to 45V DC and PS is for a range of 27 to 135V DC. P11 must be inserted ifthe maximum tach voltage at maximum motor speed is less than 10V DC. This will change the maximum voltage on SW1, SW2 and SWS from 199V DC to 19.9V DC to allow finer increments of torque taper reference.Chapter Installation and Setup 60 Chapter Objectives 61 Mounting Chapter 6 provides the information needed to mount, wire and properly adjust the Bulletin 1388 Servo Controller for operation. Since most start- up difficulties are the result of incorrect wiring, every precaution must be taken to assure that the wiring is done as instructed. All items must be read and thoroughly understood before the actual installation begin: proper installation. The National Electrical Code and any other governing regional or local code will overrule this, information. The Allen-Bradley Company cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this controller or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are not adhered to during installation. p WARNING: The following information is merely a guide for “Mounting dimensions for the Bulletin 1388 Servo Controller can be found in Appendix A. Chapter 2 provides information on power dissipation and environmental specifications. The controller must be ‘mounted vertically on a flat, solid surface. It must not be subjected to shock, vibration, moisture, dust, corrosive vapors, oil mist, liquid spray, ete, or temperatures that exceed 60° C (140°F) ambient. Controllers can be mounted adjacent to each other with a minimum clearance of 0.312” (7.9mm) between units and/or surrounding cabinetry ‘and non-current carrying surfaces. However, itis recommended that a space of approximately 1.0” (25.4mm) be left between adjacent units to allow easy access and removal of the snap on protective front cover. A minimum clearance of 2.0" (50.8mm) is required along the top and bottom of the unit and any adjacent components. This will allow proper airflow and wiring access. ‘The transformer that supplies 120V AC, three-phase and 35.5V AC to each servo controller should have 3” (762mm) of clearance around it and any adjacent components. This will allow for proper airflow and wiring ‘access, The transformer can be mounted in either a horizontal or vertical position, planned such that all cutting, drilling, tapping and welding can be accomplished with the controller removed from the enclosure, The controller is of the open type construction and any metal debris must be kept from falling into it. Metal debris or other foreign matter may become lodged in the circuitry resulting in component damage. p CAUTION: The installation of the controller must bePage 6-2 n and Setup 62 Wiring Recommendations General Information ‘The information supplied in this manual on wire sizes, practices, layouts, system configurations and groundingishielding techniques for the Bulletin 1388 PWM Servo Controller are presented as guidelines. Due to the diversity of applications and systems, no single method of wiring is completely applicable. IMPORTANT: Th's information represents common PWM servo system wiring configurations, size and practices that have proven satisfactory in a majority of applicetions. The National Electrical Code, local electrical codes, special operating temperatures, duty cycles or system configurations will take precedence over the values and methods listed. Refer to Figure 6.4 for controller system interconnections. Chapter 10 contains Allen-Bradley PLC & ONC Typical Interconnection Diagrams. Wire Sizes Unless noted, the wire sizes in this manual are recommended minimums and assume type MTW wire (machine tool wire, 75° C, minimum) per NFPA 79. Since ambient conditions vary widely, on certain applications, aderating factor has to be taken into account. Also, wiring to controllers or motors exceeding 50 feet (15.2 meters) in length (total includes to and from device) may case excessive voltage drops. Consult the National Electrical Code for factors on ambient conditions, length ete. Shielding Reasonable care must be taken when connecting and routing power and signal wiring on a machine or system. Radiated noise from nearby relays (relay coils should have surge suppressors), transformers, other electronic drives, ete. may be induced into the velocity command signal lines causing undesired movement of the servomotor. Likewise, the Bulletin 1388 system may induce noise into sensitive equipment lines adjacent toit. ‘To help alleviate the problem, machine power and signal lines must be routed separately. The Bulletin 1388 power and signal lines must be shielded, twisted and routed in separate conduit or harnesses spaced at least 12" (504.8mm) apart. Power leads are defined here as the transformer primary and secondary leads, motor armature leads and any 120V AC or above control wiring for relays, fans, thermal protectors ete. Signal wiring is defined as velocity command, tachometer feedback, enable lines and low level logic signal lines. Feedback, command signal and other shields must be insulated from each other and connected at a common machine or system earth ground ina “tree” fashion (i, al shields connected toa single earth ground point). This helps to minimize radiated and induced noise problems and ground loops. Refer to Figure 10.2 for further grounding information, Open ended shields itach feedback cable at the tach and velocity command cable at the servo controller) must be insulated at the source ‘end so that they do rot accidentally cause ground loops.Page 6-3 Installation and Setup 6.2 Wiring Recommendations (Continued) 63 Wiring ‘The common points on the Logic Control Board, ASTB1-2, 3, 4 and 8 are “floating.” That is, the Logic Control Board Common is not tied to ground at the factory and must be done during servo controller wiring. This Common, through one of the points listed above, must be connected tothe machine Common or system earth ground. This would be part of the “tree” grounding system for the whole machine or system electrical network. ‘The Interconnection Diagrams in Chapter 10 show suggested shield grounding arrangements that shall, in addition to the instructions provided by the position control manufacturer (NC, CNC, PLC, etc.), result in a minimal amount of system noise interference. Additional information on system wiring practices is contained in Allen-Bradley Position Control Interface Manuals listed in the Interconnect Drawings. ‘Two additional Allen-Bradley publications that list information on system wiring practices are: “Application Considerations for Solid State Controls” (publication SGI-1.1) and “General Grounding and Field Wiring Practices for Programmable Controllers” (publication 1770-4.) Grounding All equipment end components of a machine or process system shall have their chassis connected to a common earth ground point. This ground system provides a low impedance path that helps minimize shock hazards to personnel and damage to equipment from short circuits, transient overvoltages and accidental connection of energized conductors to the equipment chassis. Grounding requirements, conventions and definitions are contained in the National Electrical Code. Local codes will usually dictate what particular rules and regulations are to be followed concerning system safety grounds. codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. p WARNING: The National Electrical Code (NEC) and local Earth Ground It is suggested that a #8 AWG wire (minimum) be connected between the machine/system earth ground point and each of the points listed below: 1. The isolation transformer ground (GO) terminal. 2. The servo controller earth ground stud. 3. The isolation transformer secondary neutral point (XO) if desired or required by local codes. 4, A:#6 AWG wire (size based on the wiring connected to the actual servomotor) attached to the motor case.Page 6-4 Installation and Setup 63 Wiring (Continued) Signal and Logic Supply Inputs Recommended wiring for the various signals and logic power supply are provided in the following paragraphs. Velocity Command - Wiring consists of a twisted, shielded pair of #18 ‘AWG or larger (Belden #8760 or equivalent). The shield isto be open and insulated on the servo controller side (for single ended input) and routed back through the position controller and ultimately connected to the machine ground stud. ‘Tachometer Feedback - Wiring consists ofa twisted, shielded pair of #18 ‘AWG or larger. The shield is to be open and insulated on the servomotor side and connected to the servo controller shield input. Enable Input ~ Wiring consists of a pair of #16 AWG or larger wires. Fault Contact - Output wiring consists ofa pair of #16 AWG or larger ‘wires, depending on the size of the load the contact is making/breal 35.5V AC Center Tepped Logic Supply Voltage - Consists of three ‘twisted #20 AWG or largor wires. ‘Motor and Transformer Thermal Protection Contacts - Each set consists of a pair of #16 AWG or larger wires, depending on the size of the load that the contacts are making/ breaking. Controller Three-Phase Input Wire Sizes ‘The maximum wire sizes that the Bulletin 1388 controller will accept are listed below. ControllerCstalog Number Wire Size 13888-AV10 AWG 13888-AV20 #rawe 13888-AVa0 #oawG 1388-av60 #10 AWG Isolation Transformer Three-Phase Input Wire Sizes ‘The minimum recommended wire sizes for the isolation transformer are listed below. Primary input ‘Transformer kVA Voltage 125 25 50 15 100 2001 #2 #2 v2 #0 7% 220) #2 #2 m2 0 #0. 240) m2 #2 #2 0. #10 380) v2 m2 #2 #2 #2 a5 wie 2 #2 #2 #2 80 2 #2 #2 #2 #2 IMPORTANT: Allwire sizes are AWG. The transformer primary requires protection against short circuits by means of a customer supplied disconnect and fusing or cireuit breaker. Refer to Chapter 7 for transformer connection information.Page 6-5 Installation and Setup 63 Wiring (Continued) 64 Setup and Adjustment Servomotor ‘The servomotor armature wiring is determined per its continuous and overload current requirements. In general, motors operated from the following controllers would not require wire sizes larger than those listed. In addition, to reduce radiated electrical noise, the armature leads should be twisted throughout their entire length. ‘Maximum servomotor wire sizes that the Bulletin 1388 Servo Controller will accept are shown below. ontrollerCatalogNumber Wire Size 13888-aVi0 #ITAWG 13888.aV20 FAW 13889-ava0 #5AWS 1388-AV60 waaws Fusing ‘The isolation transformer primary must be fused using a time delay type similar to Bussman Fusetron FRN Series or equivalent. Fuse ratings shown in Table 6.4 are the highest ratings allowed in a 25°C (77°F) ambient temperature. Higher electrical enclosure ambient temperatures ‘will require fuses with higher current ratings. Fuses that are larger than those shown in the table may result in transformer damage. Table 6.8 Recommended Fuse Current Rating (amperes) ‘Transformer kVA, Input vac_ 125 25, 50 75 700 200 4 3 173 25 35 220) « 2 5 20 30 240) 35 7 5 20 30 380) 225; 45, 3 2 75 a5 z a 2 2 5 0 18 35 7 0 15 perform many of the adjustments specified in the following paragraphs. Voltages behind the front panel are at incoming line potential. To avoid injury to personnel and/or damage to equipment, only qualified service personnel should perform thefollowing setup procedures. Thoroughly read and understand the following procedure before beginning. Ifan event does not occur while performing any of the following procedures, Do Not Proceed. Remove Power by opening the branch circuit disconnect device and correct the malfunction before continuing. h WARNING: Power must be applied to the controller to, IMPORTANT: DO NOT proceed with the Setup and Adjustment procedure unless Chapters 4 and 5 of this manual have been read and thoroughly understood.Page 6-6 Installation and Setup 64 Setup and Adjustment (Continued) This procedure has been structured in a general manner under the assumption that the Bulletin 1388 is being controlled by a position controller in a closed loop positioning system. This procedure describes the setup and adjustment for a single controller in a machine or system. Ifthe Bulletin 1388 will be operated manually, proceed to section 6.5 controller must be setup and adjusted separately. Circuit p WARNING: On multiple controller systems, each servo breakers must be open (OFF) on each servo controller not being setup. This helps minimize the possibility of ‘uncontrolled servomotor rotation which may result in personal injury or equipment damage avoid hazard of electrical shock, verify that all voltage on the A WARNING: This product contains stored energy devices. To capacitors has been discharged before attempting to service, repair or remove this unit Voltage attest point “NB” and “COM,” must be 0.00V DC as measured with a standard digital voltmeter or multimeter, Only qualified personnel familiar with solid-state control equipment and safety procedures in publication NFPA 70E should attempt this procedure. Refer to Figure 6.3 for approximate positions of Logic Control Board components. o1 oa o3 o4 Remove and lockout all power sources supplying the transformer, servo controlier and cabinet. Ensure that the circuit breaker on the servo controller is OFF. ‘Verify that the unit has been properly mounted and wired per the instructions in this manual. ‘Note the servomotor and controller nameplate data. As required, use this information and the information presented in Chapters 3, 5 and Appendix C to determine the following adjustments and settings. Set the scaling potentiometers, plug jumpers and torque taper switches as fellows: Potentiometer Settings Set the potentiometers as shown in the table below. Refer to section 5.3 for further information and Figure 6.3 for component locations. Pot setting Gain 5 um ° ‘MoDR Set per appropriate motor OFFSET &TACH Leave atthe present setting until adjustments necessary in the procedurePage 6-7 Installation and Setup 64 Setup and Adjustment (Continued) OB Sumper/Switch Settings Perform the jumperiswitch settings as described below. Refer to Figure 6.3 for component locations and sections 5.3, 5.4 and Appentix C for further information. Plug Jumper Inga (Yes ot No) ” No P2 No 73.4 Insert per motor requirements as described in section 5.4 Ps No °6 No ” Yee 78,9,10,11 Insert per maximum tach voltage as described in section 5.4 Switeh Setting SW1,SW2,SWW3 Set per motor and tachometer parameters as described in sections 5.3 and Appendix C . Apply power to the controller transformer Only. DO NOT ENABLE THE CONTROLLER. ;. Use a voltmeter to verify that the voltages listed in the following table are present. All voltages will have a tolerance of + 10%, ~ 15%. Refer to Figures 6.3 for test point locations. Test Pot Voage AMBL-Tto8 — 120VAC AMBL7t09 — 120VAC AmB1at09 —120VAC ASTB1St0 10 178VAC AaTB-9t011 —7AVAC ASTBI-10t0 11 35EVAC TP+5tocom +5 THwcOM +12 TPriztscom -12 Remove and lockout all power sources supplying the transformer, servo controller and cabinet. Itis recommended that the controller be commanded from a battery box initially as described below. This will assure that the servo system is stable prior to operating the complete system with the position controller and position feedback device, ‘The wires connected to ASTB1-12 and 13 (Enable input) must be marked and removed to allow for local operation of the Enable circuit. Connect a suitable switch between these terminals and insulate the switch connections. See Figure 6.1 ‘The wires connected to ASTBI-6 and 7 (Velocity Command input) must be marked and removed. A +10V DC local control (battery box) isto be connected to these terminals. ‘The polarity of the Command signal from the battery box should bbe the same as the actual control source to assure correct motor rotation when the controller is placed into operation as part of the system. See Figure 6.1.Page 6-8 Installation and Setup 64 Setup and Adjustment (Continued) Bulletin. 1388 aaB1.6 asre17 1 aares.12 od plasters Local Enable Switch Figure 6.1-Local Control (Battery Box) Connections meter (ILIM) is set to ero, the servomotor may begin to rotate and cause incorrect machine movement when the controller is enabled. Be prepared to remove controller power by opening the circuit breaker or the branch circuit disconnect device if this occurs. This movement may be due toa wiring error or system component malfunction and must be corrected before proceeding with this procedure. ‘Damage ‘o machine system components can occur due to uncontrolled machine movements. tis recommended that the motor be mechanically discon- nected from the load if: a) Improper direction of rotation could cause damage to equipment. ’) Uncontrolled motor rotation due to improper phasing will cause damage to the equipment. p CAUTION: Even though the Peak Current Limit potentio- © 10. Once control connections are made: a) Set Velocity Command input to zero at the battery box. b) Open Enatle switch. © 11, Apply power to the transformer primary and position the circuit breaker to ON. WARNING: In the following step, reverse rotation or uncon- trolled rotation at high speed can occur. To avoid injury, read through the procedure before attempting to start the motor.Page 6-9 Installation and Setup 64 Setup and Adjustment (Continued) ow O13. O16. a) Witk a 10% velocity command input signal applied from the battery box, momentarily close the local Enable switch and observe motor speed and direction of rotation. The motor should rotate slowly under control (following the Velocity Command signal). Ifthe motor is uncontrollable, remove all power and reverse either the tachometer or armature leads. Reapply power and check for proper rotation. Ifthe motor operates correctly, but rotates in the wrong, direc:ion, remove all power and reverse both the armature and tachcmeter leads. Reapply power and check for proper rotation. Ifthe motor does not operate, use a voltmeter at test point NB to verify that the correct bus voltage is present (+5V DC=150V DC Bus, +10%/-15%). b) Slowly adjust the ILIM pot to the desired setting after the ‘motor is stable (refer to Chapter 5, for further information on the ILIM potentiometer). ©) Adjust the battery box to give a velocity command that is 20% of the desired speed on the machine. Adjust the TACH pot until the motor achieves desired speed. Open the Enable switch. Remove and lockout all power sources supplying the transformer, servo controller and cabinet. Remove battery box and connect a jumper between terminals ASTBLS and 7. Apply power and close the Enable switch. Adjust the OFFSET potentiometer to obtain zero rotation of the motor shaft. Remove all power. Remove jumper and reconnect the ‘command input wires at A3TB1-6 and 7. Also remove the local Enable switch and reconnect external wiring at A3TB1-12 and 13. Reapply power. Apply a 10% Velocity Command input signal. On position controlled systems, set the position loop gain (system following error) by adjusting the TACH potentiometer while commanding various moves from the position controller to achieve desired following error. On velocity controlled systems (no position loop), adjust the TACH pot to give the maximum motor speed at the maximum desired command (reference) voltage. Ifthe proper position loop gain or speed cannot be set at maximum. motor speed, plug jumpers, P8, 9 and 10, may be improperly set. If the speed command signal is + 10V DC maximum and the DC tach will output between 27 and 135V DC at maximum machine speed, then insert P8. If the tach output is 9 to 45V DC, insert P9 ‘and if the output is 3 to 15V DC, insert P10. Refer to Chapter 5 for further information.Page 6-10 Installation and Setup 64 Setup and Adjustment (Continued) 17. Adjust the GAIN potentiometer and insert/remove plug jumpers P6 and P7asaeeded. The GAIN adjust pot is used to fine tune the servo system response, jumpers P6 and P7 can be inserted to give varying degrees of response. Setting GAIN at position #5 and inserting P7 will give satisfactory response for most applications, Iffurther optimization of the system response is required, the ‘System Compensation Procedure should be followed. If optimization is not required, proceed to step 27. IMPORTANT: Ifthe controller being utilized has catalog number 1388-AV20-B or 1388B-AV10, it may be necessary to adjust the IGAIN potentiometer to compensate for any armature current instabilities. Increase the IGAIN pot until the motor begins to vibrate or shudder, then reduce it until the motor is, stable. during Setup or Troubleshooting, it must be properly grounded. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. Always connect the oscilloscope chassis to earth ground. A WARNING: If an oscilloscope (or chart recorder) is used ‘System Compensation Procedure © 18. Monitor the techometer feedback signal at test point TF or TS with an oscillescope or chart recorder. 1 19. Adjust the GAIN potentiometer and observe the velocity response profile at various commanded speeds. Response curve #1 in Figure 6.2 witha single velocity overshoot of 20-30% on accel and decel is optimal on a point to point positioning or velocity controlled system. Response curve #2 is desirable on a contouring or metal removing system. ‘The GAIN pot should be adjusted so that the motor achieves the commanded speed or pulls into position as quickly as possible with 1no overshoot. In addition to the dynamic response, the motor shaft should not hunt or exhibit erratic motion at zero speed. 5 20. Ifthe desired response cannot be obtained by adjusting the GAIN pot, repeat step 19 for each of the following combinations of plug Jumpers P6 and P7: a) Insert P6 (Medium Response) ») Insert P7 (Low Response) ©) Insert P6 and P7 (Medium Response) 4) Remove P6 and P7 (High Response) © 21. Ifthe combinations in step 20 do not provide sufficient system response, the Velocity Loop Compensation components will have to be altered as explained in the following steps. 1 22, Remove the standard Velocity Loop Compensation components (C64 and R101) and in their place insert a variable capacitor and resistor across the standoffs provided. Set the resistor for 100k, the capacitor for 1uF and the GAIN pot to the middle position.Page 6-11 R101 controls amount ‘COMMANDED ‘veLociry ~ 64 ‘Setup and Adjustment (Continued) stownfact \ 6s sets engthof yaa |. Underdamped Low Frequency Oscillation R101 Too Small, C68 Too Large High Frequency Osilation Ri01 Too Large C68 To0 Sm 2. Critically Damped ‘I01 & Coa Maximized 3. Overdamped RI} Too Large C58 Too Large Figure 6.2 - Velocity Response Profiles 0 23. 0 24. 0 36, 5 26. 0 21. 0 29, O 30. Oo a1. In situations involving low velocity moves or motor speeds with a ‘maximum of 10% of the top motor speed on the machine: slowly reduce the value of the capacitor until overshoot occurs increase the value until the overshoot ceases (refer to Figure 6.2). Repeat step 23 and vary the value of the resistor. When acceptable performance is achieved, vary the capacitor again, If these components provide the desired response, insert the closest standard values on the standoffs provided (C64 and R101). Adjust the GAIN potentiometer to provide the final desired response Remove and lockout all power sources supplying the transformer, servo controller and cabinet, Reconnect motor to load if necessary. “Apply power. Check system operation and remove power. Record all settings, adjustments and changes to the Bulletin 1388 using the Adjustment Record in Appendix E. Retain the manual with these settings for future reference,Page 6-12 Installation and Setup Motor Overload Detection Time Compensation Stanaorts IcaINon 13888-AV10 1388-0208 Velocity loop. compensation ‘Standofts ‘Tach Lead Network standotts “Vey @ neo og Ow Qo Ger Ow Loop Contactor and Fan Fuses are behind the Logic Board in thislocation for the 1388-AV20, 1388-AVa0 and 1388-AV60, Shunt fuse for 1388-AV60 s ako inthis location, Fuses on remaining models are located next to the circuit breaker. ‘These jumpersare spares ‘and may be vied for Logic Control Board settings, Remove the brass screws ‘only through insulated Bushings when removing or replacing the Logie Control Board Logic Supply Fuses '220000000000000 0000 Figure 6.3 - Bulletin 1388 Logic Control Board Component LocationsPage 6-13 Installation and Setup RANCH ORCUTT DISCONNECT DEVICE senrocwraren [] (EEEELEET @ BULLETIN 1388 ISOLATION TRANSFORMER ——__ soomnons roaoomowacconrnowers @ assvAC BULLETIN 1388 SERVO CONTROLLER ‘Tousen stor ‘eneurt © eenrocoarrens FoR PUT voLTAcs AND FREQUENCIES OTHER THAN 24/401 A. 1012 © Faaerounen sconoany js est FOCOMTHEAPOWE.ON SOHOT SCO Figure 6.4 - Bulletin 1388 System Interconnect DiagramPage 6-14 Installation and Setup 65 1388 Manual Operation ‘The Bulletin 1388 can be operated manually with controlled acceleration. and deceleration when the Bulletin 1388-XB and XC Accessory Modules (Linear Accel/Decel and Velocity Reference Boards, respectively) have been installed per Figure 6.5. Refer to the following procedure, 1. Follow steps through 7 of the Setup and Adjustment Procedure provided in the previous section. © 2. Ensure that power to the transformer, controller etc. is still OFF. © 3, Install and interconnect the Bulletin 1388-XB, the Bulletin 1388- XC and recommended control circuitry as shown in Figure 6.5. Refer to Appendix A for module mounting dimensions. © 4. Disconnect the Stop contact from A3TB1-12, 13. potentiometer is set to zero, the servomotor may begin to Totate and cause incorrect machine movement. Be prepared to remove controller power by opening the circuit breaker or the branch cireuit disconnect device if this occurs. This ‘movement may be due to a wiring error or system component malfunction and must be corrected before proceeding with this procedure. Damage to machine system components can occur due to uncontrolled machine movements. Itis recommended that the motor be mechanically discon- nected from the load if 4) Improper direction of rotation could cause damage to equipment. ) Uncontrolled motor rotation due to improper phasing will causedamage to the equipment. p CAUTION: Even though the Peak Current Limit (ILIM) © 5. Apply power to the transformer primary. Using a voltmeter, verify that 120V AC is present at terminals 1 and 2 of the Bulletin 1388-XC (Velocity Reference Board) and terminals 2 and 4 of the Bulletin 1388-XB (Linear Accel/Decel Board). Allso verify a £10V DC output from the Bulletin 1388-XC, +10V DC should be present at terminals 4 and 5, while -10V DC should be measured at terminals 18 and 5. © 6. Press the Stop Reset switch and rotate the Speed Control pot fully clockwise. With a voltmeter connected to terminals 17 and 18 of the Bulletin 1388-XB, press the Start button. Verify thata voltage is present from the Bulletin 1388-XC. Adjust the Speed Calibrate pot for +10V DC at terminals 17 and 18, ‘Toggle the Forward/Reverse switch. The voltage measured at, terminals 17 and 18 should change in polarity. Ifthe polarity does not change, recheck the wiring and connections of the Forward/Reverse relay and the Forward Reverse switch.Page 6-15 Installation and Setup 65 1388 Manual Operation (Continued) a7. a a o Move the voltmeter leads to terminals 6 and 8 of A3TBI located on thecontroller. Rotate the Speed Control pot fully counter- clockwise. Adjust 1RH on the Bulletin 1388-XB until 0.00V DC is present, Rotate the Speed Control pot fully clockwise. Turn potentiometers 2RH (Accel Time) and 3RH (Decel Time) fully counterclockwise to give minimum acceldecel time. 2RH and SRH ean be adjusted over a range of 0.1 to 20.0 seconds. With the proper voltages present, press the Stop button, The voltage should drop to zero, Pressing the Start button will eause the voitage to again be present. Pressing the Stop button will cause the voltage to again drop to zero. Pressing the Stop Reset button followed by the Start button will cause the voltage to be present at terminals 6 and 8 of A3TB1. With the voltmeter connected to terminals 6 and 8 of ASTB1, alternately press the Start /Stop buttons, adjusting 2RH and 3RH for desired ramp time. The voltage measured will slowly increase and decrease. Leave the ramp set at maximum until final calibration of the system is performed. Rotate the Speed Control pot to minimum speed (0 volts). Remove and lockout all power sources supplying the transformer, servo controller and cabinet. ). Reconnect the Stop contact across A3TB1-12 and 13 on the Bulletin 1388, trolled rotation at high speed can occur. To avoid injury, read Q WARNING: In the following step, reverse rotation or uncon- through the procedure before attempting to start the motor. on Oe, O18, Apply power to the transformer primary and position the cireuit breaker to ON. Press the Stop and Start pushbuttons. Use a voltmeter at test point NB to verify that the correct bus voltage is present (+5V DC=160V DC Bus + 10%, 15%). ‘Command a speed through the Speed Control pot that represents approximately 10% maximum (ie. 1 volt). ‘The motor should rotate slowly under control (following the Speed Control). Ifthe motor is uncontrollable, reverse either the tachometer or armature leads. If this does not correet the problem ‘the position feedback device (encoder or resolver) may be incorrectly phased. If the motor operates correctly but rotates in the wrong direction, reverse both the armature and tachometer leads. Slowly adjust the ILIM pot to the desired setting after the motoris stable (refer to Chapter 5, for further information on the ILIM potentiometer),Page 6-16 Installation and Setup 65 1388 Manual Operation (Continued) 14. Use the OFFSET potentiometer on the Bulletin 1388 to set a 0 (cero) motor speed with a 0 (zero) velocity command from the Bulletin 1388-XB. Refer to Chapter 5 for further information on the OFFSET potentiometer. IMPORTANT: The motor may begin to “creep” after a period of time (several minutes) even though the OFFSET pot is set to zero. If this rotation is a problem, the controller may need to be disabled, 15. Adjust the TACH potentiometer on the Bulletin 1388 to give maximum motor speed with maximum velocity command (10V DC) from the Bulletin 1388-XB. 16. Ifthe proper motor speed cannot be set at maximum command voltage, plug jumpers, P8, 9 and 10, may be improperly set. Ifthe speed command signal is +10V DC maximum and the DC tach will output between 27 and 135V DC at maximum machine speed, then insert Pa. Ifthe tach output is 9 ta 45V DC, insert P9 and if the output is 3 to 15V DC, insert P10. Refer to Chapter 5 for further information. 17. Adjust the GAIN potentiometer and insert/remove plug jumpers P6and P7 asneeded. The GAIN adjust pot is used to fine tune the servo system response, jumpers P6 and P7 are inserted to give varying degrees of response. Setting GAIN at position #5 and inserting P7 will give satisfactory response for most applications. If further optimization of the system response is required, the ‘System Compensation Procedure presented in steps 18 through 26 of section 6.5 must be followed. Ifoptimization is not required, proceed to step 18. IMPORTANT: If the controller being utilized has catalog number 1388-AV20-B or 1388B -AV10, it may be necessary to adjust the IGAIN potentiometer to compensate for any armature current instabilities. 18. Adjust 2RH and 3RH to the desired accel and decel time. 19, Remove and lockout all power sources supplying the transformer, servo controller and cabinet. 20, Reconnect motor to load if necessary. 21. Apply power. 22. Check system operation and remove power. 23. Record all set:ings, adjustments and changes to the Bulletin 1388, using the Adjustment Record in Appendix E. Retain the manual with these settings for future reference.Page 6-17 Installation and Setup BRANCH CRCUT DISCONNECT DEVICE wnrurrower {1 THREE PHASE, BULLETIN 1388 ISOLATION TRANSFORMER a toamanata ronarai7.as Pel TACHOMETER ‘VELOCITY REFERENCE BOAR @ SPEED CONTROL BULLETIN 1388 ‘SERVO CONTROLLER Peco cAUMRATE we a(S sr0F@ LUNEAR ACCEL/DECEL BOARD @ rant Fwo eV tai ea stor Y a er RUN ‘ums ay i (@ _REFERTOCHAPTER FOR NPUT VOLTAGES AND FREQUENCIES OTHER THAN 2107 AC. 602 stor © ermomayagane comer ouTor obs nazanor «sa DUES © dowoT creLesTo» CONTACT MORE THAN TWEAN HOUR SEE SECTION 41 part Part (Catalog Number Tearstormer Fard/Rev Switch ‘S007. 428 Sere Contaler Stop Resets Star 7.8 sora Seremotee Stop & of Duable Ps. moor 088, [Unear Ace/Dece Board Rese, 1 wate +1056 E Velo Reference board seexc Speed Corl R2)- 5000, 1 wat soor.un2 ‘Stop FIR Run Relay FODHCIEA’ Relay) Speed Cabrate(Ra)-Nk, /2wate +108 = “Joo-nNto3 aes) Fone, F2- 14,2500 Min Type MN Ty. = Figure 6.5 - Manually Controlled Bulletin 1388 System Interconnect Diagram70 Chapter Objectives 74 Bulletin 1388 Transformers Chapter 7 Transformers, Inductors and Shunt Regulators Chapter 7 provides connection, dimension and enclosure information for the Bulletin 1388 Isolation Transformer. In addition, inductor dimensions and external shunt regulator dimensions are provided. ‘Transformers supplied with the Bulletin 1388 can provide power for up to four (optional 6 axis units in 7.5A, 10.0kVA are available) controllers. ‘The kVA values specified are the continuous outputs of the units ina 60°C (140° F) ambient. The maximum rating available is 10 kVA and is, imposed to ensure that the power input rectifiers surge rating is not exceeded. The transformer may be customer supplied, provided it meets Allen-Bradley supplied transformer specifications. Contact your local Allen-Bradley Sales Representative for further information IMPORTANT: The Bulletin 1388 transformer secondary must be used for controller power only. Do not use for control or other devices. 60 HZ Transformers ‘Two 60 Hz transformers are available with the following ratings: 1. 240/460 AG, three-phase (Catalog Number 1388-TxxxDR) 2, 208/230/460/575V AC, three-phase (Catalog Number 1388-TxxxNR) ‘The output voltages are 120V AC, three-phase and 35.5V AC center- tapped. Refer to Figure 7.1 for connection information and Figure 7.2 for dimensions, 50/60 HZ Transformers ‘The 50/60 Hz unit that is available has an input rating of 240/380/415/460V AC, three-phase (Catalog Number 1388-TxxxER). ‘The output voltages are 120V AC, three-phase and 35.5V AC center- tapped. Connections to the 50/60 Hz unit are shown in Figure 7.1 with dimensions provided in Figure 7.2. ‘Ifother input voltages or special enclosures are required, consult your local Allen-Bradley Sales Representative.Page 7-2 Transformers, Inductors and Shunt RegulatorsPage 7-3 Transformers, Inductors and Shunt Regulators cr r . | one St 8 Max. |~§—___ » —__ >| oe |< ——— cmax. ———>| webs Catalog Number__kVA__(ka) A 8 ¢ By e 7356-T01208 72528027) 900(28) 100058) 130030) s0o(1a) 3100) 1388-TOTZER/FRNR 36(163)___9.00(228) _1200(305)_13.00(330)__—6 50(165)__—_—3.53(92) 1388-70250", 35190) 11.0078) 11.0073) 14.00(356) 6 00(152) 3.30188), 1388-TO2SER/FRNR 58263) 1100279) 11000273) 14000356) 6 50165) __—_—.S0(174) 1388-TO500R, 50 75(980) __11.00(278) 11.0073) _14.00(356) __6.00(152)___525(133) 1388-TOSOER/FRNR 99(@49) _1.00(279) __t1000(273)__—ta.00(356) 6.50165) 6.75171) 1388-T0750R 75 92(@i7) 12.00(305)1250;317) _16.00(408) 8.00203) 5.70(145) 1386-TOPSER/FRUNR 1161525) 1200(305)__—1500(380) __—_16.00(406)* __7.90(200) __—_—§.30(138), 1388-T70008 700 112608) __1200(305) 1250317) 1600(«06) 8.00 203) 5514s) 1388-TTOOER/FRNR 132638) 1200305) *1500(380)—‘16.00(406)* —7.90(200)—§.90(150) * Onoptional axis units this dimension hasa maximum of 19° (483mm) Figure 7.2 - Approximate Dimensions and Weights, Isolation Transformer 7.2 Dimensions fo: the NEMA Type 1 isolation transformer enclosure are NEMA Type 1 Enclosure shown in Figure 7.3, ———— Ty | Dimensions ininches and (mm) Weight Nomoer a c . £ testi) T3EBTA? T7.00GGT) —18SO(WEH) —1aDOGSH) —TesO(eT=) —T2O0GD) 3551 (16) side Figure 7.3 - Approximate Dimensions and Weight, NEMA Type 1 EnclosurePage 7-4 Transformers, Inductors and Shunt Regulators 73 External Shunt Regulators Specifications 675 Watts continuous at 60°C 2 Connections are made at A2TB1-1,20n the servo controller a noted inthe figure, using a #6 screw (supplied) Fuse -Bussman FN M12 or equivalent. P= Notes 1) Mount the resistor assembly withthe wiring facing down, 2) The insulator between the resistor and bracket has a5" (38.1mmm) DIA. 3) #OAWG RHW wire to be used (or type and gauge dictated by local codes), 0.16(4.1) Figure 7.4 - Bulletin 1388-MOD-SR88 External Shunt Regulator Ki REO Approximate dimensions for the external shunt regulator and fuse are provided in Figure 7.4. Connect to 2781-2 N@ 9.00 228.6) Connect to A2TBI-1 |____ 37 som Te Le “te RESISTOR ASSEMBLY RISA EE Dimensions ae in inctes and (mm) 0203. w0.343 018.8. 2, kK 031 can |_138 a0) SHUNT REGULATOR FUSEPage 7-5 ‘Transformers, Inductors and Shunt Regulators 7.4 Approximate dimensions for the Bulletin 1388 Inductor are provided in Inductors Figure7.5. Le Amen, [ane —=| - t ff . t [2] 2] ci aa | | ie) 2) [ome | J 8 mex >| (2\F ee D a FIGURE B 2 7 a Kd oueoaneren Jee +] Snoteouneren = CL ee catalog Inductance Curent Dimensions inches and (rm) Diameter Weight Pe a —_ eset a ae enmecsEeT a eS Sa SOO GSTS a ee Histo ae FS) CaS Tae TOT ae esa a Figure 7.5 ~ Inductor Dimensions and WeightsPage 7-6 Transformers, Inductors and Shunt Regulators |< amas Inductors 7.4 Approximate dimersions for the Bulletin 1988 Inductor are provided in Figure 7.5. lea —| t t (2) 2] tH Oot a le omer —>| i | b a ad to - tie toe catalog Inductance Current Dimensiane inches and (mm) Diameter Weight ees See eee ES oe aust tr ma 4d tessa ene — at ist rt tenn) tonto ast Si it ttn tose testes ae) —smay ane ase ara Figure 7.5 ~ Inductor Dimensions and WeightsChapter Servomotor Operation and Maintenance 80 Chapter Objectives at Receiving a2 Storage 83 Location Chapter 8 provides information on the operation and maintenance of Allen-Bradley Bulletin 1326 DC Servomotors. This section covers typical details for various motors but cannot provide for every possible contingency in relation to installation, operation and maintenance. If information is required beyond the scope ofthis chapter, please contact your local Allen-Bradley Area Support Center. ‘DC servomotors must be placed under adequate cover immediately upon receipt as the packaging is not suitable for unprotected storage. Each shipment mustbe carefully examined upon receipt. Any physical damage to the motor must be reported to the carrier. All motors are tested and inspected before shipment, Ifa recetving test is performed on the motor, all connection diagrams must be followed. When the receiving test is being performed, all voltages and currents applied must be within the specified values. Ifa motor or any part of a motor isto be stored, it must be stored in a clean, dry area and protected from extreme variations in temperature, humidity and dust. Brushes must be lifted from the commutator during prolonged storage to prevent corrosion and flat spots on the commutator. Corrosion and flat spots may cause destructive commutation when the motor is placed into operation, If the motor has been exposed to a low temperature for an extended period ‘of time, allow itto come up to room temperature before unpacking to avoid condensation in the motor. Moisture condensation can shorten, insulation and motor life. Stored motors should be periodically inspected and the insulation ‘checked with a megger. A log should be kept on stored motors and insulation resistances noted. Decreasing insulation resistances would suggest moving the motors to a drier area. Rust must not be allowed to form on a motor. External rust could indicate internal rust which could cause irreparable damage to the motor. ‘Motors must be installed where they will be readily accessible for inspection and maintenance. All Bulletin 1326 Servomotors are oil resistant (except for shaft extension when oil seal is not provided) to guard against liquid contamination. Mounting Bulletin 1326 DC Servomotors come with a combination C and D flange mount. This affords the user the option of overbolt mounting or through bolt mounting.Page 8-2 Servomotor Operation & Maintenance ‘TheustLoad- 83 Location (Continued) 84 Operation bs. Figure 8.1 ~Radial vs. Thrust Load All motors can be mounted in any shaft orientation desired. This is made possible by axially restricting the pulley end bearing with a locking cap and preloading the commutator end bearing with a load spring. It is imperative that allradial and thrust loads on the shaft be kept within the specified limits, ‘The radial vs thrust load charts shown in Figure 8.1 are for Series DP-P, DP-S, DP-U, DP-A and DP-I Bulletin 1326 DC Servomotors. Alignment Be sure toalign or check the alignment on all direct coupled applications. Misalignment can cause excessive vibration and damaging forces on the bearings and shaft, This leads to decreased motor life and excessive down time. Electrical Connections After the mounting and alignment procedure has been completed, the electrical connections should be performed next. All connection diagrams supplied with the motor should be followed when connecting the motor to Bulletin 1388 Servo Controller. Bulletin 1926 Servomotors used with the Bulletin 1988 Servo Controllers will be in a closed loop configuration WARNING: The polarity ofthe integral tachometer with A reference to the direction of armature rotation is of extreme importance. Ifthe polarity is not correct, the motor will exceed the maximum speed allowable, causing possible personal injury and/or field demagnetization.Page 8-3 Servomotor Operation & Maintenance Used On... DPA DPC. DPE, ps, DP-P DPS.DPU a4 Operation (Continued) Vonage voc ‘30100 ey 30-100 24 ‘To obtain the correct polarity of the tachometer in a closed loop configuration, refer to Figure 8.2. MAGNET Notes ~~ 1) Bulletin 1326 0CSenvomotor Tach Voltage Constant is, 31:5V10C/1000 RPM, 2) Motor thermal protection is Dcem ‘normally closed (NC). Leads rTechometer——arelabeled KT and K2, 3) Brake leads if supplied) are labeled 81 ana 82 \Viewed from the end ‘opposite the dive shaft Red Black Rotation, Motor Tachomet Clockwise TAI, Negative Black, Negative smonetns [A2\ Positive. Red, Positive Counterdockwise At, Positive Black, Positive menoced ‘AZ, Negative Red, Negative Figure 8.2 - DC Servomotor Connections ‘Thermal Overload Detection All Bulletin 1326 DC Servomotors have a thermal overload detector as standard equipment. This device is provided on all motors to assure that the armature winding is kept within the temperature limits. The ther- mal detector provided is of the normally closed type and has leads marked Ky and Ka. The detector must be connected in such a manner as to shut down the Bulletin 1388 in case of motor overheating (see Chapter 10) ‘The contacts of this device are designed for control logic interface only and are not designed to carry the armature current. The maximum con- tact ratings are listed in Table 8.A. Table8.A Maximum Contact Ratings Volts 2av 0c Tisvac 230V AC ‘Amperes 18 Brakes An integral brake may be supplied as an option (Option A) with Bulletin 1326 DC Servomotors. This brake is to be used as a holding brake only and is not intended to be used to stop the motor. The brake is adisc type with release accomplished by energizing either a 24 or 90V DC Coil. The brake disengages/engages in approximately 0.300 seconds. Refer to ‘Table 8.B for brake specifications. Tables.8 Nominal Brake Specifications Holding Torque Current Resistance Pullin Vokage Dropout Voltage es ‘a ‘Ohms. vor voc > ‘026 3 3035 720 3 038 2 78 25 8 02 306 3040 750 8 120 2 78 20 0 Series 30100 24 75 079 726, 35.40 700 6 230 3 10 20Page 8-4 Servomotor Operation & Maintenance as Operation (Continued) as Maintenance ‘The 90V DC is supplied by applying 115V AC across a single-phase bridge rectifier (Catalog Number 1326-MOD-BPS). The output of the rectifier is then applied to the brake. Refer to Figure 8.3 for further brake connection information. Under rated operating conditions the brake will not require maintenance. Ps os 90V DCColl Z tio nSvAC 2 5 24V DC Coll f awoc 1 8 Figure 8.3 - Brake Connection Diagram Altitude Ifthe motor will be operated at an altitude exceeding 3300 feet (1000 meters), contact your local Allen-Bradley Sales Representative. Brushes Itis recommended that brushes be inspected after every 2000 hours of operation or once a year. More frequent inspection may be necessary on lightly loaded or contaminated atmosphere applications. All brushes ‘must move freely in their holders. If the brush sticks, itis usually due to accumulated carbon dust. Brushes must be replaced when the length of the brush reaches 1/4 inch (the original length is 3/4 inch). All brush, springs should have equal tension. On a replacement basis, only brushes of the same size, grade and shape as those originally supplied must be used, Refer to the Servomotor Spare Parts in Appendix B for more information. Armature Commutator A light brown carbon film will build up on the commutator under normal use. Do not remove this film unless the commutator is in poor condition. If the commutator becomes rough and burned or black, it must be recon- ditioned at a recognized motor service facility. Never use emery cloth or emery paper. Ifthe commutator is badly burned, have a light cut taken off using a lathe and then repolish. After a commutator is recut, the runout must be checked with the armature bearings on V-blocks. The maximum runout is 0.001 inches T.LR. for 2500 RPM or higher. For low- er than 2500 RPM, the runout should be 0.002 inches T:LR. ‘The commutator mica can be undercut to a minimum depth of 1/64 inch and to a maximum depth of 3/64 inch. The sides of the undercut must be free ofall mica.Page 8-5 ‘Servomotor Operation & Maintenance 85 Maintenance (Continued) 86 Spare Parts ‘Tachometer ‘The tachometer provided on Bulletin 1926 Servomotors isa through shaft, type and requires very little maintenance. The field of the tachometer is permanent magnet and must be kept free of all dirt and magnetic material. All tachometers are provided with cartridge brushes and must bbe maintained in much the same manner as the motor brushes. The tachometer commutator must be cleaned ONLY with a non-abrasive material, The material used must not be conductive and must not contain flammable solvents. Permanent Magnet Field ‘The permanent magnets used in the Bulletin 1326 DC Servomotors are of ‘an exceptionally stable material and will not demagnetize under rated operating conditions. All motors (except the 1326DP-R Series) are designed such that they may be completely disassembled and reassembled without affecting the permanent magnets. Periodic inspection and cleaning of the magnets must be made to see that they are not accumulating dirt and magnetic material. Dirt can hinder rotation and cause armature overheating. Bearings All Bulletin 1326 Servomotors are equipped with ball bearings. The bearings are of the single row, single width, shielded type and are permanently lubricated. The bearings require no maintenance under rated operating conditions Blowers Ifa blower is used, the filter must be cleaned at regular intervals according to the manufacturers instructions to guard against dirt entering the motor. Also, dirt can restrict the air flow through the filter and motor causing the motor to overheat. Mechanical Parts Arregular check of all mechanical parts on the motor must be made. This isto see if any bolts or couplings have loosened during operation. Refer to the Servomotor Spare Parts in Appendix B for part numbers and ‘quantities, When ordering replacement parts, itis imperative that the specific motor catalog and model number stamped on the motor nameplate be provided (see Figure 5.2)9.0 Chapter Objectives 94 ‘System Troubleshooting Chapter Troubleshooting and Maintenance Chapter 9 contains the information needed to help troubleshoot the Bulletin 1388 Servo Controller and properly maintain the unit. Included in the chapter are substitution procedures for the controller and Logic Control Board, LED Fault Indications, General System Faults, Test, Point Descriptions and suggested maintenance. during Setup or Troubleshooting, it must be properly grounded. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. Always connect the oscilloscope chassis to earth ground. p WARNING: If an oscilloscope (or chart recorder) is used controller are at incoming line potential. To avoid personal injury and/or equipment damage, only qualified personnel familiar with solid-state control equipment and safety procedures in publication NFPA 70E should attempt these troubleshooting procedures. p WARNING: Voltages behind the front panel of the controller fault circuits. The cause of a fault indication must be determined and corrected before attempting operation, Failure to correct a controller or system malfunction may result in personal injury and/or equipment damage due to uncontrolled machine system operation, p WARNING: Do not attempt to defeat or override the ‘Most controller faults are annunciated by the LED diagnostic indicators on the Logic Control Board assembly. The troubleshooting information provided will take advantage of the LED's and list a number of potential system problems related to each LED indication (Table 9.4). In addition, a number of common system malfunctions are described in Table 9.B. ‘The majority of faults cause the fault relay to operate. Many system malfunctions manifest themselves through a controller fault. The use of LED fault indications may aid in identifying servo controller and motor malfunctions. Ifa controller fault occurs, the fault detection circuitry can be reset by removing and reapplying power to the transformer supplying the servo controller. ‘This material along with the diagnostic/troubleshooting information included with the position controller, will help identify most common system malfunctions to an assembly level. The position controller is considered to be a: numerical control, computer numerical control, programmable controller, custom microprocessor, ete. controlling a closed loop position or velocity system. ‘Substituting or interchanging complete servo controllers or major board ‘assemblies is ¢ common technique used in troubleshooting closed loop position systems. The Bulletin 1388 has been designed to facilitate this technique. The procedures provided must be followed when substituting or interchanging controllers or Logic Control Board assemblies.Page 9-2 Troubleshooting and Maintenance ot System Troubleshooting (Continued) DC by connecting a voltmeter to test point “NB” and “COM” on the Logic Control Board. This verification must be done A WARNING: Verify that the Power Bus has decayed to 0V prior toremoval of the Bulletin 1388 from a machine system or removing the controller side plate (which will expose the power bus capacitors and power circuitry). Also verify that all power and signal voltage sources have been disconnected and locked out. A hazard of electrical shock exists if acciden‘al contact is made with energized power components, Servo Controller Substitution 1 1, Remove all power supplying the servo controller and system. o o o 3 o a 2, 3 4. 8. 6 1, ‘Remove the Signal Input Connector, ASTB1. Label and disconnect the motor armature leads and three-phase input at the Fower Terminal Block, A2TB1. Also remove the controller grcund wire. Make note of all potentiometer and switch settings, if not previously done in Appendix E. Remove controller and insert replacement unit. Reconnect the ground wire, motor armature leads, three-phase input and Signal Input Connector, A3TB1. Set the potentiometers, switches and plug jumpers to settings identical to the unit that was removed. Follow the Setup and Adjustment procedure in section 6.4. Logic Control Board Substitution Discharge) sensitive parts and assemblies. Static control p CAUTION: This controller contains ESD Electrostatic precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. Ifyou are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook. oooo a |. Remove all power supplying the servo controller and system. .. Remove the protective plastic front cover. . Disconnect connectors, ASTB1, A3TB2 and A3JL. Remove the two screws holding the Logic Control Board as, indicated in Figure 6.3 3. Depress the locking tab on each nylon standoff supporting the Logic Control Board and pull up on the board slightly at that point. ‘When all tabs have been depressed, remove the entire board. . Insert the replacement board . Set the potentiometers, switches and plug jumpers to settings identical to the unit that was removed. Follow the Setup and Adjustment procedure in section 6.4.Page 9-3 ‘Troubleshooting and Maintenance te Table 9.4 LED Descriptions and Fault Diagnosis TED Description "CURRENT FOLDBACK The RED CURRENT FOLDBACK ‘Condition / Potential Cause ‘CURRENT FOLDBACK LED is urinated ™ LD iluminater when the |” 1, The ngicsupply (+ 12V DC, +5V00 circuits have malfunctioned (fuse Current Foldback circuitry is blown etc.) or the AC input at A3TB1-9, 10, 11 is incorrectly wired. ‘operating, Indicates that the 2. The output current is exceeding its time-current rating. Limeys-currentoverload rating” 2) celration deceleration command from the fostion Control is the power ansstors has pithe power vanssorshas |, *) requing peak current foram excessive amount of me been gxceeded. The ntenstyof oy The cain pot set to high, causing excemve peak currents {Re LED varesin propor ©) Themachine fiction, ier toad andor viscous loading excessive 4) Theservomotor hasbeen improper aed §) Ashort craters acre the contol output terminals. 4) The earrent ripple exesve, caused by motor Inductance being Below minimum, ENABLE The appiation ofan Enable ENABLE LED NOT Muminated en signalby themachine postion 1. The oston Controller has not enabled the contol. onvolerwilcausethe GREEN} Te fost ee rc ee Enable wiring tothe controllers open, 2. The Fston Controller Enable elayswitn as malfunctioned, 1. The Foution Controller hae detected a machine system mafuncton that ‘lot aliow the controllers tobe Enabled 5. Powerhas not been applied to input wansformer. 6. Thelogiesupply (+127 OC, +5V 00 cuts have malfunctioned (ute Dlown-ete) oF the ACinput at ASTBY-9, 10, 1 isincorrecty wed ENABLELEDisiluminaed, bt Controle doesnot Enable 1. AControlermafunction has ocurred but isnot annunciated by the LED inaeators. Check the atorof the aul Contact output 2. AComponent malfunction exists inthe Enable crc. 3. Thecontroller Circuit Breaker (Cis wiped 4, Fankontactor ute ha blown. Verify that the fn operational with power applies 5. Thelne/D8 contactor has malfunctioned. 6 The controller logic supplies are not operational 2) The logiesuply fuses are blown 3) Legieauppiy AC votage & ming 8) Acontallermafunction has ocurred bu not annunclted bythe LED inaicator. check the status of re Fault Contact output 7. wv LED illuminated £5) Enable signals present prior to power being applied to the power transformer wait at east second aftertho 20V AG, three-phase Bowers applied before enabing te contol OTOR OVERLOAD The RED MOTOR OVERLOAD" MOTOROVERLOAD LED ituinated (woo) LED iluminates when the motor 1, Thelagicsuppy (+ 12V OC, +5V DO ‘SERVOMOTOR sutetin [JC Feansronucr | [_r2 | nenmacsornen Ll 17N@ e n cp © 8 3 ® om = BULLETIN 845H/N LIL s ee, t — ENCODER® 7 : 2" |} 121 ef] 1 : oe || 2 vol] BEES, i 2. 2); |} 2] eel ; “| © © Wai. ||| fa els : z a $ 5 ‘TACHOMETER HE || : ol *@ mecuacne CO 2p }} 121 ¥ al || sal iS oc Aw ‘ale ||) sta a 2") | 12 fr3}-n2) rau crn ain) | nfl eae ah [Ll ; womers@ lo ee © oO occu nour rT crouno stu0® ® : FORITERFACEDETALS, RFA TOA PURUCATION 1771.87 SERS A)OR71SDSRIESD, LET 171 SRV POBTONNG ASSEMBLY USER'S MANUAL nen 972008 SQUVALENT, SFE (1.2 METERS MARIMUM 000008 900 Figure 10.3 - 1771-QC Servo Positioning AssemblyPage 10-6 Interconnection Diagrams BULLETIN 7300 INTERCONNECT DIAGRAM BULLETIN 7300 8 na auutern ae BULLETIN 1388 SERVO 1326 be “UMTS sro CONTROLLER SERVOMOTOR [ate] agra 1m [rma oases yen | are, ff “— wfelfe ie Beato yh lol ewo.mich at] OH i vevocry ‘TACHOMETER iow fe z Se lel i floes ® sonnet off * sacnow asl af oat Ee ms mle) meee ae oon Sern ssvoe 01] off + @| do semenmer | + @ 2 of} £ 1p ° ob : — ore ‘ one “ * oy = Fo ore . i BULLETIN e45HiN a ENCODER © rommenrace eras FER TOA 8 PUBUCATION 2005, SERS 7ROOITERACE DG MANUAL © usersuerusocourovent @ eUss.eRGAYssHoWN ASTYPALONY BULLET 188 CAN BE E4820 /THOUTAN EXTERNALAELAY @ sows Fon soy waonun ar TERUMNALSAIOAND AIT ATMAXMUM HOTOR SED © _rcau.yosFEENTAL UN ORDER OUT. © sacaratoc numatn soca 40 ANONUWER OOH MOUNTING ASE RELAY 4POTTOENASLE UPTO FOURSERVO.CONTROLERS, ® se1osusranoa quan, FEE 152 METERS MAxMUA. sitios GROUNDED AT CONTROL ONY. © ssxare now ecootn cOV'RD. LOGIC POWER MOTOR THERNAL SUTCHIS HEAR MOTORPOMERANO @ neenroncune 12 FoR GROUNDS OTALS Figure 10.4 ~7300 Series CNCPage 10-7 Interconnection Diagrams BULLETIN 8200 INTERCONNECT DIAGRAM BULLETIN 8200 ® Sumy sea, A BULLETIN 1388 SERVO BULLETIN ‘overrnave, — MMOTE a CONTROLLER 1326 DC UMTS: sor ‘SERVOMOTOR Seca ot ot emo. mig 23) 2) t Fy aouew 3 "lol nonosins F]9@ © renter os} “renew fe ala e] ace af scuncane “fo |. “12 2 De TACHINPUT valle < 3a ; Hi la 2. A r] crounosrv0® a lal n x aon = % + ‘Tall: ar left 2 ‘Le BULLETIN ASHIN i ENCODER® Ach cos ADWSTUNT WOULD TALLY BEA POTENTNETERORFE BESSTORSET TO: NOMS 1800 x VIAK—10} WHERE: VMAK=MAXTACHVOLTSAT [A eATALOG HMaER7ODHC1AAT RELAY AND NUMBER 008109 (MOUNTING BASE) HELA'S PDT TOENARE UPTOFOURSERVO CONTROMERS ftiogh 97908 EOUVALENT, 0 FEE (15.2 METERS ANIM SHELDSGROUNOEO AT CONTROL ONY. ©8008 ©0900 Figure 10.5~-8200 Series CNCPage 10-8 Interconnection Diagrams BULLETIN 8400 INTERCONNECT DIAGRAM BULLETIN 840009 ‘ove Swe BULLETIN, ® 1326 DC ‘SERVOMOTOR BULLETIN 1388 SERVO ‘CONTROLLER crowns lol ® loo 09 998 TS99S BULLETIN 845H/N ENCODERS ° FonINTEPACEDETANS RFERTOA @ | eNAs.eReLav shown ASTYPCALONY,BULETII288CAN BE EARLEDWATHOUTAM EXTERNAL ELA © oxmrsrverson shown, nO ORES VERSION NOULDAEQUAE AXS NTERCONNECT HOARD. © ymca onFERENTALUNonNEROUTIUT © nacatatos numeer 70 C14 (ELAY AND MUMIER 7oD4N 03 MOUNTING BAS, RELAY 4707 TOENAE UPTO FOUR EVO CONTROWERS ® sx1pevs72908 sqUVALENT, 50775. 21ETERD) MAXIMUM, SeLDF GROLNOED ATCONTROL ORLY @ ssouarerrow tcooeRcNTROLLCGICPOWER MCTORTHERMAL SMITCH'S NEAR MOTOR POWER AND CANE SOURCE OF NTAFERNCE @ neenroncuAe 192 FoR GROUNONG DANS. Figure 10.6 - 8400 Series CNCPage 10-9 Interconnection Diagrams BULLETIN 8600 INTERCONNECT DIAGRAM BULLETIN 86000 © savac wo] ee ‘Sota Swe a BULLETIN ® 1326 DC Peuhores BULLETIN 1388 SERVO ‘CONTROLLER S989S99 BULLETIN 845H/N | ENCODER® © FonITERFACEDETALS AFERTOA.BP>URUEATON D4), SERS BO CNC NTERFACE DESI MANUAL © usensvrueocouronenr. @ eyas.e REV SsHOWNASTYPICALONLY, BET 1B8 CANE ENABLE ATHOUTAN ETERNAL EL. @ rynca acs srsteMsHOWN FORSEHES Bn, BEIDANDEESDCNC © _rymeAyowTeRENTALUME DIVER OUTPUT © kecaraioe WAMBEN 706r4nt LAY AND NUMBER 7OHO8 MOUNTING BAS) RELAYS APT TO ENABLE UPTO FOUR SERVO CONTROLLERS © stieversaon quvanr, sb FEE(152 METERS MALIMU HELDSGAOUNOED AT CONTROL ONY. @ souare mow encooen cownoL Ric POWER. MOTORTHERMAL SACHS NEAR MOTOR POWERANO CANBEASOURCEOF EMI MTERFESENCE, © reer nGURE 192 fORGHOUNONGDETALS Figure 10.7 -8600 Series CNCPage 10-10 Interconnection Diagrams IMC 120 INTERCONNECT DIAGRAM TERMINATION ais PANEL = Creep wm E] EY gunenn ae 1326 DC =p seaVOMOTOR =i[2 oa vel 13 Pelli reall [2 ‘ex fo smeer| 5 4 4 4 4 4 4 4 | eI a own aa ont oi oll43 — © rerearoRGUns 1o2Foxcnounom oeaKs, © usersurrutoconsonenr Figure 10.8 -INC 120Page 10-11 Interconnection Diagrams IMC 123 INTERCONNECT DIAGRAM TERMINATION PANEL sounoysnonn wen F] BULLETIN, 1326 DC ‘SERVOMOTOR “rnen| Uh [SSSSSS]? SHTSTG RESOLVER OR ENCODER TERMINATION PANEL © neenroncuae192roncnownon Oras © usersverutocouronent Figure 10.9 - IMC 123Page 10-12 Interconnection Diagrams GREONICS MAX & MAX4/CONTROL INTERCONNECT DIAGRAM rea ren ore CREONICS MAX & 1326 De MAXA/CONTROLO senvoMoroR — BULLETIN 1388 ‘cusTOMER ‘SUPPLIED 24av DC ISOLATED POWER SUPPLY IMPORTANT: FUSING & 1388-AVXX-C (TORQUE BLOCK) ~SET MAX TO “PWM /CURRENT.” IFUSING A STANDARD 1388 (VELOCITY LOOP) -SET MAX TO “VELOCITY.” © neenrorensxoe ureecowrnoc NsTALLATIONANO SETUP MANUAL FOROETAS, @ seenroncuRe 192 FoRcroUNOING TANS. © useesvrnucoconrone. Figure 10.10 - MAX & MAX4/ControlChapter 11 Torque Block Operation 11.0 Chapter Objectives 144 Description 11.2 Installation and Setup ‘This chapter contains the information needed to help installl and setup the Bulletin 1388 in a torque block mode. Bulletin 1988 controllers with the Torque Block option (1388-AVxx-C-D) ‘can be operated as a torque regulator. Applications that may require torque block operation include: = Web handling where the controller is maintaining tension on material coming off a roll. « Position control requires torque block operation when a controller receives a torque command from a position controller (TMC 120, ete.) ‘The position controller performs velocity and position calculations and ‘outputs the torque required to get toa position. - When a load is shared by two motors, one motor will act asa master and output a torque signal toa slave. The signal is related to the torque required for the motors to remain synchronized. - Anti-backlash configurations where one motor provides torque against another to minimize “play” in a gear mechanism. ‘These systems require the Bulletin 1388 to accept a 0 to +5V DC signal that represents the torque required for the application. This signal which is connected toterminals 6 and 7 (or 6 and 8) of A3TB1, reflect 0 to 100% peak torque capacity of the controller. Setup and adjustment of the Bulletin 1388 controller with the Torque Block option installed is identical to the procedure given in section 6.4. Refer to Figure 11.1 for interconnect. information. injury could result ifa load is not connected to the motor and the torque command input to the Bulletin 1388 (A3TB1-6 and 7,07 ASTB1-6 and 8) is not set to 0.00V DC. p WARNING: Uncontrolled motor acceleration and personal ‘the machine system may accelerate rapidly without velocity control. To guard against injury and/or equipment damage, be prepared to remove controller and system power immediately. p WARNING: If the tachometer feedback polarity is incorrect,Page 11-2 Torque Block Operation BRANCH ORCUTT DISCONNECT DEVICE BULLETIN 1388 ISOLATION ‘TRANSFORMER sountoay assvac roasrar9. 1011 BULLETIN 1388 -AVxx-C-D ‘SERVO CONTROLLER orqut J Teyoccouuano ‘COMMAND NeUT®. | _veTuRN ow SSSVAC = ENABLE INPUT: 4 ToUseRstoP ‘CRCUT @ nereatocnapren7 FoR NPUT VOLTAGES AND FREQUENOES OTHER THAN 240490V AC © somanorven sue 1383814 POSTON CONTHOLER OR THE TORQUELFRENCE Figure 11.1 ~ Bulletin 1388 System Interconnect Diagram for Torque Block Operation‘Appendix ensions Objectives Appendix A coatains dimension information for the Bulletin 1388 Servo 231 635) o Controller, Bulletin 1388-XB and XC Accessory Modules. Refer to the specific chapters for remaining dimension information. SEEDETAILA DeseRvo CONTROLLER DIMENSIONS AREIN INCHES AND (M14) S 1938 19001750 a as25) (asa) SEEDETAILE oss | 325 | t — | 075) 25) os 35) 450 (7.0) 1050 ia) 266.7 DETAIL A DETAIL 8 ro ay aoe osizasi0n oareasi01n Lf 7 Tau rol onan t 0.60(15.2)1A 9912" (70) SREGURED Be™WEENADACENT CONTROLLERS. 10" 25.4 S RECOMMENDED. Figure A.1 ~ Bulletin 1388 DimensionsPage A-2 Dimensions DIMENSIONS ARE IN INCHES “AND (Mn) 775 | I 325 (196.8) 25) a7 sa) Figure A.2 - Bulletin 1388-XB, XC Module Dimensions‘Appendix Spare Parts List Controller Spare Parts Spare parts for the Bulletin 1988 Servo Controller are available separately or in kits. The following tables provide listings of the recommended spare parts. The Spare Parts Kits are explained in the paragraphs that follow. For further spare part information refer to publications 1388-6.1, 6.2, 6.3 and 6.4 Figure B.1 provides a general location of the parts listed below. BULLETIN 1388 ~ SERIES A BULLETIN 1388 ~ SERIES B tem _Desciption tem _ Description TT completeuae 1 Complete unit 2__ogieControloara 2__Legie Control Soars "3 Base Driver Assembly 37 ase Drwver Assembly @_fan 4 fan 35 _LogiSupply Fuse 5 legieSuppiy Fase &_FanvContactor Fuse 6 _FaniContactor Fuse 7___ Contactor Sub Assembly 7__Contactor Sub Assembly 8 SignalvO Plug 3 Signal /OPlug 9 Shunt Regulator Fuse IMPORTANT: For parts not listed, contact the nearest Allen-Bradley Area Sales/Support Center. The identification of boards will contain a manufacturer's number and a spare part identification number. On older boards the spare part number may not be included. Use the manufacturer’s number and a word description of the part ordered, indicating thatit is to be used as a spare. CONTROLLER SPARE PARTS KITS Spare parts are recommended for support of any Bulletin 1388 installation. “Spare Parts Kits,” consisting of common components, provide a convenient method of ordering and stocking the required parts. ‘Three levels of support are available: Level 1 -Fuses, 4ea. - Logic Supply and Fan/Contactor. Level 2 - Circuit Boards, 1 ea. - Control and Base Driver. Level 3 -Power Devices, 1 ea. - Contactor wisurge suppressor and Fan. Servomotor Spare Parts ‘The part numters shown below are for a single motor brush. The number of brushes ordered must equal the number of brushes on the motor. A minimum of four brushes are required for all motors listed, with some requiring as many as 16. The tachometer brush part number is also for a single brush (four are typically required). When other motor spare parts are required, please furnish all motor nameplate data. Motor Series/Allen Bradley Part Number Dec, 0P-, Des DPA, DPA DPu _DP.W.DPX__DPK. DPM PP. Replacement Motor Brush Tiers__ia7é__1ite79__—aines0__t7 Tere_1188r Replacement Tachometer Brush —111882—~111882—~*117882~—~+109882~—111882—117882~—~1717882Page 8-2 Spare Parts em Not Shown Figure B.1 ~ Bulletin 1388 Spare Part Locations‘Appendix Motor and Controller Setup Data Motor and Controller Setup Data _ Allen-Bradley Bulletin 1326 DC Servomotors supplied with Bulletin 1388 DC Servo Controllers are manufactured by the Peerless-Winsmith Company. Table C.B gives a cross reference between Allen-Bradley and Peerless-Winsmith catalog numbers. In addition, the table contains the set points for all potentiometers, switches and jumpers on the controller totailor it to « particular servomotor. The information shown was generated using the instructions in sections 5.3 and 5.4. ‘The majority of the adjustments on the Bulletin 1388 are common to all 1326 servomotors and can be set identically. These common settings are listed in Table C.A. The remainder of the settings can be obtained from Table C.B or calculated. ‘The rated motor currents in Table C.B are for motors without a blower. If ablower is to be used, the motor rated current will have to be recalculated. Contact your local Allen-Bradley Sales Representative for further information. If the motor being used is not listed or is ‘manufactured by someone other than Peerless-Winsmith, the settings and adjustments will have to be determined per the instructions in section 5.3 and 5.4. Table CA Common Settings ‘Adjustment Designation _ setting Potentiometer —1LIM 70 Conga Table to seit isseting shoul be Tes tan #TOTor the servomotorbenB GAN e TACH persection6a ‘OFFSET persection 64 MOOR, per Table ce ‘sw per Table ‘Swi perTable CB Swi perTable CB Tumper Pr Insert jumper 2 Nolumper 3 perTable CB ifthe servemotaris equipped with a Blower, the setingsshown in Table CB are incorrect Consul section 5. for instructions Pa ‘per Table CB ifthe servomotor is equipped with a Blower, the settings shown in Table CB are incorrect. Consul saction 58 for instructions Nerumper Ps ‘No umper This setting may require a change depending on the machine system or the application. Pr Insert Jumper This setting may require a change depending on the machine system or the application. Ingert Jumper This setting may require a change depending on the machine system or the application. Nojumper This setting may require a change depending on the machine system or the application. Nolumper This setting may require a change depending on the machine system or the application. ‘Nolumper This setting may require a change depending on the machine system or the application.Pagec-2 Motor and Controller Setup Data Table CB Bulletin 1326 DC Servomotor Cross Reference List and Controller Settings Motornnea HSETO) Torque ToperSetings note CatalogNumber_Seres__FrameSize ___Winding__"““Curent"_P3_PA_SWI_SW2_SW3_ceerorecsd “Tuasppata__4010 owas? __xsris_———Ss XX OO R26 DPATB 9217 Sixx © TRE DPAZA DRMPaS? «S218 55x x 138 o 1525.DPA20 ford i a 3 1526.0PAIA ‘DPMPaMS2 —__K9221 ex xt © 1526.07A38 Ko222 isi Xx 1526.07AIC 9592 ai xx TR26DPAAA ‘DrpaTsa__Ko220 50x x 06 9 o 13260PA8 19068 | nz x16 0 15265.09c1A___@080__DPMAIS? e309) 25 x ee 7 o 1526.0°C18 SAG 35 xo 83 © 1526.09C1C 6309 35x x1 TSBEDRCID 7209 yoo xe T326DRCZA, Dewars 8396 53 xo 70 o 1326-0728 E395 66 xo 89 1325.0PCRC e394 Tas) ee} 152600020 KTaO ni) x18 TRRGOPEIA_a0B0R _DREAOSE 8620 53 x 146 TRR6OPETB 8679) 66 x 18s TRREDPEIC e619 76 x TSREDPEZA, DREN 608 ea xo so 1526-0PE8 9602 az x18 1R2EDPEC KO607 Tha) x14 1326 0°E3A DRENTSZ e608 135; x12 0 TROFEO E25 159 a ee TaR6-0PEIC 13137 18a x 1s TaR6-DPEAA, DaeaeSz 9651 sax x oe 1326.07E48 O62 ox xO 1326.0PEIC___@090R__OREAZSE Ke500| 208 x1 se 1S26PESA DREAZOS___K8691 nz xe 74 1326-07656, e650 135 a ee ee 12EDPESC e689 a0 x18 132607568 DRE __K8739 77 a ee 1526.DPE68, Ka 6a x1 oe 8 THRE DPESC x10 248 x? TSR6DANA «50 DPMAGESS__K9230 6s x 73s TRREDPIB 9231 vax ee) TRREDRIC 9048) 37x a ee) TRREDPA DeMasIsS 9188 sx 123 1526-0928 9050 ax 1s 4 1326-092 9232 70x 733 TRR5DPRA, DeMaesss___K9233 102 os 1326-078 S051 ws _x ee Tae DPC Ko234 max 7s 73260950 19499 vax ee) Ta260PKIA___4660___OPUAGSSS __—_Kaata 3c xe 6s 1326.0°K18 Koa3 joa SOSPagec-3 Motor and Controller Setup Data Table C.B Bulletin 1326 DC Servomotor Cross Reference List and Controller Settings (Continued) MotorRated HSRO) Torque TaperSetlngs ory CatalogNumber Series _FrameSize Winding _—_—urrent—P3_—P4__—SWI__—SW2__—SW3_ rere) 1326.0°K1C Kee12 780) x xt a) 1326.0°K2A ‘Dewaazess 8407 143) xx 069 7326.00K28, 8405, 28, xx 1? 1326-0°K2C 8806 373, xx) 7S 1326-0°K2D_ 7608 269) x10 8 1326-0PK3A, DPMagzLSs 8876 200. x xo 6 8 T326-0PMIA__4890R _DRE@BRSS Ka163 Zz x 065 7326-0°M18 K9156 147 x 13 1326-DPM2A K9168 2s x 065 1326:0PM28 48908 DREABKSS K9155 250) x 73st 1326:0°M3A DREABTSS: K9165 165 x 062 1326:0°M38 K156. 330) x 122 1226 DPIC rom ane x o Ta 1326-0PMaA, DREREZESS __K9166 193 x os 6 1326:0°Ma8 KoI57 336. x 1 re) 7326:0°MaC 9260 292 x o 77 1326-0°MSA DRECBKSS 9167 Ba x 062 7326-0PMSB 1158 267 x 7 22 7326-0°P1A___5610__DPMSGDG2__K8S97 0) x x07 8 7326-00P18 8596 a7 x xt 73 1326.0 7P1C e569 240) xx 53 1326: DPP2A, Drwseec2___KarI2 zt x oso 1326-0928 8790 275: xx 0399 1326-07920 KS773 385. xx 3 1326:0PRIA___5670___DHRSEV. 6663 292, xs 1326-0951A 5680 DPMSGDFS___K7707 102 x x0 63 7326:09518 17708 143 xx 087 1326.0°51¢ 17709 73 x xt 7 o 1326:0°51D K7710 29 xx 14 ~6 1326-DPS2A, DPMseRrA__K77IT 195 xx 06S 7326-00528 Km 249 xx 083 1326-952C Kms 32 x xt 73 1326-DP520 Kr oa xx st 1326 DPS 9020 ne xx 073 1326-DPS2F 9754 325, xx zo 1326-07534, Drwsezre__KT7I5 289) a 7326-07538 x76 372 xx O08 7326:0053¢ 5680 DPMBGZFA__KT717 a7, xx 4 4 1326-07530, 71 305) a ee 7326-DPS3E Kora Ba xx os 2 1326-0753 Kar 206. xx 0 96 1326:DPS3G 3026 186 xx 042 1326-07534 Ka77S 35 x x 072 1326-07548, DPMSGENFA __K7719 351 x xo 5 8 73260548 K7720 a9 xo 82 7326:0°54C KT a7 xx to 3 7326:0°540, KT 2 x1 3SPage C-4 ‘Motor and Controller Setup Data Table C3 Bulletin 1326 DC Servomotor Cross Reference List and Controller Settings (Continued) Motor Rated SSE) TorqueToper Settings note Catalog Number Series __frameSize ___Winding __Current__P3_—PA__SWI__— SW SW3__feetnlon) 7326 DPSAE 9028" 236 xx ost 1326-0050F 959 209) xx 067 1326:0P546 9838 237 x xo 46 T326DPS5A___5685__DPMSEZPFA___Keasa Buia XA o 1326.0°558 Kaas? 67600 x X07 © 1326. 0PS5C 8310 351723 x x 08 6 © 1326-07550 com 70904 x x1 o 1326-DPSSE Kara 324675 x0 o 1326-DPUTA _5690R__DRESGSS 8700 130 x oso 1326.07078 Ka659 23.4 x o. 8s 1326.0PUIC 8695 365) x 148 1326:0PU2A DRESEKSS Ka703 287, x os 9 7326-0PU28 8702 a9) x o 39 7326-DPU2C 8557 38 x 1 a7 132607030, RESETS 8708 343, x ee 1326-07038 8661 338. x 0399 1326.07U3C 8646 749) x o 3 7 1326-DPUAA DRESGZOS3___K8677 a2. x os 9 T326-DPUG8___S650R _ORESGZSS3___K8576 308. x o 73 1326-DPUAC 8570 Ta x os 3 7326-DPUSA DRESEZTSS __KB762 a5 x 033 7326-0PUS8 S765 735, x o 6 6 TB26DPWIA__2190___DPMRIOMFS 8496 25 xx 048 1326-0018 Keo 323) xx 053 1326-DPW2A DewaiazGrs __K8496 62 xx os 3 7326-DPW28 8499 302. x xo 6 6 7326-DPW2C_ 9967, 5 x xo 5 6 7326-DPW3A DPM2IGABFS —_K8500 To. xx 058 1326-0°Wat 3507 1312 x x06 9 Notes: © Motor may be partially demagnetized f peak current tot exceeds 12A, AdjutILIM so that maximum peak current tothe motor is 124 © Motor may be partially demagnetized if peak current to it exceeds 25A, Adjust ILIM so that maximum peak current tothe motor is25A. © Motor maybe partially demagnetized if peak current to it exceeds 30A. Adjust ILM so that maximum peak current tothe motor is30A. © Motor maybe parvaly demagnetized if pe current toi exceeds 358. Adjust ILIM so that maximum peak current to the motor is 354, ® Motor may be partially demagnetized if peak current to it exceeds 16A. Adjust ILM so that maximum peak current tothe motor is 168 © Thismotor hasa machine duty rating. The fst curent figure 4x ex, isthe motor rating. The second figure xxx xxxis the duty rating of the motor. Adjustments must be made based on the first figure.‘Appendix A-B 7900 Series Cross Reference General Bulletin 1988 Servo Controllers, transformers and Bulletin 1926 Servomotors may have Bulletin 7900 catalog numbers if the equipment is provided as an integrated system with an Allen-Bradley ONC. The cross reference listbelow will alow you to convert 7900 series catalog numbers to Bulletin 1388 and 1326 numbers. Bulletin 1388 Servo Controllers 1388 Catalog Number 7900 Series Catalog Number 1388B-AV 10 7920-AA, 1388B-AV 20 7920-AC 1388B-AV 40 7920-AE 1388-AV 60 7920-AG. 1388B-AV 20-B-A02 7920-AAP 1388B-AV 20-A02 ‘7920-ACP, 1388B-AV 40-A02 7920-AEP. 1388-AV 60-A02 7920-AGP_ Bulletin 1388 Transformers 1388 Catalog Number 7900 Series Catalog Number 1388-TO25DR_ 7920-TNXP/TNXS, 1388-TO50DR. 7920-TPXP/TPXS 1388-T075DR 7920-TRXP/TRXS 1388-T100DR, 7920-TSXP/TSXS, Bulletin 1388 Inductors 1388 Catalog Number 7900 Series Catalog Number 1388-L10-10 1388-L20-5 7920-LBA 1388-L40-2 7920-LBB 1388-L60-2 7920-LBC. Bulletin 1326 Servomotors _ 1388 Catalog Number 7900 Series Catalog Number 1826-DPS4E 7900-MA 1826-DPS4F 1826-DPS4H 7900-MC. 1826-DPS1A 7900-MD 1826-DPS2B 7900-ME 1826-DPP1C 7900-MG 1326-DPS1C 7900-MK“Appendix Machine/System Adjustment Record INSTALLATION DATE oy [MACHINE OR SYSTEM DESCRIPTION AND LOCATION INPUT VOLTAGE FREQUENCY PHASE Axis axis2 axis3 54 ANSS 56 EQUIPMENT UST CONTROLLER 13888.aV. SERVOMOTOR 13260P. TRANSFORMER 1388-7. ENCODER BSN. POTENTIOMETER SETTINGS, uM GAIN MoDR ‘TACH & OFFSETSET? Yes NO YES NO YES NO YES NO YES NO YES NO SWITCH SETMNGS swt sw swa PLUG JUMPERS Indes iumeen romeo OUT Nour IN Our IN OUT. sWN OUT. IN UT. sN OUT Pe IN OUT IN OUT IN UT_—IN UT IN UT. N OUT 3 IN OUT IN OUT IN OUT sIN OUT, NUT. NUT Pa IN our IN OUT IN OUT IN UT IN OUT, NUT Ps Nour N OUT IN OUT. IN OUT. IN OUT. ourT °6 iN our IN OUr IN OUT IN UT IN OUT ourT "7 IN OUT IN Our IN UT WN UT. IN OUT. our re IN our IN Ur NUT. N UT IN UT N ur 9 IN our IN OUT IN OUT IN OUT. IN OUT UT Pio IN our IN OUT IN. OUT IN OUT IN OUT. UT Pit IN our IN OUT IN OUT. IN OUT. sIN OUT UTNotesNotesCUTALONGOOTTEDLINE See ® We Want Our Manuals to be the Best! Youcan help! Our manuals must meet the needs of you, the user. This is your opportunity to make sure they do just that, By filling out this form you can help us provide the most useful, thorough, and accurate manuals available. 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