1395 Connection Guide Adapter Board Connections, Encoder Connections and Armature Current Ratings Adapter Boards Discrete Adapter Board The Discrete Adapter Board is connected to Microbus Port A with wiring to external devices being accomplished at TB3, terminals 23 to 52. The drive is shipped pre-configured, meaning that all of the inputs and outputs are linked to a predefined signal. Figure 17 shows the 1395 standard configuration for the Discrete Adapter Board. The user has the flexibility to configure the drive for a particular application. Refer to the Discrete Adapter Manual for detailed information. 115V AC Connection- The 115V AC power source can be wired to be referenced or not referenced to common (zero volts) as shown in Fig. 16. Figure 16 Typical 115V AC Digital Input Connections Figure 17 Discrete Adapter Board Configuration 24V DC Connection/Digital Input- Sizing of the power supply is based on the number of input and output selections. Figure 18 shows the typical connection of the digital input using the external power supply. Analog Input - Velocity and Trim Reference. Connections for the velocity and trim reference inputs can be for uni- or bi-directional operation, using the internal drive±10V DC power supply (see Fig. 19). Figure 18 Typical 24V DC Digital Input Connections using External Power Supply Figure 19 Typical Analog Input Connections Tach Velocity - The analog tachometer device generates a DC voltage that is direction sensitive and proportional to speed. The tach output must be connected to an analog input channel on the Discrete Adapter Board. Most industrial tachs have an output greater than the ±10V range of the analog inputs. The tach output must be scaled down, by an external voltage divider network, so that the entire speed range of the motor can be represented by a + 9V feedback signal. CAUTION: Connecting a tach which has an output range greater than ±10V directly to the analog input channel can severely damage the adapter board. The tach signal then must be scaled in the adapter board to determine the proper relationship of output voltage/ motor velocity to base speed in Drive Units. This scaled configuration data must then be linked to Parameter 156 "Tach Velocity." Many problems relate to the scaling of the tach signals. Below is a procedure for checking the scaling of the analog tach feedback for proper drive operation. 1. Determine the Volts/RPM rating of the tach (refer to tach name plate). Multiply this rating times the absolute maximum speed the motor will be commanded to accelerate to. This value should also be programmed in Parameter 607 "Rev Speed Lim" and 608 "Fwd Speed Lim" to assure that the velocity command will be properly clamped. Volts/RPM Rating x Max Speed = Max Volts Out put 2. The Max Volts output must then be scaled to a level within the±10V analog input channel range. This can be accomplished by using a voltage divider network external to the drive. The voltage divider will take the Max Volts output and scale it to a maximum 9V input. This allows for protection against 10% overshoot. Figure 20 uses a 10k ohm resistor across the input channel. R1 represents the dropping resistor for the scaling network. To determine the value of R1 use the equation that follows (R1 should be rated for 0.5W, 1%). Figure 20 Scaling Circuit (Max Volts Output) x 6666 9V 3. The analog input channel on the adapter board must now be scaled to represent an accurate velocity feedback signal. First determine the analog input signal for base speed. Parameter numbers are given in ( ) where applicable. Base Motor Speed (606) x 9V Max Speed 4. − 6666 = R1 = Base Speed Input The input voltage at base speed is then converted to Raw AdapterUnits according to the following equation. Base Speed Input x 2048 10 = Raw Adapter Units 5. The Raw Adapter Units are then used to determine the correct scaling parameter value according to the equation below. 4096 Raw Adapter Units = Scaling Parameter Value 6. The Scaling Parameter Value should then be entered into the associated analog input scaling set -up parameter. This procedure will be correct to within 5%. Verify that the scaling is correct yb measuring the actual motor velocity with a hand tachometer. Fine tune the scaling by adjusting the appropriate value to minimize any error. 7. Any drift at zero speed can be minimized by adjusting the offset parameter associated with the channel in use. Analog Output- Figure 21 shows typical analog and digital output connections. Figure 21 Typical Output Connections Reference Adapter Board The Digital Reference Adapter Board is connected to Microbus Port A with wiring to external devices at terminals 23 to 62 of TB3. The drive is shipped pre-configured, meaning that all of the inputs and outputs are linked to a predefined signal. Figure 23 shows the 1395 standard configuration for the Digital Reference Adapter Board. The drive has the flexibility to be reconfigured for the application or as required. 24V DC Connection- A properly sized 24V DC power supply is required to power the 24 volt inputs. Digital Reference Input - The Digital Reference Adapter Board contains one digital reference commandfor the drive. The board is set up by default for the encoder input signal to be single channel, dual edge (i.e. both the rising and falling edges are used by the counting logic). The hardware is configured for +5V DC signal inputs with jumpers J6 and J7 in the 1- 2 position. For a +12V DC signal the jumpers must be placed in the 2- 3 position. ATTENTION: To guard against possible component damage, assure that jumpers are positioned correctly. Figure 22 shows the typical encoder connection used as a signal for the digital reference input. This encoder can be machine mounted or mounted on the motor of the lead section. Figure 22 Encoder Connections Figure 23 Example Digital Reference Adapter Board Configuration Figure 24 Typical Analog Input Connections Analog Input - Velocity and Trim Reference Connections for the velocity and trim reference inputs can be for uni-directional or bi-directional operation, using the internal drive +10V DC power supply (see Figure 24). Tach Velocity - The Digital Reference Adapter Board is not pre-configured for DC tachometer feedback. The user will have to reconfigure the drive by replacing the Trim Velocity Reference (parameter 161) with the Tach Velocity (parameter 156). The analog tachometer device generates a DC voltage that is direction sensitive and proportional to speed. The tach output must be connected to an analog input channel on the Discrete Adapter Board. Most industrial tachs have an output greater than the±10V range of the analog inputs. The tach output must be scaled down, by an external voltage divider network, so that the entire speed range of the motor can be represented by a±9V feedback signal. ATTENTION: Connecting a tach which has an output range greater than ±10V directly to the analog input channel can severely damage the adapter board. The tach signal then must be scaled in the adapter board to determine the proper relationship of output voltage/ motor velocity to base speed in Drive Units. This scaled configuration data must then be linked to Parameter 156 "Tach Velocity." Many problems relate to the scaling of the tach signals. Below is a procedure for checking the scaling of the analog tach feedback for proper drive operation. 1. Determine the Volts/RPM rating of the tach (refer to tach name plate). Multiply this rating times the absolute maximum speed the motor will be commanded to accelerate to. This value should also be programmed in Parameter 607 "Rev Speed Lim" and 608 "Fwd Speed Lim" to assure that the velocity command wi ll be properly clamped. Volts/RPM Rating x Max Speed = Max Volts Output 2. The Max Volts output must then be scaled to a level within the +10V analog input channel range. This can be accomplished by using a voltage divider network external to the drive. The voltage divider will take the Max Volts output and scale it to a maximum 9V input. This allows for protection against 10% overshoot. Figure 25 uses a 10k ohm resistor across the input channel. R1 represents the dropping resistor for the scaling network. To determine the value of R1 use the equation that follows: Figure 25 Scaling Circuit (Max Volts Output) x 6666 9V 3. − 6666 = R1 The analog input channel on the adapter board must now be scaled to represent an accurate velocity feedback signal. First determine the analog input signal for base speed. Parameter numbers are given in ( ) where applicable. Base Motor Speed (606) x 9V Max Speed = Base Speed Input 4. The input voltage at base speed is then converted to Raw Adapter Units according to the following equation. Base Speed Input x 2048 Raw Adapter Units = Raw Adapter Units 5. The Raw Adapter Units are then used to determine the correct scaling parameter value according to the equation below. 4096 Raw Adapter Units = Scaling Parameter Value 6. The Scaling Parameter Value should then be entered into the associated analog input scaling set -up parameter. This procedure will be correct to within 5%. Verify that the scaling is correct by measuring the actual motor velocity with a hand tachometer. Fine tune the scaling by adjusting the appropriate value to minimize any error. 7. Any drift at zero speed can be minimized by adjusting the offset parameter associated with the channel in use. Digital Input - Figure 26 shows a typical digital input connection. Figure 26 Typical 24V DC Digital Input Connections using External Power Supply Analog/Digital Output Figure 27 shows typical analog and digital output connections. Figure 27 Typical Output Connections Node Adapter Board The Node Adapter Board is connected to Microbus Port B and is not preconfigured. Refer to the Node Adapter manual for configuration and installation information. Multi-Communication Adapter Board The Multi-Communication Board is not preconfigured. Refer to the Multi-Communication Adapter manual for configuration and installation information. Armature Current Ratings The following tables provide nameplate data information to help you size wires during installation. Table P 230VAC Input - Armature Current Ratings ARMATURE Power Output .75KW/1HP 1.2KW/1.5HP 1.5KW/2HP 2.2KW/3HP 3.7KW/5HP 5.6KW/7.5HP 7.5KW/10HP 11.2KW/15HP 15KW/20HP 18.7KW/25HP 22.4KW/30HP 29.9KW/40HP 37.3KW/50HP 44.8KW/60HP 56KW/75HP 74.6KW/100HP 93.3KW/125HP 112KW/150HP 149.2KW/200HP 186.5KW/250HP 223.8KW/300HP AC Input Volts Max A 230 3.85 230 5.4 230 7.0 230 10.0 230 16.4 230 23.7 230 31.0 230 45.0 230 65.3 230 80.0 230 89.8 230 135.3 230 168.0 230 188.0 230 233.3 230 302.7 203 416 230 497 230 591 230 810 230 864 DC Output Volts Max A 240 4.7 240 6.6 240 8.5 240 12.2 240 20 240 29 240 38 240 55 240 80 240 98 240 110 240 140 240 180 240 210 240 260 240 345 240 472 240 564 240 670 240 918 240 980 FIELD AC Input Volts Max A 230 10 230 10 230 10 230 10 230 10 230 10 230 10 230 10 230 10 230 10 230 10 230 20 230 20 230 20 230 20 230 20 230 40 230 40 230 40 230 40 230 40 DC Output Volts Max A 150 10 150 10 150 10 150 10 150 10 150 10 150 10 150 10 150 10 150 10 150 10 150 10 150 20 150 20 150 20 150 20 150 20 150 40 150 40 150 40 150 40 Table Q. 460VAC Input -Armature Current Ratings ARMATURE Power Output 1.5KW/2HP 2.24KW/3HP 3.75KW5HP 5.6KW/7.5HP 7.5KW/l0HP 11.2KW/15HP 15KW/20HP 18.7KW25HP 22.4KW/30HP 29.9KW/40HP 373KW/50HP 44.8KW/60HP 56KW/75HP 74.6KW/l00HP 400/400/500 400/400/500 400/400/500 186.5KW/250HP 223.8KW/300HP 298.4KW/400HP 373KW/500HP 448KW/600HP AC Input Volts Max A 380/415/460 3.35 380/415/460 4.82 380/415/460 7.84 380/415/460 11.35 380/415/460 14.95 380/415/460 22.9 380/415/460 29.4 380/415/460 36.8 380/415/460 41.7 380/415/460 54.9 380/415/460 71.9 380/415/460 86.6 380/415/460 135.5 380/415/460 168.0 380/415/460 188.0 380/415/460 233.3 380/415/460 302.7 380/415/460 390 380/415/460 466 380/415/460 591 380/415/460 805 380/415/460 864 DC Output Volts Max A 400/400/500 4.1 400/400/500 5.9 400/400/500 9.6 400/400/500 13.9 400/400/500 18.3 400/400/500 28 400/400/500 36 400/400/500 45 400/400/500 51 400/400/500 67.2 400/400/500 88 400/400/500 106 400/400/500 140 400/400/500 180 400/400/500 260 400/400/500 260 400/400/500 345 400/400/500 442 400/400/500 529 400/400/500 670 400/400/500 913 400/400/500 980 FIELD AC Input Volts Max A 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 10 380/415/460 20 380/415/460 20 380/415/460 20 380/415/460 20 380/415/460 20 380/415/460 40 380/415/460 40 380/415/460 40 380/415/460 40 380/415/460 40 DC Output Volts Max A 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 10 250/270/300 20 250/270/300 20 250/270/300 20 250/270/300 20 250/270/300 20 250/270/300 40 250/270/300 40 250/270/300 40 250/270/300 40 250/270/300 40