IQ Series Installation Manual Part2

t
42 Reference lnstallation Drawings. Outline Drawings

t
(
e
=
L) s
1,i
I (D
i
Jm_ +
I H
a
la>
]J:
tL) @ .Ea
I úJ
I
t =CI
-'.lo *
E§>H = 2T.
t
slCI{" >
z
g l[L <i E I
o E E ü]
u E
H
*'t
;!-F
i
@
J
u z
e o
a
É
-+
i{ t
ñ U¿
I
I
FJ
AE
_, 6q
E
(.)
e
5
ñ=
-'
J xO
(-l
I2 o{
e'
o
i
-c4
e2
:qtL s< ñ qó
=
d
e 5
=B I
z
ñ
i
I
I
I
Im
f---l
t\
-h,-{¿l
.{
H J
E
c
f
z
\.t
I
t
NC
ir95É:
=sfsuE a I
É n es=
o
aoozr= ñ
a E;9ÉEF P *=8
ü3= =da
A X=?HAY -.
b F
,qh Éd o P>
B d
EE33== H éE =p
r i 6 ÉEE
É
Éss5É5 É §." k o$o

zQC z
íi-=,,2éZZ
r
íf x *-"4É;.i P E A E
EA
+> f d<
ñe
=E
É=
H
é éEH
Ezó
==á
ú 9(FaES
.
u € u z d .
GU =
H Eóp
--ii!+ =L ñ =kg
É :áE?eE x ?É HPE ÉE 9 rEE
; E ¿ kÉ
¡ 9= ?¿:"-=*
gEE xp=
ilEr?B H == *i
ÚE =
ÉÉ B==
,lk'J z ñ;;z:'l
<-==u7 ú Íz -2
=¿ e?6 8é á B6u.
H fr ÉETEEe É Éá i: EEÉ EH E Él+*
I qLú
x E [gEE3i Éz sZ Ep 224 ñ úOe

qni
=3 E
i
s H. tiÉ:+§
E aÉ fr* is
í.=HE6"s 0i Éu z-
OrE
ñEE EE
Y^
H
I
exd
OsO
6 8Be
* á HE= 8
z r=rfÉÉ
áER
zL-=4#7 z= E==ac
É9 H_9¡; ;nH EE
7HS ztr;
* a
= 5É Qtu
ñ E8E
6
2 - - -i
<#ri :FE -P a *Eá
L,.
lO 2000/5000 lnstallation Manual
a
E}
- Wiring. System Power Connections 43
\Et
-
\ D
-J
-
-
-
l!'
-
-
llr
E
-
Wiring
-
-
-
-
-
-
-t System Power Connections
=ü
qt DANGER
ry The user is responsible for conforming to NEC and all other
: applicable local codes. Wiring, grounding, disconnects and
overcurrent protection are of particular importance. Failure to
ry observe this precaution could result in severe bodily injury or
loss of life.
-
- IQ-2OOO PCM
ry The PCM-10, PCM-20 and PCM-30 require single phase AC power, lo}-24o vAC. The pcM-75
requires single or three phase AC power, 100-U.O VAC. The input power may be optionally isolated
= through a transformer. Field wiring must be copper, with a minimum rating of 60"C. The phasing of L1
= and L2lI.{ to the PCM-10, PCM-20 and PCM-30 is arbitrary. The phasing of rhe PCM-75 is Ll, L2A.{
and L3 The earth ground connection is required for safe and proper system operation. Terminal block
=
!, connections should be torqued to 11 lb-in (1.25 Nm). The IQ-2000 does not contain supply fuses or dis-
connecting devices. These must be supplied by the machine builder and co¡nected externally for safety
!, and maintenance pu4)oses.
Refer to üe following drawings for complete power wiring details.

=
. PCM-10, -2O ar:Ld -30 Power Wiring Diagram, drawing 9l0l-Zlg5 on page 76
=
. PCM-75 Power Wiring Diagram, drawing 9LOI-1453 onpageTT
=
= - These drawings show an optional AC line filter, and shielded motor cable. These can be used in con-
junction with the grounded metal enclosure to meet tle Electromagnetic Compatibiüty requirements of
=Ü the European Machinery Directive. A discussion of EMC can be found in "system Installation for Elec-
Y
ry
lQ 2000/5000 lnstallation Manual
Y
L
44 Wiring. System Power Connections
tromagnetic Clmpatibili ty" otpage 25.
DANGER
Shielded power cables must be grounded at a minimum of
one point for safety. Failure to ground a shield power cable
will result in potentially lethal voltages on the shield and
anything connected to it.
Auxiliary Logic Power

Single phase AC power, IOO-240 VAC, may be supplied to the internal logic supply through Ll ALIX
and L2lN ALIX.
Supply power to the logic supply is useful if the PCM logic must stay ON when üe motor power must
be turned OFF. Absolute positioning is one example of when üis would be useful, since position infor-
mation is maintained as long as logic power is on. Another example would be mahtaining PCM logic
power so the PCM serial interface could be used for troubleshooting and diagnostics.
IQ.5OOO PCM
Power Supply Module (PSM)
The Power Supply Module (PSM) can supply DC power to as many as six PCM modules. Three phase
AC power, ll5l23Ü VAC, is the only required input power for the PSM. The input power may be
optionally isolated through a transformer. Field wiring must be copper, with a minimum rating of 60"C.
The phasing of üe input power L1, L2, andL3, is arbitrary. The earth ground connection is required for
safe and proper system operation. Terminal block connections should be torqued to 11 lb-in (1.25 Nm).
on the PSM-50 ard24lb-rn (2.75 Nm) on the PSM-125. The IQ-5000 does not contain supply fuses or
disconnecting deüces. These must be supplied by the machine builder and connected externally for
safety and maintenance purposes. The Power Suppty Modules will continue to operate with reduced
capacity with the loss of one phase. The red phase loss LED on the front of the PSM will turn ON to
indicate the loss of the phase.
CAUTION
The power supply module allows for operation to continue
even in the event of loss of one phase or during power
disruption on the three phase AC inputs. Under these
conditions, the Phase Loss LED will light, but the power
supply is not disabled. Extended operation of this product
with an AC phase input missing will reduce the life of the
product.
Refer to drawing 9101-0411 on page 74 for details. This drawing shows an optional AC line filter, and
shielded motor cable. These can be used in conjunction with the grounded metal enclosure to meet the
Electromagnetic Compatibility requirements of the European Machinery Directive. A discussion of
EMC can be fouud in "System Installation for Electromagnetic Compatibiüty' otpage 25.
Positioning Drive Modules (DC Bus Power)
The DC bus from the PSM supptes power to the IQ-5000 PCMs. The DC bus must be connected as
shown in drawing 9101-0411 on page T4,wifhthe PSM in the center, ¡¡sing the connection wires pro-
vided.
I
D.
L
Wiring. System Power Connections 45
H
tJ
I
l*.}
L
CAUTION
H,J
t:
b.v
Do nof substitute the DC bus wires provided with other wires.
Failure to observe this precaution may result in damage to or
b destruction of the equipment.
b
F Auxiliary Logic Supply
§Lr
An auxiliary power supply module (PSM-AUX) is available to supply DC power to the logic supplies
b of up to four PCMs if the PSM is OFF. The PSM-ALIX uses single phase 115 VAC power as the input.
b
h
The PSM-AUX option is usefrrl if PCM logic power must stay on even when the motor supply (the
PSM) is off. Absolute positioning is one example of when the PSM-AIIX would be useful, since posi-
LY
L
l\t
tion i¡formation is maintained as long as logic power is on. Another example would be maintaining
PCM logic power so the PCM serial interface could be used for troubleshooting and diagnostics. Refer
b to the drawing 9l0l-OL34 on page 75 for wiring information on the PSM-AUX and optional PSM-ALX
L
tv
isolation ffansformer.
L
LY
PSM Interface logic
L
LY
The Status signal and the Enable signal on the PSM are proüded to interface the PSM wiü the PCM or
another control. The following drawings illustrate typical internal circuitry for the interface connec-
L
LY
tions, and sample external connections of the PCMs.
L
LY
L I
TB I POI.IE R SU?PLY XODULT

I
E"l
b il
!r
b ar
:l
F
F E
ENABLE_
XIE RNAL ENABLE J NPUI
P )
NO
E I r-oxrN
b ftl
-tltl
I
b I . 5K OHti
0. 5 itAiT
z {/!/{/ I
I
*YOY
L
ry L]
I
b lqlr¡ll l
b PSM Interface - Internal Circuit Examples

b
¡
\
¡
t
\
¡
I
b
t_
46 Wiring . System Power Connections
SAIYPTE E XTE RNAL CONNE CT ] ONS
I
1
t_
I
L-
ilt)
ll)
-f
PSM Interface - External Connection Examples
PSM Connector Pin # Signal Name
P1 I Status-
General 2 Status +
Purpose J PSM Enable-
Inputs/Outputs 4 PSM Enable + rL
I
Wiring'System PowerConnections 47
Status
The Status outputs are the contacts of a normally open relay, which closes to indicate that the PSM is
operating properly. An open relay signals that no AC power is applied to the PSM or that a PSM fault
E" has occurred. Refer to the above drawing for connection examples.
Enable
The PSM Enable input is an optically isolated input which controls the power output of the power sup-
P ply module. The PSM Enable input is turned on by sourcing current through the opto-isolator. Refer to
the above drawing for connection examples. The input is only functional ifjumper Wl is il the optional
position, A (see figure below).
F
With the jumper in the enable input activated position (optional Position A), the PSM is enabled if the
P enable input is ON. With the enable input OFF, üe PSM DC bus is turned OFF and the dissipative shunt
P is turned ON to quickly discharge the DC bus capacitors and dynamically brake synchronous motors.
r
E
This is to allow time for the PCMs to power-up and apply the enable signal to the PSM if the PSM is to
remain on.
F WARNING
F lf the PSM is disabled during a power up, the DC bus voltage
will be present for at least two (2) seconds before returning to
lrr
p a zerc (0) Volt condition.
trt
p With the jumper in the enable input deactivated position (standard Position B), the enable input has no
h, effect on the PSM operation and the PSM activates itself when tkee phase voltage in the proper voltage
range is connected to the input.
[.,, a
I DIAGNOSTTC
INDICATOR
l., LIGHTS
lu POWER SUPPLY MODULE

CIRCUIT BOARD
1- (COMPONENTSIDE) TB1
L INTERFACE
CONNECTOR
F
p W1 JUMPER SETTING SELECTS:
b SHORTING JUMPER ACROSS

TOP 2 PINS (POS|T|ON A)
EXTERNAL ENABLE INPUT IS SELECTED.
EXTERNAL CONNECTION IS REQUIRED
F TO CONNECTOR TB1 SIGNALS ENABLE+

AND ENABLE-. REFERTO INSTRUCTION
MANUAL FOR SIGNAL SPECIFICATION
l', AND DETAILS OF OPERATION BEFORE
b USING POSITION A,
t SHORTING JUMPER ACROSS EXTERNAL ENABLE INPUT IS DE.ACTIVATED,
I
BOTTOM 2 P|NS (POSTTTON B) POWER SUPPLY I\4ODULE IS ENABLED WHENEVER
(STANDARD SETTING) INPUT POWER IS APPLIED AND NO POWER SUPPLY
I\4ODULE FAULT CONDITIONS ARE DETECTED,
lu
tL Power Supply Module Jumper Location
l'.,
U
Y
Y
p
>.
48 Wiring r System Power C"onnections
Replacing the PSM Shunt Fuse (IQ-5000 only)

To check anÜor replace this fuse:
The DC Bus shunt fuse is located in the Power Supply Module.
1. Measure voltages atLl,L2,and L3 phase to phase to ensure

incoming power is OFF Make sure
L
OFF Remove the PSM cover'
that the green PSM READY LED is
Remove the shunt fuse and test with an ohmmeter'
WARNING
when replacing the PSM 50 and PSM 125 s-hunt fuse a DC
rated fuse must be used'
J. Replace the shunt fuse.

4. Install the PSM cover.
Shunt Resistor
Power SuPPIY Modulg

§-
(lQ 5000 OnlY)
PSM-125
20 AmpeE KLKD-2o or KLitr2O
PSM - 50
I Ampere KLKD-8 or KLM{
PSlr-125 wiih exterml shuot

' 3OAmPeeKLKD-1OorKLl,.30
DC Bus Terminals
Shunt Fuse Location
I
i"r
- Wiring'System PowerConnections 49
E
* Opárator Termina!
The Operator Terminal may be powered from 115/230 VAC single phase or optionally, *om24 VDC or
-
EJ 24yAC. The Operator Terminal must be properly grounded to prevent it from radiating radio frequency
noise.
The following diagram illustrates the power connections to the operator Terminal.
=
\,
!' I 2/\ PL
\D
E
IFI
ts,
=t
Flt
IT GROUND (EARTH)
115/230 VAC (NEUTBAL)
L 11s1230 VAC HOT)
L Operator lbrminal Power Connections (1.15/230 \4\C Version)

it
I
l=
L L1 L2lN Pt
tr
L
F!,
Il-,
!
!t
b
- GROUND (EARTH)
- 24 VDC (DC-), 24 VAC (NEUTRAL)
24vDC (DC+), 24 VAC (HOT)

=
=, Operator Terminal Power Connections (24 VDC, 24VAC Version)
-
-
-
=
-
-
ry
t,
l-
I
50 Wiring. System Power Connections
t
Motor Power Connections
The phasing of the three phase drive module outputs R, S, and T must conform to the motor R, S, and T
leads for proper operation. Connect the earth ground to ensure a safe installation and proper operation.
Refer to the following motor connection üagrams for connector, pin, and signal identification.
S-SER]E5 AND I-5300 AND

F-5ERIE5 IIOTORS .6600 l'10T0R5
nnIvr yoou-r I IlOTOR PCi./ER fi0T0R P0\"iE a 14OTOR POIiER
TERY I NALS IlAT.NG CONNECTOR CONNE CTOR TERI,IINAL STR IP
R
A
,/e R
,/s
\-
DR IVE [,]ODULE
C ,¡¡
CFASS ] 5 ,/ l'40T0R CASE *=
D <¡--------¡ MoToR .ASE
,'7 7
I
I I
Notes:
1. Do not interchange any connections in this cable.
2. Ground Connections:
lQ-2000 - Screw Terminal
IQ-5000 - MG Stud
.r. Wire colors shown are for cables supplied by Electro-Craft
Motor Power Connections
WARNING
High voltage may be present on the terminals of the lQ-Series
Positioning Control Module. Remove power and disconnect L
the power cable before making or removing any connection.
Cab1e sizes are inücated in the appropriate drawings:

. 910l-2195 on page 76 for the PCM-10, PCM-20 and PCM-30 (IQ-2000)
. 910l-1453 on page 77 for the PCM-75 (IQ-2000)
. 9101-0411 on page 74 for the IQ-5000.
Standard cables supplied by Electro-Craft are not intended for applications where frequent flexing
occurs. The motor connectors are intended to be connected or disconnected only when the system
power is off, and must zol be used to disconnect live equipment.
WARNING
Motor power connectors are for assembly purposes only.
They should notbe connected or disconnected while power
is applied to the drive.
I
Wiring. System Power Connections 51
CAUTION
Do nottin (solder) the exposed leads on cables. Solder
contracts over time and may loosen the connection.
Shield Termination of Power Cables
DANGER
Shielded power cables must be grounded at a minimum of
one point for safety. Failure to ground a shielded power cable
will result in potentially lethal voltages on the shield and
anything connected to it.
F-, H-, N- and S-Series Power Cables

Electro-Craft motor power cables are shielded. The power cable is designed to be terminated at the
drive during ilstallation. A small portion of the cable jacket is stripped, which exposes the shield wires.
The exposed area must be clamped at the left front of the drive chassis using the clamp provided near
the bottom. It is critical for EMC performance that the shield wires be clamped against the area of the
chassis which is not painted. This section of thp chassis is labeled with the chassis ground symbol.
Cable Jacket
Motor Power EMC Shield Connection
Drawings which illustrate the power connections for specifi.c F-Series, H-Series, N-Series, S-Series, W-
Series, and I-Series motors are supplied with the motors and are available in the Electro-Craft catalog or
via the Electro-Craft BBS.
i
52 Wiring . Control Connections
a
Control Connect¡ons
This section covers the control and interface connections between the PCM and the rest of üe system.
This includes: Digital VO, Analog VO, Relay Outputs, Encoders, Step and direction Inputs, and Serial
Ports.
The following diagram illustrates all control connections to the PCM.

<P7 s <---N-f
OPERATER STATlO\ <P7 I < Ilc
<F7-7 < Nl
p7 é
< SHI¡LI
5 < CnMM¡N
¡7 ¡ ( r!Tr+
';3 a llE
< R'V2
P7-1 < RaV2+
<P6-S ( Na
PRO6RAMMI NG
10 Moster TERMI NAL <P6s<xc
<P67 ( NC
P6-6 é, :-El:L-i
Pa i ( C¡!'1¡N
<P6 4 <--XML1+
Fr r a lui'
F!-t , Rf:L'
,P3-i , Ravl +
pst¡i§!E!D
p+r¡é§lQL
P$13+]!A!q
p+l:L
Ptlr+§:l
Pala'_
^-- €vDc
H
prz+qQUTQL
Fs i coMMoN
P+¡,E
pu+
pt3,L
P'2-L
Ptr +
DIR-
<P+13
<P+12
SfEP+
P+10 ,I
. *svDc
P49
MA§TER ENCODER
<PA , DIR+
i- coMMoN
rL
( P4-6 ..
-qaulaN
P+5
.B-
B+
P€
,?!
P+1 -¿
+15VtD
8 ¡II NAC NIT (M]NIT[R)
1A EIT NAC IUT
1C 3IT A/I 1N
ANA.[G
'!{¡]N
REL¡. Cl[l:1].{
tNA¡LtI
PCM Control Connections
t
FU
L.
l-,
tr Wiring. Control Connections Sg
t-t Oigital lnputs and Outputs

tr J Each IQ-Series PCM provides 16 optically isolated inputs and
8 optically isolated outputs fo¡ machine
confol and interface. The general purpose VO uses a24 voltDCsuppty voltage.
rire pcvt has an inter-
§, nal24YDC @ 500 mA power supply for üis pu{pose, isolated rrom t¡e logic
common. The 24 volt
common must be tied to machine ground to provide a corrrmon ground
F, the PCM protecrs the hternal 24VDC supply.
reference. The 1A fuse, Fl, on
l=
F
¡:l
Note: The user may supply externar 24vDcpower by removing wire jumpÁ
the PCM logic board, and connecting the external supply to t¡e iz+únc
mon on connectors P1 and p2.
w3
*¿
and w4 on
24 volt com_
II Pin 1 of the interface connectors P1,P2, and P3 is located

at the bottom of the connector and is indi-
cated on the front of the pCM.
=
i IN|ITERNAL
=
RESTSTTANCE [S 330 oxlM Mlt{tMtiM
= INTEFÍ{AL 24 VDC §UFPLY
= 75M mS PER OLrmr

= 56emA TOir=Al.
= 24 VOú eO,MMOit
=
!
I
!
:,
: ü
?
I INPLf SW:'rq,lEg:,qES|STAN6E tS aoo! úHkl MIAX|MIUM
MMERNAL 24 V]DE SUgFIY
:
: Typical Digital VO Wiring
t
t CAUTION
!,
.':, The lQ-series uses sinking (NpN) styre inputs and outputs.
This is the most common interface used ¡n the usA. rf a
I ground fault occurs on an input, it can become active and
2 may result in a potentially hazardous unanticipated machine
state. Contact Electro-Craft for more information.
?
? The IQ 2000/5000 has sinking (active low) vo which is common
in the uS, but sourchg (active high) V
o is preferred in Europe. Electro-craft offers a DIN rail mounted interface
, from sinking to sourcing (active high). This hterface board must
board which converts the vo
be mounted in the same enclosure as
, the drive. The interface board and cables are listed below:
, . 9103-0t52 24YDC Sourcing VO Conversion Card

, . 44-0t41_o03 IQ-Series to VO Conversion Card, 3-foot Cable
t . 44-0141-OLO IQ-Series to VO Conversion Card, l0-foot Cable
t
)
a IQ 2000/5000 lnstallation Manuat
a
L--_-
Digital tnpirts
The opücally isolated inputs are connected with an internal pu[-up resistor to +24 YDC. Making a con-
nection fo the 24 volt common (closing a switch) will allow curent to flow through üe opto-isolator,
turning it on. In general, inputs are considered ON in this state, and OFF when there is no connection
from the nputto )4 volt common. The Forward and Reverse Limit switches are exceptions, with the
switch open indicating that a limit has been hit. The Home Switch input parameter defi.nes the Home
switch input to be open or closed to indicate the home position, and the PAUSE parameter can select the
Pause input as active open or active closed.
The general purpose inputs on the PCM are referred to as I1 through 116 in program statemetrts. Inputs
11 through I10 can be assigned the predefined functions shown in the table below. Inputs I11 andll2
may be used as Intemrpt inputs. Inputs I12 to 116 may be used as program select inputs. Any of these
input functions may be üsabled and the inputs used as general purpose inputs.
,
In adütion to the input functions defined below, other functions may be assigned to any available input.
These optional input functions are Hardware Reset, Kill program, and Define Home
Connector Pin Signal Name Assignable Function
P1 1 24YDC Common
General
Purpose Inputs 2 Input 1 (I1) Forward Limit
J Input 2 (I2) Reverse Limit
4 Input 3 (I3) Enable
5 Input 4 (I4) Start Program
6 Input 5 (5) Home Switch
7 Input 6 (16) Home Command
8 Input 7 (I7) Jog Reverse
9 Input 8 Q8) Jog Forward
10 Input 9 (9) Pause
11 Input 10 (I10) Emergency Return
t2 Input 11 (I11) Intl / Program Select
t3 Input 12 (I12) Int2 / Program Select
T4 Input 13 (I13) Program Select
r
lE
E Wiring ' Control Connections
T
II Connector Pin Signal Name Assignable Function
§r
¡-
P2
General
1 Input 14 (I14) Program Select
Purpose Inputs 2 Input 15 (I15) Program Select

ts and Outputs
3 Input 16 (I16) Program Select MSB
=
= t2 +24YDC
-
Note: Even if an input is assigned a function it may be used as a general purpose
- input.
-
=
-
-
-
\r
Lr
-
L.
\
-l
h
t;
b
b
b
b
tI.t
b
b
b
b
F
F'
b
E"l
t
h,
I
¡,
\a F
56 Wiring'ControlConnections
F
t
F
Digital OutPuts
F
The general purpose outputs are referred to as 01 through 08 in progfam statements' The
outputs are
optiáIy isolated and operate on the same 24 volt supply used by the general purpose inputs. These b¡
to than volt. Outputs 06, 07, and
ootprrt.-*" all capable of sinking 75 mA continuously, driven less 1
Error outputs, however,
h
08 are defined respectively as Home Sequence Complete, In Position, and
these output functions may be disabled and the outputs used as general purpo§e ouQuts'
Optionally' l¡¡
Output 05 may be enabled as an At
Output O+ûy be enabled as a Program Running output, and
h
Home output.
b¡
\
External circuitry must be used to ensure the state of digital \
outputs in an emergency stop situation. The lQ-series will nof \
automaticallY turn outputs off.
\
\
Assignable Function
\
Connector Pin Signal Name
\
P2 4 Output 1 (O1) P2 \
General \
Purpose Inputs 5 Output 2(O2)
\
and Outputs
6 Output 3 (O3) \
\
1 Output 4 (O4) Program Running
\
8 Output 5 (O5) At Home \
\
9 Ouput 6 (06) Home Sequence Com-
\
plete
h
10 Output 7 (O7) In Position h
F
Output 8 (O8) Error
11
tr
t2 +24YDC +24YDC b
h
Connecting Inputs and Outputs Tbgether \
A digital output from a PCM may be connected to an input on the same controller or another controller. §
A single wire connection between the output pin and the input pin is all that is required. If conaecting V
. O between controllers, the 24 VDC common (Pl pin 1) also needs to be connected between each
con- \
troller. h
Multiple digital outputs may be wired together to form a wire OR connection. If any one of the outputs b
turns on, tfre me is pulled low (on). This is useful for connecting the Error output§ (O8) from each axis
of a system to a host PLC or machine controller to indicate an eüor in any of the axes.
b
Multiple ügital inputs may be wired together. If the line is pulled low, all connected inputs will turn on.
b
This is .r*"ñrl fo, connecting an input on each axis of a system to an output from a host PLC or machine
conüoller to sYnchronize event§.
tb
I
t
lQ 2000/5000 lnstallation Manual E
E.-
F-
h
Wiring. Control Connections 57
§
Anrlog lnput
The Analog to Digital converter (ADC) input, ADCl, on P3-5 may be used to read any analog signal
with a range of +10V. The analog signal ground must be connected to the Analog Common on connec-
! tor P3-4. The Analog Common is tied to earth ground internally. The 10 bit ADC has a resolution of
approximately 20 mV. This analog input may be used as a general purpose analog input or as the fee-
drate input. Refer to the IQ Master Manual for detailed information on the use of this input.
E Connector Pin # Signal Name
P3 4 Analog Common
Analog UO
and Status 5 Analog Input (ADCI)
Anatog Input and Output - §pical Internal Circuits
ilir"Jr"r"'H:g converter (DAC) ouq)ut, DAC1, on pin p3-6 outputs an analog signal with a
range of t10 volt. The analog signal ground must be connected to the Analog Common on pin P3-4.
The 12 bit DAC has a resolution of approximately 5 mV. Refer to the IQ Master Manual for detailed
information on the use of üris ouput.
Connector Pin # Signal Name
P3 4 Analog Common
Analog VO
and Status 6 Analog Output (DAC)

\a
Monitor OutPut
The Programmable Monitor output allows a system variable to be monitored' The
variable to be moni-
The monitor output is a t10
tored is selected in tle Monitor menu, Variable Monitor Set Up dialog box.
for detailed information on the
volt analog signal with 8 bit resolution. Refer to the IQ Master Manual
use of this output.
P3 4 Analog Common
Analog VO
and Status 7 Programmable Monitor
Ready Relay OutPut

powered up and
The Ready output @3-1) is a normally open relay contact that closes when the PCM is
This contact is
no faults exist withi¡ the PCM. Relay Common (P3-3) is the common of this contact.
rated 0.3 A af 24 VDC. The Ready output will open if a system fault occurs.
P3 1 Ready (Relay output)

Analog VO
and Status J Relay Common
P3
I Brr DAC OUT (MONITOR)

12BIT DAC OUT
1O BIT A/D IN
ANALOG COMMON
RELAY COMMON
NORMALLY NORMALLY
Enable and Ready Relay - Typicat Internal Circuits

Wiring' Control Connections
Enabled Relay Output

The Enabled output (P3-2) is a normally open relay contact. The Enabled oulput closes when the PCM
is enabled, and opens when the PCM is disabled. Relay Common (P3-3) is üe common of this contact.
This contact is rated 0.3 A at 24YDC.
P3 2 Enabled (Relay outpu|

Analog VO
and Status J Relay Common
External circuitry must be used to ensure the state of digital

outputs in an emergency stop situation. The lQ-Series will nof
automatically turn outputs off.
L-
¡
Encoders
The pCM provides interfaces for two separate encoder feedback connections. The PCM will accept
encoder inputs at a maximum frequency of 750 kHz on a single channel (A or B) for encoders
with :
phase erroi of less than or equal to 45 degrees. There is a four times multiplier on the encoder input to
the pCM on both the encoder 1 and encoder 2 inputs, so four encoder counts is equivalent to one
per revolu-
encoder line. With a standard 2000 line encoder, the PCM will count 8000 encoder pulses
tion.
The pCM will accept differential (line driver) quadrature signals from a 5 volt incremental encoder. The
pCM accepts A, B, and I (Index) signals from the encoder, with A leading B for clockwise rotation
fac-
ing the motor drive shaft. Connections afe provided for A+, A-, B+, B-, I+, I-, +5 VDC, and common
signals.
L
Encoder Input Circuitry ExamPle
Encoder I
Encoder 1 must connect to the encoder mounted to fhe motor. This is the only motor mounted feedback
necessary for control of the motor velocity. This encoder is also nomrally used for position feedback.
The Encoder 1 interface also i¡cludes connections for the normally closed thermostat in the motor
windings, and for an analog start-up signal required for proper operation'
Refer to the drawings of cable 9101-2031-XX on page 80 and
glOl-2On-)C{J(' on page 81 for connec-
tions to H-, F-, or S-Series motors.

-
'!D Wiring . Control Connections
t
¡l
i Connector Pin # Signal Name
t17
t P5 1 A+
t Encoder
t Input I 2 A-
¡r 3 B+
f.. 4 B-
f'o
tr 5 I+ (Index)
¡t
f't 6 Common
f'r 7 Common
F
l'r 8 No Connecúon
l'r 9 +5 VDC
F,
FI 10 I- (Index)
F,
l', tu 11 TS- (thermostat)
b t2 TS+ (thermostat)
F,
F, 13 Analog (Absolute Posi-
tion)
F,
l't t4 +5 VDC
F
r' 15 Shield
F"
H
F"
FI
F?
E
F"
FI
F=v
F'
b lQ 2000/5000 lnstallation Manual
tr
62 Wiring. Control Connections
D
p5_156_snrELD_
*5 VDC
P5-14 <
p5-13 6AMLG-
ps-tz< TS*
TS-
P5-11 <
ps-rceL
*5 VDC
P5-9 <
NC
P5-8 <
coMMoN
P5_7 (
coMMoN
P5_5 <
na, ,B-
Ê^ Z--
A-
ñE ¿-:_:-
^
A*
P5-1 (
Encoder 1 Connections
Encoder 2
The Encoder 2 input interfaces to an optional second encoder which can be used as position feedback
directly from the load, or as a master input for relative positioning, master-follower systems, or for elec-
tronic gearing.
As an alternative, the Encoder 2 portmay also be used to output encoder 1 signals when only the motor
mounted encoder is used. The function of the Encoder 2port is selected as input or ouq)ut in the Param-
eter menu, Feedback Configuration dialog box. Refer to the 1Q Master Manual for detailed information. ü
The PCM will accept differential Qine driver) quadrature signals from a 5 volt incremental encoder. The
PCM accepts A, B, and I (ndex) signals from the encoder, wiü A leading B for clockwise rotation.
Connections are provided for A+, A-, B+, B-, I+, I-, +5 voLts, and common signals. The I+ and I- sig-
nals do not need to be connected ifnot needed.
The Encoder 2 signal wires to the PCM should be shielded. The shield should be connected only at the
encoder end. However, in some applications it may be necessary to connect the shield at the PCM end
of the cable also. Connector P4 includes a separate pin (Pin 15) for this purpose. Refer to the drawing of
cable9l9l-203l-X)O( on page 80.

lE
Wiring'ControlConnections 63

;
P4 1 A+
Encoder
Inpt2 2 A.
3 B+
4 B.
5 I+ (Index)
1 Common
9 +5 VDC
(250 mA maximum)
10 I- (Index)
15 Shield
P4_15
P4-14
=§!LE!Q_
( +5 vDc
P4-13 < DIR-
P4-le. STEP'
STEP*
P4-11 <
p¿-loJ
( +5 VDC
P4-g
DIR+
P4-B .
MASTER ENCODER coMMoN
P4_7 <
P4_6 <
coMMoN
l*
P4-s
P4-4 , B-
-'
P4-3 < B* -
P4-2 l-
P4-; +41
Encoder 2 Connections
Slaving One IQ to Another
In applications where an IQ needs to "follow" another IQ-Series controller using electronic geariag, the
P4 connections may be used to provide a simple method of wiring the motor encoder signals from the
master IQ to the Encoder 2 input of the follower (slave) IQ. The master IQ needs to be configured to
tt output its motor encoder signals on P4. Refer to the lQ-Series Master Manual for detaied fuformation.
A standard cable, 9101-2127-OO2,is available for this purpose. Refer to üe drawing of this cable on
al page 80.

Step and direction lnputs

The PCM can accept step and direction inputs on P4 which provide a standard interface to an indexer.
the step and direction inputs on P4 are used, the encoder 2 port may still be used as encoder 1 out, but
not for connections to an auxiliary encoder input. The step and direction inputs require a source to drive
If
L
a 10 mA load at 5 VDC. TTL levels are compatible as long as the input current is sufficient. These opti-
cally isolated inputs are suitable for open-collector drivers on the inputs. The source ofthe step and
direction signals must provide power for tle opto-isolators as well as step and direction signals. The fig-
ure below illustrates the connections for active high and active low signals to the step and direction
inputs.
P4 8 DIR+
Encoder
Input 2 11 STEP+
l2 STEP-
13 DIR-
15 Shield
Step and DiÉcl¡on

Step and D¡Ec't¡on
Act¡ve Lil Active High Q
Step and Direction Input Connections
The input resistauce provides the proper current limit for a +5 VDC signal. External resistance in series
with the step and direction lines to limit current to 10 mA allows operation with voltages greater than 5
Volts.
vcc-1'8
Re = 10
-0.470
Re = External Resistance GC¿)
Vcc = Signal Voltage
The step input is active low and will accept a square wave input with a maximum frequency of 800 kHz.
The direction input is high for motion in the forward direction. The direction input should change a min-
imum of 4 microseconds before the.first step pulse ir that direction.
lQ 2000/5000 lnstallaüon Manual
L
,
The distance moved given an input of N step pulses is a function of the software gear ratio set in üe
PCM. The number of encoder counts moved is:
,
a-, Motor Encoder Counts = (N step pulses, (;)
Motor Encoder Counts = The distance the motor moves
N step pulses = The number of pulses from an indexer
a
= The software gear ratio
b
The signal wires from the indexer should be shielded, and the shield con¡ected to the chassis of the
device generating the signals. In some cases it may be necessary to cónnect the shield at the PCM end
of the cable, at P4- 15.
Serial Ports
There are two serial ports on a PCM. Serial port 1 is on connector P7 and serial port 2 is.on connector
P6. The optional Operator Terminal is connected to the PCM through serial port 1 on P7. Serial port 2
on P6 is used as the programming port for a PC that is running IQ Master. Serial port 2 is also üe serial
port used for Host communications.
Data may be sent to, or received from either serial port by an application program. The application may
use a PRINT statemert to send data and a READ statement to receive data. Refer to fhe IQ-
Series Master Manual for detailed information.
Several parameters select the operating mode for serial communications. Both ports support either
RS-232C or RS-422 communications. The ports operate at baud rates of 12OO,2400,4800, 9600, or
19200. Refer to the lQ-Series Master Manual for detatled information
The default setup for the serial ports is:

.l
Serial Port Serial Port 2
9600 baud 9600 baud
No parity No parity
8 dat¿ bits 8 data bits
1 stop bit 1 stop bit
Handshaking ON Handshaking ON
RS-232C protocol RS-232C protocol
Host Computer
Serial Port 2 on connector P6 provides the communication interface between the PCM and the personal
computer used for programming and configuration. This is also üe serial port that must be used for
Host communications.
One or more IQs may be installed on an RS-422 multi-drop network or an RS-232C daisy-chain net-
work. If more than one IQ is in the network, each must have a unique address selected on the SW1 dip
switch. Refer to"Networking IQ-Series Controls" on page 69 for more information.

66 Wiring.ControlConnections
u
Signal Name
Connector Pin # RS-232 RS-422
P6 1 No Connection RXD+
Serial Port 2
2 RXD RXD-
3 TXD TXD-
4 No Connection TXD+
5 Common Common
6 Shield Shield
Below are figures showing the typical RS-232C connections between a personal computer (PC) and the
PCM. These diagrams illustrates the connections required for programming a single PCM.
IQ PC 9-pin
P6 Serial
Connector Connector
RXD- P6-2 2 RXD

TXD- P6-3 3 TXD
COM P6.5 5 GND
Shieid P6-6
IQ PC 25-pin
P6 Serial
Connector Connector
RXD- P6-2 2 rxD

TXD- P6-3 3 RXD
coM P6-5 7 GND
Shield P6-6
Personal Computer RS-232C Connections
For RS-422 connections between an IQ and the host computer, refer to "Networking IQ-series Con-
trols" on page 69.
F'stablishing Communications between IQ Master and the PCM
1. ConnecÍ the serial cable between PCM connector P6 and a serial communications port on the PC.
2. Start IQ Master.

Wiring. Control Connections 67
3. a dialog box with the version is displayed, your

áo to tfr" Diagnostics menu and select Version. If
communications are working properly. If you get an error message proceed with step 4.
4. If you have selected an address on the address DIP switches, verify that the same address is selected
in üe Communications menu, Axis Select dialog box.
5. If you getan "IQ not responding" error message, go to the Communications menu, PC Setup and
check your communications setup. You should first verify that the communications port that you
have selected is the one that your cable is connected to. Then verifu that the communications proto-
col matches the protocol in the PCM. If this is not a new PCM any of these setti:rg may have been
changed by the preüous user. The factory settings for a new PCM are listed above.
6. Verify that the serial cable is constructed properly
7. Verify that your system has the serial communication port that you have selected. With Windows,
you received the Microsoft Diagnostic program, MSD.EXE. Exit IQ Master and Windows and type
msd at the DOS prompt. Select the Com Ports button. Verify that there is a port address for the
serial port that you have selected. Return to Windows and IQ Master.
8. If you still have not been able to communicate with the PCM, contact Electro-Craft Product Sup-
port.
'#"':;'":#::^*rrerminat
connects to the pcM through seriat port t onw.*" connecrs to
"*r"
the COM1 connector on the back of the Operator terminal. The COM1 coilnector is a twenty-five pin
male D connector. The IQ Operator Terrninal may be wired using RS-232C for distances up to 15.2
meter (50 feet). For longer distauces, RS-422 should be used. Refer to the lQ-Series Master Manual for
details on configuring serial port 1 for RS-422 use. Refer to the following diagrams for wiring details.
As an option, any generic operator terminal may be connected to the PCM Serial Port 1. In the default
confi.guration, the PCM expects an IQ Operator Terminal to be connected, so if a generic terminal is
used, the PCM must be configured properly. Refer to the lQ-Series Master Manual,PartZ o IQ Master
Environment, Parameter menu, Serial for details.
PCM Signal Name
Connector Pin # RS-232 RS-422
P7 1 No Connection RXD+
Serial Port 1 2 RXD RXD-
J TXD TXD-
4 No Connection TXD+
5 Common Common
6 Shield Shield

Wiring . Gontrol Connections
,
IQ Operator
Terminal
COMl 1 Chassis ground
2 TXD (RS-232 transmit)
3 ru(D GS-232 receive)
l4 T)Oi (RS-422 transmir)
15 TXD- (RS-422 transmit)
t6 RXD+ (RS-422 receive)
t7 RXD- (RS-422 receive)
7 Signal ground
IQ Operator
P7 Terminal
Connector coMl §
Connector
RXD- P7-2 2 TXD

TXD- P7-3 3 RXD
coM P7-5 7 GND
Shield P7-6
IQ Operator Terminal RS-232 Connections
IQ Operator
P7 Terminal
Connector coMl
Connector
RXD+ P7-1 14 TXD+
RXD- P7-2 15 TXD-
TXD- P7-3 17 RXD-
TXD+ P7-4 16 RXD+
coM P7-5 7 COM
Shield P7-6
IQ Operator Terminal RS-422 Connections
.T
E
Wiring'ControlConnections
E Nelworking the IQ Operator Terminal
69
An additional option is to connect one Operator Terminal to multiple PCMs. This method requires RS-
422 contecttons as shown in the following drawing. A PCM may be selected from the terminal by usiag
.¡17
the NO key followed by the numeric key corresponding to the PCM Operator Terminal address which
must be set up in IQ Master. Refer to the IQ Master Manual for configuration details.
IQ Operator Terminal RS-422 Multi-Drop Connections
Networking lQ-Series Controls

One or more PCM may be i¡rstalled on an RS-422 multi-drop network or an RS-232C daisy-chain net-
work. If more than one PCM is on the network, each PCM must have a unique address selected on the
SWl DIP switch.
12345678
EEEEEEEE
Dip Switch SlVl
Switches SW1-1 through SW1-6 are used to select the address. Switch SWl-1 is the least significant bit
and SW1-6 is the most significant bit of the binary address. If the address is set to anything other than 0,
the PCM witl not communicate until its address has been selected (use Axis Select under the Communi-
cations menu). Changing the address on the dip switch will not be recognized by the PCM until a Hard
Reset is performed (or power is removed). The following diagram illustrates the dip switch setting for
address 5.
I 2345678
HHHHHIE
Dip Switch SWl Set For Address 5 Example
Switch SW1-7 is used to select the mode of operation of the serial port 1..If SW1-7 is OFF, serial port 1
functions as an independent serial port. If SW1-7 is ON, serial port 1 and serial port2 are linked
together (daisy-chained). Any data that is received on one serial port is automatically transmitted out the
other serial port. The following diagram illustrates the setting of SW1-7 ON for the daisy-chain mode.

t
12345678
EEEEEEHE
o
OFF
Dip Switch SWI-7 Set ON For Daisy-Chain Mode Example
Switch 8 on the dip switch is not used. The PCM is shipped with all switches set to OFF, for indepen-
dent operation of the serial ports and the address set to 0. If there is only one PCM in the sysfem, all of
the switches on dip switch SW1 should be OFF.
Multiple PCMs can be connected together using an RS-422 multi-drop configuration. Thefigure below
illustrates the required connections. Remember to set a different address on dip switch SW1 for each
PCM on the RS-422 network. The cable used for these connections should be 22 AWG tyisted pair wittl
an overall shield grounded at one point.
A)(ISl AXIS2 AXIS n

Port 2 Port 2 Port2
TXD+ P6.4 TXD+ p64 TXD+ P6-4
TXD- P6-3 TXD- P6-3 TXD- P6-3
'ru(D+ p6-1 RXD+ P6-1
RXD+ P6-1
RXD- P6-2 RXD- P6.2 RXD- P6-2
coM P6-5 coM P6-5 coM P6-5
§A4-7 oFF SW1-7 OFF S1,vl-7 OFF
RS-422 Multi-Drop Connections
RS-232C Daisy-Chain
The two serial ports can also operate as one port with the transmit and receive lines fed through for mul-
tiple connections. Switch 7 on dip switch SW1 selects the independent or daisy-chain operation of the
two serial ports. Remember to set a different address for each PCM in the chain. The cable used for
these connections should be 22 AVIG twisted pair with an overall shield grounded at one point.
r--
Host
TXD
RXD __l
GND
XD RXD GNE rXD RXD GND TxD RXD GND xD RXD GND XD RXD GND
(3) (2) (5) (3) (2) (5) (3) (2) (5) (3) (2) (5) (3) (2) (5)
P6 Ponf2 P7 Pon*1 P6 Port#2 P7 Port#'1 P7 Port#1
sw1-7 0N SW1-7 ON
AXIS #1 AXIS
'T2
RS-232C Daisy-Chain Connections

Expanded l/O and Memory

Note: Firmware Version 2.00 or higher is required to use an Expanded VO card or an
J Expanded VO and Memory card.
Additional memory and UO may be added with a Memory and VO Expansion card or an UO Expansion
Card (Part numbers are listed in "Component Ordering Information" on page 105). The expansion card
provides the following additional capabilities:
. 32 TTL I4puts (I17 through I48),
. 16 TTL Outputs (O9 through O24),
. 4 twelve-bit Analog inputs (ADC2 through ADC5) [only available on Memory and UO card], and
. up to 32 KB of nonvolatile memory to the basic PDM forprograrr.r storage [only available on Mem-
ory and VO cardl.
"Option Card Installation" on page 15 describes the installation and mounting of the Expanded UO card
or the Expanded UO and Memory card. The first eight positions on P1 and P2 are outputs and corre-
spond to module positions 16-23 on a24-channel expansion board. The following table defines the rela-
tionship between Pl and P2 connections on the IQ and terminals on the expansion board.
IQ Expanded VO Card IQ ExpandedVOCard

Connector §pe and Memory Terminal Connector §pe and Memory Terminal
and Pin No. Module No. and Pin No. Module No.
P1-1 Output 9 23 47 Pz-l Output 17 23 48
P1-3 Output 10 22 45 P2-3 Ou@ut 18 22 46

P1-5 Output 11 2t 43 P2-5 Output 19 2l 44
1,
Pl-7 Output 12 20 4l P2-7 Ouput 20
at P1-9 Output 13 19 39 P2-9 Output 21
20
79
42
40
P1 11 Output 14 18 37 P2-I1 Output 22 18 38
P1-13 Output 15 n 35 P2-13 Output 23 t7 36
P1-15 P2-15
Ix
Output 16 t6 JJ Output 24 16 34
P1 I7 Input 17 15 3l P2-17 Input 33 15 32

P1 79 Input 18 t4 29 P2-19 Input 34 L4 30
r( Pl-23 Input 20 t2 25 P2-23 Input 36 t2 26
H P1-21 Input 19 t3 27 P2-21 Input 35 t3 28
t( P1-25
Pl-27
Input 21
Ínp'atZ2
11
10
23
2t
P2-25
P2-27
Input 37
Input 38
11
10
24
22
( PI-29 Input 23 9 t9 P2-29 Input 39 9 20
P1-31 lnputZ4 8 t7 P2-31 Input 40 8 18

! P1-33 Input25 7 15 P2-33 Input 41 7 16
P1-35 Input26 6 t3 P2-35 Input42 6 74
Pl-37 Input2T 5 11 P2-37 Input 43 5 12
P1-39 Input 28 4 9 P2-39 Input 44 4 10
Pl-41 Input 29 3 7 P2-41 Input 45 3 8
Pl-43 Input 30 2 5 P2-43 Input46 2 6

¡
IQ Expanded VO Card IQ ExpandedVOCard
Connector §pe and Memory Terminal Connector §pe and Memory Terminal
and Pin
Pl-45
No.
Input 31
Module
1 J
No. and Pin
P2-45
No.
Input4T
Module
1 4
No.
L'
P7-47 Input32 0 1 P2-47 Input4S 0 2
P3-6 5V Pl Logic w1 P3-7 5V P2 w2
Power Logic
Power
Crimp connectors and a colnector housing for expanded analog signals are included in the expansion
card kit. Use 0.34-0.08 mm2 (22-28 AWG) stranded wire. Noise sensitive applications may require
twisted shielded wire pairs, in which case the shield is grounded at one end only. The following table
defines the relationship between P3 user crimped leads and the housing supplied with the kit.
IQ Expanded Memory
and VO Card
Connector Analog Connector and
and Pin No. Pin No.
P3-1 ADC2- J3-1
P3-2 ADC2+ J3-2
P3-3 ADC3- J3-3
P3-4 ADC3+ t3-4

P3-5 ADC4- J3-5
P3-11 ADC4+ J3-6 t_:

P3-t2 ADC5- J3-'1
P3-13 ADC5+ J3-8
The Monitor menu provides expanded VO status. Refer to the IQ Master software manual for additional
information on expanded VO display and status.
t:
I
-
Reference Electrical Drawings' Electrical Schematics 73
Reference Electrical Drawings
Drawing Description Page
9101-0411 IQ-5000 Power Wiriug 74

PSM-AUX Connections
v 9101-0134
9tot-2195 IQ-2000 Power Wiring for PDM-10, -20 and -30
75
76
9rot-t453 IQ-2000 Power Wiring for PDM-75 77
gtor-2061 Expansion Card UO Connections 78
9101-2025-)cC(. Cable: IQ P7 to Operator Terminal 79

9t0r-2024-§x Cable: IQ P6 to PC Serial Port (9 pin) 79
9101-2031-)OO( Cable: IQ P4 or P5 to Auxiliary Encoder (Unterminated) 80

9t0l-2127-OO2 Cable: IQ P4 to P4,2foot 80
9rol-2027-xxx Cable: IQ P5 to S-, H-, or F-Series Motor Encoder 81
lO 2000/5000 lnstallation Manual

74 Reference Electrical Drawings . Electrical Schematics
¡
?c- E
= I
J:
\-í É 1
EPE rF §¡
é=- E
==
*á; :3ri
PeÉ?
c:É-
:
Éc?
l
ó
,
o
!
?-a )
vú !üs
l
l áa {
ó :e
= ;; a5
l'i.! :B
3e
=
f
ó :r !i
"-,m
se
6l
9f
=)i
6r,
ad
J;
-.
(\ \ \11 p
Ji
l
\\ilt i
o
o
= Wi
l
d
il, É
=
o p?
i=
6,/^ d9=
;\ 5-.a
.
Í¡
?+ ó
-¡
j =,8ü:
\ E slll::i
B: 6-s*
iaq;zá=
3 Af.Y
.4
:\l =r
>9 3ó
- =ó
2
sr á
z
l
l
o
o
T
o ¡?
E ts
Ío g= O tr
z
-:
=
!<<<
+H
o E3
:Ji
Reference Electrical Drawings . Electrical Schematics
D E
J OU
-oI
FO
OO
U LI)
zoY
-7 *, tn
O
E C)oo
! Ol
¡
F-
GJ Lrr
=
u t)
Z¡y{1 -
l
Cf ) ><z
O O)
.iF
O z lz
(f (f nL
tf) LD^l
I
l O
r:l rl
fll
;.I
E- ll
xól
-ñl
,=
: --
I
6
- -É o u
< r[Z u
;L]
<l L
qE
>
)zzl
ól .,
E E LdÉl o
+ -t l-
tr
-órl
ts>
z
o
l+ I'll.l
lJ
"-
E
Éu *óo ú
I mF> 6ÉC
TZ+ L O l
.§ó &xú § i
oF F=a I
zÉ
arz -c
"_i
úuz IIL f
?)--l ?
.4=
., <ol //
úl
E
\\
zj
E
\-
76 Reference Electrical Drawings. Electrical Schematics
,
É
I h
Ln+¿
-
AJ K
':
+ lño
-9
oe-
o)a<
: ilz
ó ts
o
t
§
LL]
tn o :e¡
9¿
ti *2 Lt.l o
___l z E;: §t
Ltl ? ¡i; SI
C:
e F9=^ :ii EH
: o
:rr
<E o
á¡ti"j
U
uÉ N ilá9,t-ili;+'
9lzú<iur!-
.i
-
3;
a"
EpC
,n
i^
¿,
=
a
>q9
3
zo ñ
a
Í
;
-
Ni
\r
L &-q
oi
E
\
<á
Z =
2000/5000 lnstallation Manual

Reference Electrical Drawings . Electrical Schematics 77
si
tr)
ó* l,-
yl-
II
¿2 ÉB
2l 6
b
ó @
=3
rl d
Lr-l
u)
Í
o
3g
Ltl
ú
= ;
l Z
Ll.l ?
6
? .Y
d
o
<E N
: .i 53
=g
gá
>+9
<6
_rx
459
Pi
o
z > !E=
ú;
Í d=6 ¿
Í n''13
o,¡É2
ri
O
:
o
+
t \ E

78 Reference Electrical Drawings . Electrical Schematics
t
L JoY B z. or ,ôN.o'tvNV -] ir
I l00l,J lv.lN'.'l ll0 -0 S l.NNVHJ t I o
o (\
I
ñ-T O C
ol
1.,.,
I
O
al +
az
o§-n : N oo9
n
rcNo:!
ÍÍi a
*(f
ú
=
o
z
o
\]
c
Ll_l
tJ)
L_l_l
o
Z
¡oo L'I _,1
o
üLD t_ll
f-
+I ó Cf
rll J
a(f
UO
=
,il1lll11
ffIflIIIT
(f =
P
O
h IO
(J.
lc\ ?
-a(fa)z 5 =
3 -l -l .l01 -l l:==:l ñ*tn
\t o1 ol c1 =l =l =l
L ^ acl
? +u
I>
+
srndN -rnorno U
l__
r
---] ^(f
U<
(J=
}-:
rllll
FCI
O-
ZL
,11
f f f f f r-*
-f1
-1 -l EÉ1
:!.! =lJJl_l
o.j-1
u-ZAO-
$<
t- "i
tto
t
* Ouuu Có
0aaz<t *&a z
ó<.-ó* \
n 6610 d+* d
-6= A Z
<u-oot ú <
ú=,zta< d o w I
ZO=*Z Z
z>o c
<ouúto* -@-ts -
INOZ L Ó
OT< >ts§ úOZ U E
ñNd ó a
§ 0u-oz
NWZC@>O
oN o *
L >Z <- tÉ
E zo
oó,,L
<<*= OF--
ri<u
dL n
> u
F O
úz-a
Í- Íz< z- úsF + <
o ¿c o 6/ /a
Éoúd
zo<a,<z
tsu m .zo uo F c
c. z
ú-z
É*L [f u o*'-ts Í u * o
OÉ Ú UO IVÉ< NU Z
u
< Nd Z O
z)faco eroo o É l
ZOO*C o o É
Ot-+=On € ú
ucd= oo É o +z f
z-o>
o úó <z
o$*o§> N' oo>z ÉT o
-< * Í<
<--
zúo + , z-
OOuFO46o É 6*f ft O Z -t
-,, 1ú-T úuoo uu
td cL * A
a-+<¿t6L dCZ
ú< )< .-za o>e tso
AÍ Í tslód OE ú
UUUUOLI OO f > d
úZ)fZ* O uZú< - 0= <l O Z
duoÉuo: M fT É=
<o< ooov z * lft N> § ,a
O - ICE OOOó -ó ='- - O N OÉ
Lr\ztsN> t o a+ oo z
o- AZú Cm .l to Zu -
z<L )
-ltl 6--11< - [ a 6 r
-Joo-L
rl ó-ó--oo<o
oó o. ts rr'o=ú Lo =d -.
7
ol
- ,4
Al H'§l
.4A
J
Reference Electrical Drawings . Cables 79
Cables
OPERATOR
TERMINAL
POSITIONING SERIAL PORT
MODULE CONNECTOR
CONNECTOR
P7 25 PIN FEMALE
9 PIN MALE
POSITIONING
MODULE OPERATOB TERI\¡INAL
CONNECTOR SERIAL PORT CONNECTOR
P7
!L-. .: : - J-, ¡P::u ^l:: _ \ úN!
-r ti
:,- f- r ? ) r'
t*
T¡l 'rr-,< i-i-
|^ !H]T' . Rrl
3
SHIEL!
v\
P7 to Operator Terminal Cable - Drawing 9L01-2025-XXX
POSTT|ON|NG ,..1J-- ltt PC SERIAL PORT

---
I¡oquLE ,§{ ..-: coNNECroR
\J coNNEcToR §\
p6 !i
- i"
qLEr 9 ptN FEMALE
\:*\'
,/.
"§/
9 PIN MALE
POSITIONING
M6UE
couEcron I
PCSffihL PORT
rol CONNEClOF
.o! .*, ñ ^F I ú!!

-.._ r Buf- -
<
)"-oI
r ., *
!o'.t')
I r DA^
V
P6 to PC Serial Port (9 pin) Cable - Drawing 9101-2024-XXX
I
a_t
lQ 2000/5000 Installation Manual

80 Reference Electrical Drawings . Cables
i
POSITIONING
MODULE
CONNECTOR
§a
,1}.--.
ri
INDEXER/
ENCODER
coNNEcloNS
L.
P4
\.- ..,
15 PIN MALE
HIGH-DENSITY
POSIfION NG
MOOULE
CONNECTOR
!l!L: F, , r
--
D,F- p¿ f s'ovru ,,e*
" !-
-l
ta , <p¿ r¡
cDM < er-z 4
!: < P4-?
,*r.-l-:i I+
ros_U
." .rr;-li
a¡f
I
+5V
sHiEL¡ I
V"
Note: This cable riay be used on the P5 connector (to motor feedback), with the following differences:
Pin 8 is unused,
Pin 11 and 12 are TS- and TS+, respectively
Pin 13 is ABS
Reference "Encoder 1" on page 60. e_
P4 or P5 to Auxiliary Encoder (Unterminated) Cable - Drawing 9l0l-203L-XXX
MASTER AXIS /@.---- r-,-to.r FOLLOWER AX|S

CoNNECTOR 2c | \_ CoNNECTOR
P4 ^,/
óU p._--
"{,/(ó* -- ----fu Y§ p4
MALE \/§
15 PIN »..// 1s ptN MALE
HIGH DENSITY \»" HIGH DENSITY
MASTER AXIS FOLLO\ryER trIS

CONNECTOR CONNECTOR
A+ _-,1 P4 I P4 1 A+
-L-..p4-2 P4-2 ..- _. _L
81- ,t P4 3 P4-3 .. 8J
B ( P44 P4 a L
-_-_
l+ _,p4-s P¿-5 ._ l+
I P41o P4-10 \ l-
SHIELD ¿ p4-] s
VS
P4toP4,2foot Cable - Drawing 910l-2127-002
Master/Follower connections between two IQ-series Controllers 0\?

Reference Electrical Drawings . Cables 81
re=F
HTGHDENSTfl
srl-----=:r#Eii
\\ _p /
IEL
\9#_:-.:rl_
r0 s=R¡E5
CONNECfOR
P5 9rcr-2027 ot0 üOTOP
CABLE
¡-Ps2 e#
7-16Qd\
/[@)r-(o\\
a
A85 <
ps-t: ,# L010 o\ro\
v/-^^-v
l5!QL__< , ^F *o î- .r+ \iG) @ @/G)/

\o6@/
ps-s +5!,
. r u.0,. r ,:, -,
¡# CABLE IER¡INATION AT ¡ATINC CONN:CTOE
(SOLDER PINS SHOIN)
R+
s+
"
e----;+ El3p,,o
NOTE: Cable 9101-2135-XXX provides the same connections using a right angle motor connector.
P5 to S-, H-, or F-Series Motor Encoder Cable - Drawing 9L01-2027-XXX
(,

Applying Power for the First Time. Start-up Procedure for lQ-2000 PDMs 83
Applying Power for the First Ti me
Outlined below are the steps that should be followed when applying power to the equipment for the first
time. This procedure covers IQ-2000 PDMs, IQ-5000 PDMs, IQ-5000 PSM, Motors and the Operator
Terminal.
\*{7
These start-up procedures assume that the equipment has previously been mounted and wired, but has
not had power applied to it.
Start-up Procedure for lQ-2000 PDMs

WARNING
Dangerous voltages may exist after power is removedl Check
DC bus voltage each time power is removed before working on
the PDM.
1. Prior to applying power to the PDM, ensure that the supply voltage is in the proper range (lOO-240
vAC).
With power off, ensure that proper connections have been made to:
. PDM-10, -2O and -30 terminals Ll and L7N. Ensure that a proper ground is connected also.
. PDM-75 terminals L1, L2l¡{ and L3. Ensure that a proper ground is connected also.
If auxiliary power is used, ensure proper connections are made to terrninals L1 AUX and L2A{
AUX.
a
1r With input power still off, disconnect motor leads from PDM terminals R, S, aud T. Verify with an
ohmmeter that the resistance between PDM terminals R to GND, S to GND, and T to GND is

84 Applying Power for the First Time ' Start-uP Procedure for lQ-2000 PDMs
aUove SOOi< ohms. If the resistance is acceptable, reconnect the motor leads to the PDM termi¡als
marked R, S, and T.
4.
5.
Turn power on.
Double-click the IQ Master icon to run the IQ Master software.
L
6. Select InitializePM from üe File menu. The following dialog box will appear.
lQ Se¡ies lrl EStl Faclory Iefault niti¿li¡¡tion

I
Ddv* Type: PDI'l-10
I'lotol Type: H-30[7-H-H
lrlotur
Encode¡ Size: 2t}00 lines/¡ev
Percent f,omplete: l*4,
lffi Eil,ffiffiÍA
Initialize PM Dialog Box
Note: The IQ 2000/5000 carnotbe operated until the Personality Module (NVRAM) memory is
initialized with proper information about the drive and motor being used. The following infor-
mation is defined when you select the appropriate Drive Type and Motor Type/Encoder choices
in Steps 8, 9 and 10 below:
Drive Peak Current The amount of current in Amps appüed to the motor when
the IQ 2000/5000 commands ñ¡11current (10 V ICMD sig-
nal)
Motor Torque Constant The amount oftorque in inch-pounds produced when one
Amp of current is applied to the motor
Motor Inertia The inertia of the motor in inch-pounds-seconds squared.
Motor Encoder Lines per Rev. The number of encoder lines for one revolution of the
motor.
Note: IQ Master requires an encoder value between 52
and 60000. Refer to the following steps.
7. Click the IQ-Series tab.

8. Select IQ 2000 from the Drive Type window.
9. Select the appropriate drive model from the Motor Type list box. Ver§ the Encoder selection is
correct. The last letter of the Motor Type defines the encoder resolution (encoder lines per revolu-
tion).
10. Click the Update PM button to initialize the Personality Module. The Percent Complete indicator
displays the status of the initialization.
. When the Percent Complete indicator reaches lo07o the PM is initialized, click the Close but-
ton to exit the Initialize PM dialog box.
Manual
Applying Power for the First Time . Start-up Procedure for lQ-5000 85
. If you get an "IQ not responding" error message, follow the instructions below.
a. Click the Close button to exit the Initialize PM dialog box.
b. Click PC Setup from the Communications menu and check your communications setup.
You should fust verify that the communications port that you have selected is the one that
your cable is connected to. Then verify that the communications protocol matches the pro-
tocol in the IQ. If this is not a new IQ, any of these setting may have been changed by the
previous user. The default serial port seftings for a new IQ are listed on page 40.
c. Veriff that the serial cable is constructed properly. Refer to "Serial Ports" beginning on
page 40.
d. If you have selected an address on the address dip switches, veriff that the same address is
selected in the Communications menu, Axis Select dialog box.
e. Click Initialize PM from üe File menu and continue wi$ Step 7 above.
11. Make sure that the motor is not connected to the load when applying power to prevent any mechan-
ical damage in case of a fault. Ensure the PDM is disabled (turn the Enable input off, or select Dis-
able from the Run menu of IQ Master after power is applied). Apply input power and check the
LEDs.
. The green DC BUS LED should turn on and the bicolor STAruS LED should turn green.
. If the STAIUS LED is red rather than green, the PDM is in a fault condition. Select Status
from the Monitor menu to find out the type of fault. Correct the fault (the STATUS LED will
turn green when the fault has been clea¡ed and a reset or hard reset performed).
. Check that ai¡ is coming out of the top of the PDM to ensure that the fan is operating.
12. Ensure the PDM is disabled. Select Encoder frorir the Diagnostics menu. Verify that the Counts
value increases positively when the motor shaft is rotated clockwise as viewed facing the motor
shaft.
13. Enable the PDM using the Enable input or Enable from the Run menu. Verify the motor is station-
ary and has holding torque.
14. Command motion using the jog inputs or the Run Control dialog box of IQ Master. Verify the
motor rotates in the proper direction.
15. Remove input power. The LEDs should turn off within ten seconds.
Start-up Procedure for lQ-5000

Start-up of an IQ-5000 system involves starting a Power Supply Module (PSM) and at least one Posi-
tioning Drive Module (PDM). The PSM is checked first and then the PDMS. Perform the start-up pro-
cedure on all the PDMs attached to the PSM at the same time.
WARN¡NG
Dangerous voltages may exist after power is removed! Check
DC bus voltage each time power is removed before working on
the lQ-5000 Power Supply Module or lQ-5000 Positioning
Drive Module.
Power Supply Module

1. Prior to applyfug power to the PSM, ensure that the supply voltage is in the proper range (100-240
VAC 3 phase).
2. With power off, remove the PSM cover and ensure proper con¡ections have been made to terminals
Ll, L2, and L3 and that a proper ground is connected. Phasing of the input power connections is
arbitrary.

86 Applying Power for the First Time . Start-uP Procedure for lQ-5000
3. Disconnecf a[ wires from the PSM DC bus termina] posts marked + and -. Install the PSM cover,
then turn on input power. Ver§ that DC bus voltage is in the proper range (325 VDC nominal with
230 VAC inpu|. Check that the green PSM READY LED is on and that all three red LEDs are off
and that the PSM fans are operating.
,
4. Disconnect input power and check that the green LED goes off and the DC bus voltage falls to less
than 15 VDC within one second.
5. Remove PSM cover. Reconnect the DC bus wires to the PSM terminals marked + and - ensuring
that proper polarity is maintained. Install the PSM cover.
Failu¡e to observe this precaution may result in damage to or destruction of the PDM.
Ur,
I
*1

Applying Power for the First Time . Start-up Procedure for lQ-5000 87
a
Start-up Procedure for PDM
¡ l. Ensure input power to the PSM is off.
v 2. Disconnect all interface cables @1-P7) from each PDM and remove all PDM covers. Disconnect
all motor leads from the PDM terminals marked R, S, and T. Verify with an ohmmeter that the
resistance between PDM terminals R to GND, S to GND, and T to GND is above 500k ohms. If the
resistance is acceptable, reconnect the motor leads to the PDM terminals marked R, S, and T. Verify
that the DC bus wires are connected to the PDM with the correct polarity.
3. Turn power on.
4. Install the IQ Master software on the PC. Refer to part 1 of the IQ Master Manual for installation
instructions.
The IQ 2000/5000 caffiot be operated until the Personality Module (NVRAM) memory is ini-
tialized with proper information about the drive and motor being used. The following informa-
tion is defi.ned when you select the appropriate Drive Type and Motor Type/Encoder choices in
Steps 8, 9 and 10 below:
Drive Peak Current The amount of current ia Amps applied to üe motor when
the IQ 2000/5000 commands full current (10 V ICMD sig-
nal)
Motor Encoder Lines per Rev. The number of encoder lines for one revolution of the
motor.
Motor Torque Constant The amount of torque in inch-pounds produced when one
Amp of current is applied to the motor
Motor Inertia The inertia of the motor in inch-pounds-seconds squared.
\_\, Motor Encoder Lines per Rev. The number of encoder lines for one revolution of the
motor.
5. Double-click the IQ Master icon to run the IQ Master software.

6. Select Initialize PM from the File menu. The following dialog box will appear.
Factor-u D ef ault nitiali¡ation

I
Drive Type: PDht-ltl
I'lotol Type: 5-3[ft7-H-H
I'loto¡
Eneoder Size: 20fI0 lines/rev
Percent Complete: 0z
[ffiB f--::t:------::
I ftáre I
Initialize PM Dialog Box

88 Applying Power for the First Time . Start-up Procedure for lQ-5000
7. Click the tf,-Series taU.
8. Select IQ 5000 from the Drive Type window.

9. Click the Update PM button to initialize the Personality Module. The Percent Complete indicator
L,
1t-ff"h:H:",,:tr;T#:T;:;".,""ches 1002a rhe pM is initiarized, choose the crose
button to exit the Initialize PM dialog box.
If you get an "IQ not responding" error message, follow the instructions below.
a. Click the Close button to exit the Initialize PM dialog box.

b. Select PC Setup from the Communications menu and check your communications setup.
You should fust veriff that the communications port that you have selected is the one that
your cable is connected to. Then verify that the communications protocol matches the pro-
tocol in the IQ. If this is not a new IQ, any of these setting may have been changed by the
previous user. The default serial port settings for a new IQ are listed on page 40.
a. Verify that the serial cable is constructed properly. Refer to "Serial Ports" beginning on
page 4O.
d. Ifyou have selected an address on the address dip switchés, veriff that the same address is
selected i¡ the Communications menu, Axis Select dialog box.
10. Select Initialize PM from the File menu and continue with Step 7 above. Make sure that the motor
is not connected to the load when applying power to prevent any mechanical damage in case of a
fault. Ensure the PDM is disabled (turn üe Enable input off, or select Disable from the Run menu
of IQ Master after power is applied). Apply input power and check the LEDs. The green PSM
READY LED should turn on and the bicolor STATUS LED should turn green. If üe STATUS LED
is red rather than green, the PDM is in a fault condition. Select Status from the Monitor menu to
find out the type of fault. Correct the fault (the STATUS LED will turn green when the fault has
been cleared and a reset or hard reset perfonned). Check that air is coming out of the top of the
PDM to ensure that the fan is operating. The green PSM READY LED should tum on and remain
on.
11. Ensure the PDM is üsabled. Select Encoder from the Diagnostics menu. Verify that the Counts
e
value increases positively when the motor shaft is rotated clockwise as viewed facing the motor
shaft.
t2. Enable the PDM using the Enable input or Enable from the Run menu. Verify the motor is station-
ary and has holding torque.
t3. Command motion using the jog inputs or the Run ConÍol dialog box of IQ Master. Veriff the
motor rotates in the proper direction.
t4. Remove input power. The LEDs should turn off within one second.
t
L.
\ Applying Power for the First Time. Motor Start-up Procedure 89
¡a
{
¡a Motor Start-up Procedure
\a !7 WARNING
\ Motor power connectors are for assembly purposes only. They
\ should notbe connected or disconnected while power is
\ applied to the drive.
\
\r
\ WARNING
lra Rotating motor shafts can cause extensive damage and ¡njury.
Motors must be properly guarded during testing and in the final
I
!l installation.
I
F.
Fr
1.
2.
The motor(s) should be disconnected from the mechanicai load(s) when initially checking out the
system. If this is not possible, take adequate precautions in case of a fault.
Disconnect all futerface cables from the PDM and remove the PDM cover (IQ-5000 only). Connect
F. the 4 motor wires (R, S, T, and ground) to the proper PDM. Instali all PDM covers and connect all
¡r interface cables to the PDM. With each PDM disabled, reapply input power and check for proper
power up diagnostics as shown by the STATUS LED on each unit.
F,t
li Select Gains from the Parameter menu. Set trimit to a low value (25Vo of peak current is a typical
value). Select Velocity/Acceleration from the Parameter menu and set the Jog Velocity to a rela-
tively low speed, such as 50 RPM. Enable each PDM and make sure there is no shaft motion. Acti-
§§' vate the Jog forward input and check for clockwise rotation of each motor shaft as viewed facing
¡r the motor shaft. If motor does not turn clockwise, then check that motor power wires and encoder
FI 4.
wires are connected to the PDM properly.
Disable all PDMs and turn off input power. Measure the DC bus voltage to be sure that it is below
Ft 15 VDC.
Fr 5. Now that the system installation is verifled, return the Ilimit parameter to a value to suit the appli-
cation.
F
F
L Operator Terminal
F
The Operator Terminal requires no special start-up procedure. Simply apply power to the operator ter-
F minal as described under "Operator Terminal" on page 49. The operator terminal should sound a tone
Fr on power up and the üsplay LED should be iit. No message will appear on the screen unless the opera-
Fr tor terminal is connected to the PDM serial port and the PDM sends a message to the operafor termfural.
If the Operator Terminal is connected to a PDM, press the Status key to verify the Operator Terminal is
F.. communicating properly.
F..
tt Backing Up the Personality Module
F
l.a
t-
L
a After correct§ setting up the system, back up the contents of the Personality Module (NVRAM) to a
file on your PC, usiag File Transfer. Refer to the IQ Master Manual,Part 2 o IQ Master Environment,
File menu, Transfer for details.
L
t-
t lQ 2000/5000 lnstallation Manual
tr
I
Diagnostics/Troubleshooting. Light Emitting Diodes (LED) 91
D i ag nosti cs/Trou b les hooti n g
The IQ-Series system is designed to provide troubleshooting aids that help isolate any problems to a
"module" in the system. A module may be incoming power, PSM (IQ-5000 only), PDM, Personality
Module, motor and encoder, cables, or the mechanical system. The IQ-Series circuitry is designed to
prevent problems in any one module from damaging any other module. The modular package allows
very simple field replacement. If a PDM is replaced, the personality module is transferred to the
replacement module and all programs, parameters, and other information are moved to the new PDM.
The Personality Module, system firmware, and fuses are the only field replaceable items in the system.
Maintenance of the lQ-Series system is virhrally unnecessary. The primary consideration is to ensure
that the fans are operational and PDM is operated in a propedy sized and ventilated enclosure with
proper fusing.
Light Emitting Diodes (LED)

The PDM and PSM each have LEDs on the front. These LEDs provide a first level of diagnostics.
Positioning Drive Module STATUS LED

All PDMs have a STATUS LED on the top, front, right hand corner. This LED may appear green, red,
or opaque (OIf).
Green
The LED on the IQ-Series PDM indicates the present status of the PDM. During normal operation,
when no fault conditions exist, this LED is green. This LED turns red to indicate that the PDM has
detected a fault.
Red
a
If a fault is detected,
the LED turning red indicates there is a fault in the system. This does not indicate
§ that thS:PDM should be replaced immediately; many fault conditions are caused by problems extemal
to the PDM. The specific fault information is available from the serial ports. Fault messages.are dis-

92 Diagnostics/Troubleshooting. ¡¡n¡, Emitting Diodes (LED)
played oo,t of,".rror terminal screen if the operator terminal is present. The LED labeled SYS FAULT
"
on the operator terminal also will turn on (red) to indicate that a fault has occurred.
Opaque (OFF)
When power to the PDM is off, the STATUS LED is not lit and is opaque. If the PDM DC BUS LED is
ON and the STATUS LED is OFF, there may be a failure in the logic power supply.
DC Bus Power (lO-2000)

Above terminal block I is a DC BUS LED. This LED indicates that the DC Bus is charged.
Power Supply Module LEDs (lQ-5000 systems only)
LED Label LED Color Description
PHASE RED OFF = OK (Normal Operation)

LOSS
ON = Loss of one phase of incoming AC.
power. The PSM will continue to run on
two phases and the fault LED ON.
OVERTEMP RED OFF - OK (Normal Operation
ON = Excessive main heatsink temperature
DISABLED RED OFF = Not disabled (Normal Operation)
ON = DC bus disabled by extemal enable c

input
PSM GREEN OFF = No DC bus voltage

READY
ON = DC bus charged (Normal Operation
If noue of the LEDs are ON (either red or green), and incoming line voltages are found to be correct,
there may be a PSM failure. Replace the PSM with another module.
L
E
Lt
Diagnostics/Troubleshooting.OperatorTerminal 93
E.
I.
L
L Operator Terminal
L
L Operator Terminal Status Screens
L The operator terminal has 9 status screens that may be accessed by pressing the STATUS key. Each time
tL
the STMUS key is pressed the next status screen is displayed. The BACKSPACE key can be used to
scroll backwards through the status screens. The CLEAR Key will remove the status display or clear the
peak values. The following variables are available on status screens:
Name Description: Refer to the IQ Master Manual, Part 5 o Language Refer-

ence for detailed information on each flag and vaúable.
L Status Flags ATHOME, HSEQCPL, INPOSN, ERROR, XFER, READY,

F. ENABLED, PAUSE
L Program Status Program Number. If compiled with the debug option ON, the
instruction that is executing will also be displayed.
H Position Status PCMD, POSN, FE
Velocity Status VCMD, FVELI, VEL2
Input Status Inputs 1 through 16. Inputs 17 through 48 if an Expansion VO

or Memory and Expansion VO card is installed.
\t1
Output Status Outputs 1 through 8. Outputs 9 through 24lf an Expansion VO
or Memory and Expansion VO card is installed.
Current Status ICMD, IAVE, IN PEAK CURRENT
Commanded Position Status PGEN, PJOG, PEXT
Peak Status PFE, PVEL1, PICMD
All position values displayed on the operator terminal status screens are in user units, velocity values
are in user units per timebase, and current (torque) variables are in amps.

94 Diagnostics/Troubleshooting. p"r"onality Module Default lnitialization
Personality Module Default ¡nitialization

An inoperable NVRAM may be recovered by initializing the PM to the factory default settings. This I
2
command zeroes the NVRAM and performs a series of NVRAM integrity tests before installing factory
default NVRAM settings.
Note: This selection erases the existing Personality Module parameters and motion programs. If the pM
was prograÍrmed, be prepared to restore the PM settings and motion programs from your backup files.
Refer to 'Applying Power for the First Time" on page 83 to initiatize the PM with drive and motor data
and Part 2 ' IQ Master Environment of the IQ Master Instruction Manual for instructions on the
Save Program to IQ G7) command.
To reinitialize a Personality Module to the factory default settfurgs perform the following:
1. Select Initialize PM from the File menu. The Initialize Personality Module window will appear.
'l:
2. Click the Factory Default Initialization tab to display the following window.
i
:l
i
lQ Serle* ll lt¡ S¡n § Factory Default Initialization
l#AEI.IIHG
Al! personality module inlormation. parameter+. and
programs le*iding in the l8 a¡e PEHI'IAHEHTLY
HEI'IUVED by thir operation- lf you r+i*h to *ave
the eni+ting per*onality module dala- cho*e EIo*e
and perform a file tran*fe¡_
Pe¡cent Complele: OE
LEil_-l
t.*;;;;;l:r:*-;-il
Click the Factory hitialize PM button to initialize the PM. The Percent Complete indicator displays
the status of the initialization.
L
9
H . (08)
L Diagnostics/Troubleshooting Error Messages and Error Output 95
L
L Error Messages and Error Output (08)
LÚ If there is a fault, IQ Master can provide specific error messages. If a personal computer running
L IQ Master is connected to the P6 connector, the error message can be displayed in the Monitor menu,
Status dialog box. The effor messages are also displayed on the optional Operator Termi¡al.
L The Error output may be disabled and used as a general purpose output. Therefore, this output may not
L be available for diagnostic purposes. The remainder of the discussion about the Error output assumes
L that output 8 is assigned as the Error output. The output can be assigned in the Parameter menu, Outputs
dialog box of IQ Master. Refer to the IQ Master Manual,Pm2 ¡ IQ Master Environment, Parameter
L menu, Outputs for more detailed information.
L The Error ou@ut becomes active whenever the IQ detects a fault. The IQ will not begin to execute
L motion programs while a fault is present. After removing the cause of the fault, toggling the ENABLE
input OFF and back ON, or issuing a RESET command will clear the fault and allow execution of
L motion programs. Some faults, however, can only be cleared by an HRESET command. These faults
L include numbers 42,45-54, 68,69,73, and 74. Refer to üe table below for a description of each fault.
L On some machines you may want üe IQ to continue running even after some faults occur. This is
accomplished by setting Disable on Fault to Partial. In this case, the following faults are disabled: Iavg
L fault, Motor Overtemperatwe, Soft Forward Limit, and Soft Reverse Limit. All faults will cause the
L Error output to turn ON (if enabled). However, if Disable on Fault is set to Partial, and a fault listed
above occurs, the IQ will remail enabled and execute motion progfams normally. The Error output in
L this case serves as an alarm, and a programmable logic controller (PLC) or other controller can then
L gracefirlly shut down the machine without damaging the tooling or work piece. This setting is made fur
the Parameter menu, System dialog box of IQ Master, or with the FLIDIS Host Language Command.
t- Refer to the IQ Master Manual, Part2 o IQ Master Environment, Parameter menu, System, or to Part 6
L ¡ Host Language Commands.

The following table lists the faults that activate the Error output. The number preceding the fault is the
Lry error number.
L
L No. Error Message Description
h- J 2ms Reentrancy The system did not finish the required calculations in the previous
S Fault 2ms position ioop update in time for the next position loop update.
L 4 Math Overflow A maü overflow occurred (a calculation exceeded the internal sys-
hr
L tem limit). Check the values of the variables used in the program.
L 5 Divide by Zero A division by zero calculation was attempted. Check the values of
L the variables used in the program.
L 6 LOOP variable A variable used as the count for a LOOP statement was out of
L range range. The valid range of a LOOP count is 0 to 65535.
L
L 8 PRECISION Out
ofRange
Decimal point precision is not within the range of 0 to 4.
L
L 9 BCD Input Range A number larger than 9 was read in as a BCD number in a BCD
statement in a program. Check the inputs that are being used for the
L BCD input.
L-
L
L
L lQ 2000/5000 lnstallation Manual
II
T
T.
96 Diagnostics/Troubleshooting . Etrot Messages and Error Output (08)

,
t2
t
LOOP Count Out Loop constant value is not within the range of 0 to 65535.
ofRange
73 Profile The move carrot be made based on the parameters for the move:
Calculation distance, velocity, acceleration, or time. Possible causes are vari-
able values used for the move parameters that result in an accelera-
tion or time of 0.
r6 Invalid Opcode The PDM fied to execute a program opcode that was not valid
(programs are compiled into opcodes that the PDM executes).
Compile the program again to make sure it compiles corectly.
11 Home Not Home has not been defined when trying to execute a MOVP (abso-
Defined lute) move. Run the Home program or Defi¡e Home and execute
the MOVP command again.
t9 Delay Out of Time value for a Delay statement is greater than 65,535 seconds.
Range
20 KP Out of Range The parameter listed has exceeded the internal system iimit. The
2I KFF Out ofRange limit is determined at run time based on the Scale parameter. Check
22 KI Out of Range the gain values unde¡ the Parameter menu.
23 KPZ Out ofRange
24 Gear O.ut Of The calculated value for the gear ratio denominator is greater than
Range 32,767. Check that the value is correct.
Calculations: The calculation listed has exceeded the internal system limit. The
30 S-Curve limit is determined at run time based on the Scale parameter. Check
31 Accel the velocity and acceleration values under üe Parameter menu.
32 Velocity
JJ Iavg Fault The average current output ofthe PDM exceeded safe levels for the
¿ motor or PDM. Check for correct conne'ction of üe motor encoder
to the PDM or of the motor leads to the PDM. Other possible
causes are motor stall or end oftravel condition, excessive duty
cycle, or no DC bus voltage. This can also occur if the drive is
enabled and there is power supplied to the L1 and L2/N AC AUX
inputs, but not to the L1 and LzlN AC main inputs (this provides
logic voltage, but no DC bus voltage).
34 Excessive FE The following effor has exceeded the Following Error Limit for a
time greater than the Following Error Time. Possible causes are
loss of encoder feedback, low gain settings, a commanded velocity
or acceleration that exceeds system capabilities, or entries for Fol-
lowing Error Limit and/or Following Error Time that are beyond
system capabilities.
35 Excessive Speed Commanded velocity of a move exceeded the Overspeed value set
under Velocity / Acceleration in the P¿Lr¿rmeter menu.
t
Diagnostics/Troubleshooting o Error Messages and Error Output (08) 97
36 Cam Profile The target follower position in a cam profile could not be calcu-
Overflow lated.
3t POS Track The target follower position with tracking mode acúve could not be
Overflow calculated
38 Serial Port #2 A PRINT or READ statement was attempted to serial port #2 while
Busy the system was reserving the port for other functions.
39 Drive Not Ready IQ-550 only. The Ready to Run signal from the drive i¡rdicates a
fault in the drive.
40 Motor The temperature sensor in the motor windings indicated that the
Overtemperature motor temperature has exceeded the rating. Check for mechanical
binding, undersized motor, or duty cycle too high.
4t Power Module This fault typically indicates that the amplifier is trying to supply
Fault currents above its rating to the motor. Check for mechanical bind-
or ing, excessive du§ cycle, or faulty motor wiring.
Heat Si¡k IQ-2000: The IQ-2000 power module has detected excessive inter-
Overtemperature nal temperature or excessive curent to the motor. On earlier power
modules, this fault indicates the heat sink temperature has exceeded
the rated temperature.
IQ-5000: The heat sink temperature has exceeded the rating.
42 Bus Undervoltage The DC Bus voltage is too low, or power supplies for the amplifier
of circuitry were below the nominal output voltage. This indicates a
Logic Supply problem in the PDM internal power supply
Fault
43 Peak Overcurrent The PDM current sensors detected a short ci¡cuit in the motor
leads. Check motor power cables for shorts.
44 Bus Overvoltage The DC bus voltage exceeded safe levels. This error usually indi-
cates that the power supply shunt is not operating properly. Check
the shunt fuse on the Power Supply Module (IQ-5000 only). See
"Shunt Fuse Location" on page 48.
45 Encoder 1 Fault Incorrect encoder signals were detected by the IQ circuitry. The
46 Encoder 2 Fault encoder signals may be out of quadrature or an encoder signal is
missing (broken wire).
47 Watchdog Test The Watchdog circuitry test (performed at power up) failed. The
Fault PDM should be replaced.
48 Personality Fault A checksum error was detected in the personality data for the
PDM. Reload the Personality Module from a previously sayed file,
or replace üe Personality Module.

98 Diagnostics/Troubleshooting . 5rto¡. Messages and Error Output (08)
49 Watchdog Reset The watchdog timer is pulsed by the microprocessor every milli-
second to ensure that the microprocessor is running properly. If üe
microprocessor fails to pulse the watchdog, a Watchdog Reset fault ¿
occurs.
50 RAM R/W Fault The stafic RAM failed a test. The PDM should be replaced.
51 EPROM One of the EPROMs failed the checksum test at power up. All three
Checksum EPROMs, U66,U67, and U87 should be replaced.
52 TEXT Checksum The text EPROM failed the checksum test at power up. The text
EPROM, U57. should be replaced.
53 NVRAM R/W The NVRAM @ersonality Module) failed a reaüwrite test and
Fault should be replaced.
54 Parameter When parameters are entered or changed, a checksum is computed

Checksum and stored. When powering up, the PDM recalculates the check-
sum and compares it with the stored value. If the two sums differ,
the contents of the NVRAM are assumed to be invalid. The most
Likely cause of this will be a power failure while entering new data.
When a Parameter Checksum error occurs, use the Parameter menu
to check for invalid values.
57 BlankNVRAM The Personality Module is blank. To reload the contents of the PM,
use the File, Transfer menu command.
L
Limits: A limit input activated @ard limit). If the error is a soft limit, a soft-
60 Hard Forward ware ffavel limit has been exceeded. The Jog inputs can be used to
6t Hard Reverse move the PDM offthe limit (in the opposite direction).
62 Soft Forward
63 Soft Reverse
66 Compiler Version Indicates that one or more programs need to be recompiled (the
program was compiled with an older version of the compiler).
Open the program, compile the program, and save the new com-
piled program to the PDM. This may have to be done for every pro-
gram in the PDM (this error may occur when a new version of
IQ Master is installed). After compiling and saving all programs to
the PDM, do a Hard Reset to clear the error. If you do not compile
üe programs before doing the Hard Reset, any executable pro-
grams that have not been recompiled will be deleted (howeve¿ any
source programs will still be intact in the PDM).

P
Diagnostics/Troubleshooting . Error Messages and Error Output (08)
I
6',7 Firmware Version Indicates that a compiled program reqüres newer firmware to run
(this error may occur when trying to run a program compiled under
a newer version of IQ Master using an older version of PDM firm-
ware). For example, the error can occur if an NVRAM with pro-
grams compiled under a newer version of IQ Master is taken from a
PDM with newer firmware and installed in a PDM with an older
version of firmware. The error occurs because the newer PDM
firmware may have new features/program statements not supported
in the old firmware. Update the firmware in the PDM.
68 Program Directory Indicates a checksum error in the program directory. Perform a

Hard Reset, then check the progra4 directory. Due to the unpre-
üctable results of losing the directóry information, this error may
cause the loss of some programs.
69 Program File When programs are entered or changed, the PDM computes and
stores a checksum for the source program and a checksum for the
executable program. At power up and other times during PDM
operation, the checksums are recalculated and compared to the
stored checksums. If the sums differ, the PDM will deterrrine if the
error is i¡ the source or executable program. If the error is in the
source program, a warning message is generated. If the error is in
the executable program, the executable program is deleted, but the
sss¡ss ¡gmains intact. The source shouid then be recompiled to cre-
ate the executable program.
70 Illegal Pgm An invalid program number was used with the Start or Run com-
Number mand. Check to see if the program exists, or, if selecting a progülm
to run from inputs, check that the inputs are set correctly.
1t File Transfer An attempt was made to run a progr¿un while a f,le transfer was in
Active progres§.
72 Home Sw Not The Home Switch or the Encoder Index was not seen by the home
Found program between the hardware limits.
73 Uninitialized PM The Personality Module does not contain proper drive or motor
data needed to operate.
74 I{VRAM The program directory structure (stored in the NVRAM) is incom-

Compatibility patible with the current version of üe IQ 2000i5000 firmware. Per-
form a Hard Reset to delete all programs and update the directory
structure.

Specifications . PDM-10, PDM-20, PDM-30 Specifications 101
Spec¡fications
PDM-1 0, PDM-2O, PDM-30 Specifications

Model PDM-10 PDM-20 PDM-30 Units
Continuous Drive Currentl 5 10 15 Amperes
Peak Drive Currentl 10 20 30 Amperes
Input Voltage 100-240 VACrms single phase

Internal DC bus 141-340 VDC
(325 VDC wittr 230 VAC Input)
Shunt Power Watts

Continuous 50
Peak 4,500
Ambient Temperature
Operating 32"-140"F (0'-50"C)
Storage -40"-158"F (-40'-70'C)
Relative Humidity 57o to 957o non-condensing
Weight 15 lb. (6.8 kg)
Field Wiring Copper, rated 60"C minimum
Terminal Block Torque 11 lb-in (1.25 Nm)

l.peak value of sine wave per phase

102 Specifications. PDM-75 Specifications
t
PDM-75 Specifications
Model PDM.75 Units
Single Phase Three Phase
Continuous Drive Currentl 15 35 Amperes
Peak Drive Currentl 50 15 Amperes
Input Voltage lO0--240 VACrms

Internal DC bus 141-340 VDC
(325 VDC wiü 230 VAC InpuQ
Shunt Power
Continuous 50 Watts
Peak 10,000
Ambient Temperature
Operating 32"-140"F (0"-50"C)
Storage -40"-158"F (-40"-70"C)
Relative Humidity 57a Ío 957o non-condensing
Weight 21.3 lbs. (6.7 kg)

Terminal Block Torque 11 lb-in (1.25 Nm)
1.peak value of sine wave per phase
PDM-25, PDM-50, PDM-I00, PDM-I50/150X Specifications

The IQ-2000 modules include an integral power supply.
Model PDM-25 PDM-50 PDM-1OO PDM-150 PDM-150X Units

Continuous Drive Currentl 20 40 50 b5 85 Amperes
Peak Drive Currentl 25 50 100 150 150 Amperes
Input Bus Voltage t25175 VDC

Ambient Temperature Watts
Operating 32"-122"F (0"-50"C)
Storage -40"-158"F (-40"-70"C)
Relative Humidity 57o fo 95Vo non-condensing
Weight 24.2Lb. (11.0 kg)

Terminal Block Torque 1l lb-in (1.25 Nm)

1. Peak value of sile wave per phase

Specifications . Power Supply Module Specifications 103
Power Supply Module Specifications

y The Power Supply Module (PSM) is necessary only for IQ-5000 eDM-25, PDM-50, PDM-100, and
PDM-150) modules.
Model PSM-50 PSM-125 Units

Conti¡uous Current @C) 50 100 Amperes
PeakAmps @C) 150 450 Amperes
Input Voltage 100-240 VACrms three phase
Output Voltage 100-340 vDC

(325 VDC with 230 VA§ InpuQ
Shunt Power Watts

Continuous 600 t200
Peak 20,000 40,000
Ambient Temperature
Operatirg 32" - t22"F (0 - 60"C)
Storage -40" - 158"F (-40 - 70"C)
Weight 26.2rb. (11.9 kg)
Terminal Block Torque 11.0 24.0 lb-in

1.25 2.75 Nm
Operator Terminal Specifications.

Item Operator Terminal Specification
Input voltage
Standard LI0/24OYAC +15%, P/I\I9101-2017
Optional 24YDC or24YAC P/r{ 9101-2064
lnput Power 25 Watts
U
Temperature
Operating 32" -137"F (0'-55'C) ambient IEC 68-2-1, Test Ab
Storage -40"-158"F (-40"-70'C) ambient IE,C 68-2-2, Test Bb
Vibration 5 - 15.3 H2,0.25 inch d.a IE,C 68-2-6, Test FC

!
15.3-500 Hz,39
Shock 40g, 9 msec, Vz sine, l8shocks total TEC 68-2-2'7, Test Ea
Humidiry 5Vo to 957a non-condensing IE'C 68-2-3, Test Ca
Weight 7Ib. (3 kg)

Display Vacuum Fluorescent Display, 4 lines by 20 characters
Characters 0.12" wide by 0.2" high
Front Panel Seal Water tight NEMA 4 (rP64)

Dust tight NEMA t2 (rP66\
Exposed Materials Bezel: LEXAN@ covered with POLANE@ T paint
Gasket: PORON@ high density cellular urethane
Keyboard: textured polyester with UV hard coatilg

104 Specifications.TransformerSpecifications
,
Transformer Specif ications \]
I
Multi-tap isolation transformers are available for line voltage matching. The IQ-2000 (PDM-10, PDM-
20 ard PDM-30) modules use a single phase transformer. The IQ-5000 (PDM-25, PDM-50, PDM-100
and PDM-150) modules have a separate power supply module and use a three phase transformer.
Single Phase Transformer Specificat¡ons

Specification Value Units
Rating 3.0 KVA
Inputl 220 t230 t240 I 440 / 460 / 480 VAC RMS
Outputl tt5t230 VAC RMS
Ambient Temperature 32"-122"F (0"-50"C)

1. Single phase input and output (5O/60H2)
Three Phase Transformer Specifications

Specification Model Units
TF-03 TF-06 TF-I2 TF-18
Rating 3 6 t2 18 KVA
Weight 86 135 200 325 lb
3t 6t 91 148 kg
Inputl 208/230 / 240 / 380I 460 I 480 VAC RMS
Outputl tIS/230 VAC RMS
Ambient Temperature 32"-122"F (0"-50"C)
1. Three phase input and output (50160ru)
Refer to drawing 9101-0131 on page 36 and drawing 9LOt-0132 on page 37 for transformer outline
drawings and load regulaüon data.
t I

b
- Component Ordering lnformation . Positioning Drive Modules 105
Component Ordering lnformation
Positioning Drive Modules

Y Part Number Descnphon
9t0r-2t6t PDM-10 Positioning Drive Module
groL-2t62 PDM-20 Positioning Drive Module
9lo1-2163 PDM-30 Positioning Drive Module
9101-3045 PDM-25 Positioning Drive Module
9t0t-3046 PDM-50 Positioning Drive Module
9t0t-2t64 PDM-75 Positioning Drive Module
9t0t-3047 PDM-100 Positioning Drive Module
9101-3048 PDM-150 Positioning Drive Module
9101-3049 PDM-150X Positioning Drive Module
9loL-0228 Fuse, Drive Module F1 I Amp (for 24 VDC circuits
Bussman MDL 1 or Litteltuse 313 001)
9101-2005 Connector Kit
Mating connectors for PDM P1-P7
9101-0098 DC Bus Connection Kit
Pos, Neg, Gnd wires - IQ-5000 oniy
9t01-2036 IQ-Series- Series Control Station
9t01-20t7 IQ-Series Operator Terminal, ll0 l24O YAC
9t0t-2064 IQ-Series Operator Terminal, 24 Yolt
9tot-2073 IQ-Series VO Expansion Card
9101-2038 IQ-Series Memory and IiO Expansion Card

106 Component Ordering lnformation. Power Supply Modules
Power Supply Modules

Part Number Description -_/
9101-3000 PSM-50 Power Supply Module
9101-3001 PSM-125 Power Supply Module
glot-0120 PSM-AUX
9r0r-1076 Fuse Fl, PSM-125 Shunt Fuse
Bussman KLM-20 or Littelfuse KLK D 20
9tot-0225 Fuse F1, PSM-50 Shunt Fuse
Bussman KLM-8 or Littelfuse KLK D 8
9to1-0123
Bussman MDX-7 or Litteltuse 313 OO7
9101-0111 Connector TB1, PSM Screw Terminal
Cables
Part Number T'lescription
gtot-2024-xrI,.r IQ Programming Terminal Cable(RS-232) (P6 Connector)2
gt0t-2025-)C§I'.r IQ Operator Terminal Cable(RS-232) (P7 Connector)2
gtor-2027-rc<r IQ Motor Encoder Cable @5 Connector)
gtot-t474-)Crr'.r IQ Motor Encoder Cable for N-Series Motors @5 Connector)
9101-1469-)O(X1 IQ Motor Encoder Cable for N-Series Motors §o P5 Connecfor)
910l-2135-025 or 050 IQ Motor Encoder Cable - 90" Motor Con¡ector (P5 Connector)
9101-2031-X)O(1 IQ Encoder Cable3
9to1-2t27-OO2 IQ P4 to P4 Master/Follower Cable
9101-2030-010 IQ Control Station Cable
9101-025o-X)O(1 IQ-5000/S- or H-3000 Motor Power Cable with Motor Connector
9101-0251-X)O(1 IQ-5000/S- or H-4000/F-4000 Motor Power Cable
9101-0252-X)O(1 IQ-5000/S- or H-6000/F-6000 Motor Power Cable
9101-0253-X)O(1 IQ-5000/S- or H-8000 Motor Power Cable
9101-1080-)O(Xr IQ-2000iS- or H-2000/S- or H-3000 Motor Power Cable
9101-1081-)O(Xl IQ-2000/S- or H-4000/F-4000 Motor Power Cable
910r-1467-lrfcr'.r IQ-20004{-Series Motor Power Cable
910t-2r79-]/JCI'.\ IQ-2000/S- or H-6000/F-6000 Motor Power Cable
44-0141-oo3 IQ-series to VO Conversion Card, 3-foot Cable
44-0t4t-0t0 IQ-Series to VO Conversion Card, 1O-foot Cable
1. Standard cable lengths are 010 = 3m (10 ft),O25 =7.68 m(25 ft),050 = 15 m (50 ft),
075 = 23 m (75 ft), 100 = 30 m (100 ft). )OO( in the part number denotes the cable length-in"f.eet
2.RS-232 cables are available in 3m and 7.68m (10 ard25 ft) lengths only
3. Cable terminated on PDM end only.
\
B
t Component Ordering lnformation . Personality Modules 1O7
Personality Modules
IQC25AS4l]3OPH-CX
X = Cr¡stoner- Special
No Le-iter' = Stanoend
0 - lVotor without Fo.n
2 = Mcton with Fan
Feedhack [ncoden ine Count
n = 2000 (StondonC fon S crnd f motons)
Motor Vino ng Ke (Volts,z10C0 RP¡4)
Moro^ Yoder Nr roe'
PIN'l Switching Fr-equency
A = 5KHz (IA 5000 Stondor d)
B = 10KHz (1e a00C Stando.r'd)
Dnive luJodule Peok lur r'ent Ro.ting
PPnsonoLity lvloCule
Personality Module Model Number Description
Note: IQ Master version 3.2 artd above provide software selection and programming of PMs.
Motors
H-4030 --8-E _0q
i , FACTORY DESIGNATED SPECTAL OPTIONS
AA = STANDARDFLANGE
I. AN = NEMASoC FLANGE
OPTIONS
OO = STANDARD
01 = 90Vdc BRAKE
04 = 24VdcBRAKE
OPTICAL ENCODER LINE COUNT
F = 1000
H = 2000 (sTANpARp)
J = 2500
K = 5000
L =500
M = 3000
N = 1500
MOTOR WINDING K6 DESIGNATOR
NOTE: SPECIAL ORDER WINDINGS AVAILABLE
FRAME SIZE
SERIES DESIGNATOR
F = FEBRITE MAGNET
H = LOW INERTIA
| = |NDUCT|ON
N = RARE EARTH MAGNET
S = RARE EARTH MAGNET
W = WASHDOWN
. Not all Iine counts are available on all motors
Motor Model Number Description

108 Component Ordering lnformation. Motor Mating Connectors
Motor Mating Connectors

Part Number Description
gtor-0325 Motor power connector kit, A1l 2000 and 3000 motors
MS3 106F1 8-4S connector
9tot-0326 Motor power connector kit, All 4000 motors
MS3 I 06F208-4S connector
910t-0327 Motor power connector kit, All 6000 motors
MS3106F24-22S connector
9101-0328 Motor power connector kit, All 8000 motors
MS3106F32-17S connector
9tor-0329 Encoder connector kit, H-Series, S-Series and F-Series motors
MS3106F20-29S connector)
9101-0330 Brake connector kit, H-Series, S-Series and F-Series motors
MS3106F12S-3S connector
Motor Shaft Seal Kits

Part Number T)escription
0041-5056 Shaft seal kit, H-2000 and 5-2000 motor
22mr¡¡ O. Dia. x 12 mm I. Dia. x 7 mm Wide Seal
28 mm O. Dia. x L5 mm I. Dia. x 7 mm Wide Seal
47 r¡:rr¡t O. Dia. x 20 mm I. Dia. x 7 mm Wide Seal
80 mm O. Dia. x 38 mm I. Dia. x 8 mm Wide Seal
0041-5053-005 Shaft seal kit, H-8000 and 5-8000 motor
85 mm O. Dia. x 45 mm I. Dia. x 8 mm Wide Seal
0041-5060 Shaft seal kit, F-4000 motor
1.437 lnch O. Dia. x 0.875 inch I. Dia. x 0.25 inch Wide Seal
0041-5061 Shaft seal kit, F-6000 motor
2.L25 lnch O. Dia. x 1.438 inch I. Dia. x 0.31 inch Wide Seal
Transformers
0020-5091-001 3 KVA three phase transformer (IQ-5000)
0020-5093 PSM-ALX transformer (IQ-5000)
0020-5097 3 KVA single phase transformer (IQ-2000)

Component Ordering lnformation ' lnterface Cards 109
lnterface Cards
9t03-ot52 24V Sourcing UO Conversion Card
-i' r.

lndex
Numerics Control Connections.. ......52

Analog lnput .......57
24V Sourcing !/O Conversion Card Outline Analog Output .....57
Diagram . . .35 Digitallnputs ......54
2msReentrancyFault .......95 Outputs
Digital .....56
Enabled Relay Output . . .59
A
Encoders .....60
MonitorOutput .....58
PSM and PDM lnterface Logic ......45
..
Accel Calculation . ...96
Ready RelayOutput .....58
Analog lnput . ....57
Step and Direction lnputs ......64
Analog Output ...57
Current Rating
Auxiliary Power Supply Module (lQ-5000
Only) Short Circuit .. .... . 10
. .....7
B D
BCD lnputRange .....95 Daisy-chain... ...7O

Danger
Blank NVRAM ...98
Defined .......v
Bus Overvoltage ......97 DC Bus Power LED ...92
Bus Undervoltage .....97 Delay Out of Range ...96
\, Diagnostics
c DC Bus Power LED .....92
ErrorMessages ....95
Cables . .7,106 ErrorOutput(08). .......95
Overflow
Cam Profile ... ... .97 LED . ...91
Caution OperatorTerminal .......93
Defined .......v Personality Module Default lnitialization
Communications, see Serial Ports 94
CompilerVersion ......98 Digital lnputs ....54
lQ-2000/lQ-5000 lnstallation Manual . lndex

112
a
DigitalOutputs .. .56 H
DipSwitches ....14
DividebyZero ...95 Limit
Hard Foruvard ....98 L
Drive Not Ready ......97 Hard ReverseLimit ....98
Heat SinkOvertemperature .......97
Home NotDefined.... ......96
E Found
Home Sw Not .......99
Electrical Noise .......25
ElectroMagnetic Compatibility (EMC) . . .25 I
ElectroMagnetic lnterference (EMl) . . . . . 25
Model
EMI Source-Victim ...25 l/O Conversion Card
EnableOutput ...47 Mounting .....24
Enabled RelayOutput ".....59 Expansion
I/O ....6
Encoderl Fault .......91 Card
l/O Expansion .....6
Encoder2 Fault .......97 lnterfaceCard
l/O ......6
Encoders .. .60 lavgFault..... .......96
EPROM Checksum . .. .98 lllegal Pgm Number . . .99
ErrorMessages .......95 lndexer lnputs, see Step and Direction
ErrorOutput(08). .....95 lnputs
European Directive Compliance Analoglnput .......57
Electromagnetic Com patibil ity Di rective Digital lnputs ......54
3T lnstallation for European Union Compliance
Contactor ....33
Emergency Stop Electromagnetic Compatibility Directive
Card
I/O Conversion
....
LowVoltage Directive
Cables
Motors and
. ....33
.....33
. . ... .33
31
EmergencyStopContactor ....33
l/O Conversion Card ... . . 33
t
ExcessiveFE.. .......96 LowVoltage Directive .... .....33
Excessive Speed ......96 Motorsand Cables ... ........33
lnterface Cards
Ordering'lhformation ....109
F Opcodq.
Invalid .......96
!Q-2000 ¿''
TransferActive
File ....99 PDM '.":'.'.. ...:. ..4,43
Firmwarelnstallation ... 13 Transformer Load Regulation Curve .35
FirmwareVersion . ....99 Transformer Outline Diagram . . . . . . . 35
Fuse F1.. .......53 lQ-5000
Fuse Requirements. .. . 10
FuseRestrictions.... .......10
Fuse, Shunt .48,106
f ,?Y,i; ;,;;,i; á¿bliáii"; ¿:;*i;o' t!
Transformer Outline Diagram . ,.,..r,,.. . 35
FusingRequirements . ......10
' r' ,. : i'.'.:; :11....
'tii"t{}1. , ',rf,[
G J ,i{r dA
Gear Out Of Range ... .96 Jumper Location . . ... .'.,.:'.. .... .::,1:SI
GenericOperatorTerminal .......67 Jumpers L4,53
Graphical Symbols .....v
Grounding Types
Single Point .......28
113
K N
KFF Out of Range .. .. .96 Networking

Kl OutofRange .......96 OperatorTerminal .......69
KP Out of Range 96 Networking lQ-SeriesControls ....69
KPZOutofRange .....96 Noise ......25
NVRAM Compatibility .. .....99
NVRAMRAIVFau|t ....98
L
LED . ......91 o
LogicSupply Fault .....97
LOOP CountOutof Range .......96 Operating Environment .....17
LOOP Variable Range .. .. ..95
Diagram ......5
Mounting .....23
M Networking... .....69
Manuals . .. .5
PowerConnections... ...49
Serial Port. ...67
Math Overflow . ... .. ..95 Specifications . .... 103
Memoryand l/O Expansion ........6 Start-up ......89
MonitorOutput ...58 Status Screen .....93
Motor Option Cards
Compatibility with lQ-Series Control . .4 lnstallation ...15
Mating Connectors . .. 7, 108 Ordering lnformation
Mounting .....22 Cables ......106
Ordering lnformation .... .....107 Motor Mating Connectors. .. . . 108
PowerConnection .... .......50 Motor Shaft Seal Kits . . . 108
Shaft Seal Kits ,* o-. . . . . 108 Motors ......1O7
Motor Overload Protection ..:,:. . . . . . . 10 PersonalityModules ....1O7
Motor Overtemperature . .. .. ..97 Positioning Drive Modules ... . 105
Mounting ;:::
.¿:a.¡,:,,L7,2I,35 Power Supply Modules . . . 106, 109
Sourcing l/O Card . . ... . 109
24V Sourcing l/O Conversion Card ..35 Transformers. ....108
AuxiliaryFSM Transformer ....22 Outputs
Environrñent... ....17 AnalogOutput .....57
IQ-2000 Transformer Outline Diagram Digital Outputs .....56
35
Enabled RelayOutput ...59
19:5000 Transfgrmer Outline Diagram
35 'i'l
MonitorOutput .....58
Ready RelayOutput .....58
.t Motors....':"... '
....22 Overview ....3
OpeiatorTeiminal ... ....23
Positioning Drive Module ......2I
Shunt Resistor . .. . .35 P
Ventilation ....17
:t4punting Requirements . .... 18 ParameterChecksum... ....98
PDM, see Positioning Drive Module
PeakOvercurrent .....97
Personal Computer(PC). ....5

114
,
Personality Fault ......97 Requirements
Personality Module . .. . .5 Fusing .......10
BackingUp.. ......89
Factory Default lnitialization . . .94
lnstallation ...11 S
Ordering lnformation .... ..... 107
POS Track Overflow .......97 S-Curve Calculation ...96
Positioning Drive Module . . .4,21,1O5 see Technical Assistance . .123
DC Bus Connections ....44 Serial Ports ......65
LEDs ...91 Daisy-chain... .....7O
Mounting .....27 HostComputer .....65
Ordering lnformation .... ..... 105 Networking... .!... .....69
Power Connections OperatorTerminal .......67
Auxiliary Logic Power lQ-2000 . . . . . . 44 Personal Computer ......65
Auxiliary Logic Supply lQ-5000 . . .. . . 45 RS.422 Multi-Drop .......70
lQ-2000PDM ......43 Service, see Technical Assistance
lQ-s000PDM ......M Shoft CircuitCurrent Rating ...... 10
Motor Power Connection .. . ...50 ShortCircuitProtection .....10
OperatorTerminal ......49 Shunt Fuse ......48
Positioning Drive Modules (DC Bus Pow- Shunt Resistor ...35
er).. ...44 Connection Diagram .....35
PowerSupply Module (PSM) .......44 Mounting .....35
PSMAUX Outline and Connection Dia- Single Point Ground Types .......28
gram .......35 Soft Forward Limit .....98
Power Module Fault ...97 Soft Reverse Limit ... ..98
PowerSupply Module ........4 Sourcing l/O Card
EnableOutput .....47 Mounting Dimensions .... .....24
JumperLocation ...47 Ordering lnformation . " . ..- .,. r.r . . .. .,.109
LEDs ...92 Specifications
Mounting .....21 lQ-2000 . t}r, toz
Operating Environment .......17 lQ-5000 .....\o2
Ordering lnformation .. .. . . ... 106 OperatorTenninal ...... 103
PowerConnections... ...44 PowerSupplyModule ...103
Specification.. ....103 Start-up Procedure . . .. 83
PRECISION Out of Range .. .95 rQ-2000 PDM ......83
ProductSupport ......123 rQ-5000 ......8s
ProfileCalculation... .......96 1Q-5000 PDM .. "...87
Program Directory .....99 rQ-5000 PSM . .....8s
Program File .. ...99 Step and Direcüon lnputs . . . .64
PSMAUX Outline and Connection Diagram Support, see Technical Assistance
35 SystemOverview ......3
Pulse and Direction, see Step and Direction System Power Connections ... -, ,43
lnputs
T
R
Technical Assistance
RAMRAA/FauIt .......98 Applications Engineers " . 723
ReadyRelayOutput ...58 BBS . r23

115
Distributors:.... ..123
Europe ......123
- Field Service Engineers .. ....123
Representatives ...L23
United States .....L23
TEXT Checksum ......98
TransformerSizing ....18
Transformers.. ....7, 108
Troubleshootin g, see Diagnostics
Uninitialized PM .......99
V
Velocity Calculation .... .....96
Ventilation .......L7
w
Warning
:- Defined .......v
WarningClassifications . .....v
Watchdog Reset . .. .. :. . . ..98
watchdog Test Fault . . . .,)ij¡.]f . . . . .97
i¡oi!,;
.. r]0{-
ll,;"
¡19T' '. ;'
¿l*i, i:1
1.1irj:1
,'r,rL) -" "¿
irt::á ¿

*
t-
European Union - Low Voltage Dircctive
Declaration of Conformity by the Manufacturer
Application of Council Directive 7 2123 |EEC, 93 I 68 |EEC
Manufacturer: Reliance Motion Control

Address: 6950 Washington Avenue South
Eden Prairie, Minnesota 55344, USA
Í.
A registered ISO 9001 Company
Herewith declares that all servo drives listed below
IQ-Series Positioning Drive Modules, models:
PDM-010 PA{ 9101-2141 (16MHz Clock)

PDM-020 PIN 9lOI-2142 (16MHz Clock)
PDM-030 PA{ 9101-2143 (16MHz Clock)
PDM-010 P/N 9101-2161 (2Olvfrlz Clock)
PDM-020 PIN 9LOL-2162 (20WHz Clock)
-
PDM-030 P/N 9101-2163 (ZONlLlz Clock)
PDM-075 P/N 9101-2164 (201vfr12 Clock)
When operating any of the following motor families:
S-, H-, F- and LD-Series motors
And when operated with or without the IF2 24V Sourcing Module, P/NI9103-0152.
And when operated with or without the Operator Terminal, P/I{ 9101-2017.
When installed in accordance with the installation instructions, contained in the "IQ-2000Instal-
lation Requirements for Compliance to European Directives" conforms to the following standard.
EN 60204-1
Signed:
(John Durrant, Technical Manager)
iqt?
Date: lE*É'r¿'¿
I
Electro-Cruff,Ltd, Fourth Avenue, Crewe, Cheshire, CWI 1XL, UK

Euopean union - Eleclrromagneüc compatibility Directive
Declaration of Incorporation by the Manufacturer t
Applic ation of Council Directive 89 / 33 6 IEEC, 92 I 3 I IEF;C, 93 I 68 IEEC
Manufacturer: Reliance Motion Control

Address: 6950 Washington Avenue South
Eden Prairie, Minnesota 55344, USA
A registered ISO 9001 Company

Herewith declares
All products sold or distributed by Reliance Motion Control or Electro-Craft Ltd., under the
Electro-Craft@ Motomatic@ IQ-Series@ or BRU AdvantagerM fademarks, consisting of servo
motors, amplifiers or confrol systems, and accessories as speciñed in üe product manuals:
. Are classified as components;
' Are intended to be incorporated into a drive or control system or to be assembled with other
machinery to constitute machinery covered by directives listed above;
' Do therefore not in every respect comply with the provisions of directive as supplied;
The manufacturer further declares that it is not allowed to put the product into service until the
machinery into which any of the above products are to be incorporated or of which they are to be
a component has been found and declared to be in conformity with the provisions of the directives
and with the national implementing legislation, i.e. as a whole including the equipment referred to
in this declaration.
:# /-
ir,. )ifr .: ; i
The product which is the subject of this declaration is detailérién page 2 of this dgclaiation.
Signed:
(John Durrant, Technical Manager)
Daúe: ?ÜrE flafi'trt l??t
Electro-Craft,Ltd, Fourth Avenue, Crewe, Cheshire, CWl 1XL, UK

Products covered by this declaration are IQ-2000 servo amplifiers as follows:
- PDM-O1O PAI9101-2141 (16MHz Clock)
PDM-O2O PtN 9701-2742 (16MHz Clock)
PDM.O3O PnY 9101-2143 (16MHz Clock)
PDM-O1O P/N 9101-2161 (ZOlN{Hz Clock)
PDM-O20 PA{ 9101-2162 (ZOIN{Hz Clock)
PDM-O3O PA{ 9101-2163 (20MHz Clock)
PDM-075 PA{ 9101-2164 (ZOiN{}{z Clock)
These amplifiers must be used as part of a system incorporating motors and shielded motor cables
supplied by Reliance Motion Control, and installed in accordance with the installation instruc-
tions contained in the document "IQ-2000Installation Requirements for Compliance to European
Directives", available by request from the manufacturer, and the specific insffuctions in the prod-
uct manual
Installation must be in a grounded metallic enclosure and all shields must be bonded to the enclo-
sure wall where they pass through it. An AC line filter of an approved type must be used for the
supply to the amplifier. When so installed the EMC requirements of the following European stan-
dards are met:
Emissions: EN 5501 I: 1993
- (CISPR 11) Group 1 class A
Immunity j1...
EN 50082-2:1995
,:e'l:,rri ... ii ¡-r'.
Electrostatic Discharge EN 61000-4-2

Radiated RF IEC 801-3
Electrical' Fait Transient "tfu8'too o-4-4
Conducted RF Er{v 50141
Magnetic Fields EN 61000-4-8
<¡
Electro-Craft,Ltd, Founh Avenue, Crewe, Cheshire, CWI lXL, UK
s\ü
Products covered by this declaration are IQ-2000 servo amplifiers as follows:

PDM-010 PA{ 9101-2141 (16MHz Clock)
PDM-020 PIN 910I-214'2 (16MHz Clock)
PDM-030 PIN 910l-2143 (16MHz Clock)
PDM-010 P/N 9101-2161 (2OMHz Clock)
PDM-020 P/N 9101-2162 (ZOMHz Clock)
PDM-030 PA{ 9101-2163 (2O}l[}Iz Clock)
PDM-075 P/I,[ 9101-2164 (ZOMHz Clock)
These amplifiers must be used as part of a system incorporating motors and shielded motor cables
supplied by Reliance Motion Conúol, and installed in accordance with the installation instruc-
tions contained in the document "IQ-2000Installation Requirements for Compliance to European
Directives", available by request from the manufacturer, and the specific instructions in the prod-
uct manual
Installation must be in a grounded metallic enclosure and all shields must be bonded to the enclo-
sure wall where they pass through it. An AC line filter of an approved type must be used for the
supply to the amplifier. When so installed the EMC requirements of the following European stan-
dards are met:
Emissions: EN 5501t: L993
(CISPR 11) Group 1 class A
Immunity
j',;i,iir:'i .'l'^.'
EN 50082-2:1995
r.rij"i,.
-"
Electrostatic Discharge EN 6L000-4-2

Radiated RF IEC 801-3
Elecrical'FástTransient otft8fooo-4-4
Conducted RF ENV 50141
Magnetic Fields EN 61000-4-8
Electro-Craft, Ltd, Fourth Avenue, Crewe, Cheshire, CWl lXL, UK

Mail or Fax: *o"Oror, Automation Technical Writing
Technical Support Group
Internal Use:
6950 Washington Avenue South
Eden Prairie, MN 55344
DIF#
Fax: 612-942-3636
Documentation Improvement Form

Manual Number:
Page Number:_
Comments: Please give page numbers and specific paragraphs that the change will affect. Include markups from the
document or attach additional pages if necessary.
What improvements will this suggestion provide?.
Originator: City: State: Zio:

Company: Phone:
Address: Date:
Technical Writing Internal Use:

Follow-Up Action
lD RocI«weII Automation
t-
,\
t*-¡
Fi$t Fold
l"l'l¡l"lilll,l,,,l,'l'll"l¡l'rl"llt'rl.l'tl¡l¡l
89¿6-tre99 Nt l
:¡lHlVUd N3O3
S fAV NOI9NIHSVM 0969
]oHrNoS Nolloyll ScNvl'l3u
33SS3UCI0V^8 GtVd 3S -r-rM30V1SOd

Nl,'U '3lHlVHd N3O3 06¿ 'ON rlnu3d
SS\flC ISUIJ
- ilvl/! ssSNrsn8 t-l

-
- salels pallun ^rd=u ...tl *üs;, "-
1i :: ''
eql. ul
- petlen¡ -r ni Y.dq ; i. r
- Árcssace¡ lt
'i' ' 't'rir;.¡ ri''- ."
- a6e¡so¿ o¡ .: , ,1:r;q]x,
- 'i ..,.i: r',.¡ .tl$ttij., ¿- 1:
,. ¡
lil til 'r .ir'Ii ¡:;i-{ñ'j -
Second Fold
: 't':.
¡ e
§. ,P
,.i
d
td
ti 'ii
..n
r r_ - - ¡ll
i . ' a,',' :.- r.i , -,
t r;-,
¡t
Product Support
Electro-Craft product support is available over the phone. When you call, you should be at your com-
puter and have the hardware and software manuals at hand. Be prepared to give the following informa-
tion:
. The version numbers of the Electro-Craft hardware and software products.
. The type of hardwate that you are using.
' The fault indicators and the exact wording of any messages that appears on your screen.
. How you have tried to solve the problem.
Distributor & Representative Network

Rockwell Automation has a wide network of Electro-Craft distributors that are trained to support our
products.If you encounter problems, call the distributor or rqpresentative where you purchased the
product before contacting the factory.
Applications Engineers and Field Service

In the United States you can reach the Rockwell Automation factory based support staff by phone
between 7:00 AM and 5:00 PM (CST) Monday through Friday at 1-800-328-3983. The applications
engineers can assist you with programming difficulties as well as ideas for how to approach your auto-
mation task. Should yourproblem require on-site assistance, field service is available.
The applications engineers can also be reached via fax at l-612-942-3636. The fax machine is open 24
hours 7 days a week. Faxes will be answered during regular business hours only.
In Europe, support can be obtained through Electro-Craft Limited. The suppof staff may be reached by
telephone between 8:30 and 17:30local time, Monday through Friday at0l1 441270-58}14},or via fax
at0ll 441210-580141.
Bulletin Board Service (BBS)

If you have a modem, you can reach the BBS for Electro-Craft products 24 hours a day,7 days a week
at 1-612-942-3618. The following services are available through rhe BBS:
. Example application programs
. Technical bulletins
. CAD .DXF files of standard products
. Software Upgrades, the latest versions of Electro-Craft software
. Leave messages and files for the application engineers
. Help with your application.

IQ Series Installation Manual Part2

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

IQ Series Installation Manual Part2

Hochgeladen von

Copyright:

Verfügbare Formate

t

42 Reference lnstallation Drawings. Outline Drawings

Éss5É5 É §." k o$o

x E [gEE3i Éz sZ Ep 224 ñ úOe

Refer to üe following drawings for complete power wiring details.

tromagnetic Clmpatibili ty" otpage 25.

Auxiliary Logic Power

lQ 2000/5000 lnstallation Manual

TB I POI.IE R SU?PLY XODULT

b PSM Interface - Internal Circuit Examples

SAIYPTE E XTE RNAL CONNE CT ] ONS

PSM Interface - External Connection Examples

PSM Connector Pin # Signal Name

Purpose J PSM Enable-

Inputs/Outputs 4 PSM Enable + rL

lQ 2000/5000 lnstallation Manual

lu POWER SUPPLY MODULE

b SHORTING JUMPER ACROSS

F TO CONNECTOR TB1 SIGNALS ENABLE+

l', AND DETAILS OF OPERATION BEFORE

t SHORTING JUMPER ACROSS EXTERNAL ENABLE INPUT IS DE.ACTIVATED,

Replacing the PSM Shunt Fuse (IQ-5000 only)

1. Measure voltages atLl,L2,and L3 phase to phase to ensure

J. Replace the shunt fuse.

Power SuPPIY Modulg

PSlr-125 wiih exterml shuot

Shunt Fuse Location

lQ 2000/5000 lnstallation Manual

L 11s1230 VAC HOT)

L Operator lbrminal Power Connections (1.15/230 \4\C Version)

- 24 VDC (DC-), 24 VAC (NEUTRAL)

24vDC (DC+), 24 VAC (HOT)

S-SER]E5 AND I-5300 AND

Motor Power Connections

Cab1e sizes are inücated in the appropriate drawings:

lQ 2000/5000 lnstallation Manual

Shield Termination of Power Cables

F-, H-, N- and S-Series Power Cables

Motor Power EMC Shield Connection

The following diagram illustrates all control connections to the PCM.

PCM Control Connections

lQ 2000/5000 lnstallation Manual

t-t Oigital lnputs and Outputs

II Pin 1 of the interface connectors P1,P2, and P3 is located

= INTEFÍ{AL 24 VDC §UFPLY

= 75M mS PER OLrmr

, . 9103-0t52 24YDC Sourcing VO Conversion Card

Connector Pin Signal Name Assignable Function

J Input 2 (I2) Reverse Limit

4 Input 3 (I3) Enable

5 Input 4 (I4) Start Program

6 Input 5 (5) Home Switch

7 Input 6 (16) Home Command

8 Input 7 (I7) Jog Reverse

9 Input 8 Q8) Jog Forward

10 Input 9 (9) Pause

11 Input 10 (I10) Emergency Return

t2 Input 11 (I11) Intl / Program Select

t3 Input 12 (I12) Int2 / Program Select

T4 Input 13 (I13) Program Select

lQ 2000/5000 lnstallation Manual

Purpose Inputs 2 Input 15 (I15) Program Select

E Connector Pin # Signal Name

Anatog Input and Output - §pical Internal Circuits