Allen-Bradley 1391B Series User manual

1391B-ES Instruction Manual

Table of Contents

Introduction Chapter 1

Manual Objectives 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1391 Series D 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Precautions 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Description 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Features 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options/Modifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Layout 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications Chapter 2

Chapter Objectives 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Specifications 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environmental Specifications 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Power Dissipation 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformer Power Dissipation 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving, Unpacking and Chapter 3

Inspection Chapter Objectives 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of Operation Chapter 4

Chapter Objectives 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300V DC Power Bus Supply 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PWM Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt Regulator Operation 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Logic Power Supply 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Logic Control Boards 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Monitoring and Detection 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Isolated Current Sensing 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integral Circuit Breaker 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line/DB Contactor 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Driver Board 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Quad B Board 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power-Up/Down Sequence 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1391B-ES Instruction Manual

Table of Contents

Inputs, Outputs and Adjustments Chapter 5

Chapter Objectives 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inputs/Outputs 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer Adjustments 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch Settings 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Chapter 6

Chapter Objectives 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Recommendations 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-Up Chapter 7

Chapter Objectives 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-Up Procedure 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The 1326AB AC Servomotor Chapter 8

Chapter Objectives 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Options/Accessories 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformers and Shunt Regulators Chapter 9

Chapter Objectives 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1391 Transformers 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt Regulator Operation 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt Regulator Installation 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Chapter 10

Chapter Objectives 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Troubleshooting 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Point Descriptions 10-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions Appendix A

Interconnect Drawings Appendix B

Cable Information Appendix C

Controller Options Appendix D

Chapter

1-1

Introduction

Manual Objectives This manual is meant to guide the interface, installation, setup and

troubleshooting of a 1391B-ES AC Servo Controller. The contents are

arranged in order from a general description of the controller to

troubleshooting and maintenance. To ensure successful installation and

operation, the material presented must be thoroughly read and understood

before proceeding. Particular attention must be directed to the Attention

and Important statements contained within.

Important Information about this Manual

This manual has been prepared primarily to support this product in a single

controller application. It is a standard document that is intended to help the

user understand the individual operating characteristics and limitations of

this equipment including hazards associated with installation, setup and

maintenance procedures. Note the following points:

nThis equipment has been designed to meet the requirements of a

component controller in an integrated controller system.

nWhile the potential hazards associated with the controller remain the

same when used in a system environment, it must be noted that special

considerations are to be given to characteristics of other peripheral

solid-state control equipment and the cumulative impact on safety.

nManufacturers and engineering groups responsible for specification or

design of electrical control equipment must refer to applicable industry

standards and codes for specific safety guidelines and interface

requirements.

nIn the actual factory environment, the user is responsible to ensure

compliance with applicable machine and operator safety codes or

regulations which are beyond the scope and purpose of this document.

1391 Series D Allen-Bradley’s commitment to continuing product improvement has led to

the introduction of the 1391 Series D Servo Controller. The catalog

number string for the Series D will be unchanged, however, the controller

nameplate will appear as follows:

CAT 1391B-xxx SER D

This new series incorporates a re-designed Power Driver Board that

increases manufacturing quality and provides a platform for new versions

of the 1391 that are now in development.

This enhancement is totally transparent to the user of this product. The

Control Board and all other components of the controller remain the same.

Introduction

Chapter 1

1-2

General Precautions In addition to the precautions listed throughout this manual, the following

statements which are general to the controller must be read and understood.

ATTENTION: Only personnel familiar with the 1391B-ES

Servo Controller and associated machinery should plan or

implement the installation, start-up and subsequent maintenance

of the controller. Failure to comply may result in personal injury

and/or equipment damage.

ATTENTION: An incorrectly applied or installed controller

can result in component damage or a reduction in product life.

Wiring or application errors, such as, undersizing the motor,

incorrect or inadequate AC supply, or excessive ambient

temperatures may result in malfunction of the controller.

ATTENTION: This controller contains ESD (Electrostatic

Discharge) sensitive parts and assemblies. Static control

precautions are required when installing, testing, servicing or

repairing this assembly. Component damage may result if ESD

control procedures are not followed. If you are not familiar with

static control procedures, reference Allen-Bradley publication

8000-4.5.2, Guarding Against Electrostatic Damage or any

other applicable ESD Protection Handbook.

Important: In order to maintain UL listing on Allen-Bradley 1391B-ES

Servo Controllers, the user must provide power from a 1391 Isolation

Transformer. Use of any other transformer voids the UL listing.

The user is responsible for providing motor overload protection in

accordance with the National Electrical Code (NEC), and any other local

codes that may apply.

Controller Description The 1391B-ES Pulse Width Modulated Servo Controller is a dedicated,

single axis, AC servo controller. It has been packaged to require a

minimum amount of panel space while containing, as standard, a number

of features required by the machine tool and automated equipment

industries.

The 1391B-ES allows the user to achieve higher operating speeds with

purchased motors or from motors already in use. Depending on the motor,

the 1391B-ES can produce up to 30% more speed without loss of torque.

This can help achieve greater precision, a finer finished product and

increased production from existing machinery.

Introduction

Chapter 1

1-3

The 1391B-ES is generally used with a computer aided, closed loop

positioning system to control the position and linear or rotary motion of

various machine members on an automated machine.

All components are mounted in an open framed package with a slide-on

front cover. The controller is intended to be panel mounted in an enclosure

and ventilated with filtered and/or cooled air. An internal fan is included to

circulate air over the power heat sink.

The 1391B-ES converts a three-phase, 50/60 Hz input, to a variable AC

voltage with controlled phase, amplitude and frequency. The output which

is proportional to a user supplied analog command, regulates the speed

and/or current (torque) of a 1326 permanent magnet AC servomotor. The

controller is available in ratings of 15, 22.5 and 45A RMS with all package

sizes being identical. A 1391 Transformer, 1326 AC Servomotor and 1326

Cables complete the servo system.

Standard Features The 1391B-ES contains a number of standard features required in a typical

automated machine servo system.

•Input protected against transient voltage.

•A power line/DB contactor which opens the AC line to the controller

and inserts a shunt regulator resistor across the DC bus whenever the

contactor is de-energized.

•An integral circuit breaker which will open all three AC line leads in the

event of a short circuit condition in the power circuitry.

•A standard 300V DC power bus supply that includes an integral shunt

regulator.

•A shunt regulator resistor to dissipate the energy generated by the motor

during regenerative braking.

•Velocity loop components to compensate for a system inertia range

between 0.03 to 1.0 lb.-in.-s2.

•User selectable mechanical resonance filtering.

•Patented current control implementation.

•Acceleration or torque feedforward differential input.

•DIP switch configurable.

•Logic Boards that can be quickly removed and easily interchanged for

troubleshooting and diagnostics.

•Three controller ratings that are in the same physical package and have

identical mounting dimensions.

•True vector control.

•Up to 300 feet (91.4 meters) between controller and motor.

Introduction

Chapter 1

1-4

Options/Modifications The 1391B-ES contains most functions needed in a servo system.

The following are selectable at the user’s option:

- Contactor Auxiliary Switch

Two N.O. contacts are mounted on the main power contactor and wired

to the power terminal block. These contacts can be used in a motor

brake control circuit or as an indicator that the contactor has closed.

- Current or Torque Amplifier Operation

When the velocity loop is being closed as part of the position control

system, the controller can be configured to operate as a current or torque

amplifier by use of the S2 switch settings.

- External Shunt Regulator Resistor

On 15 and 22.5A controllers an internal power resistor that is part of the

DC bus voltage shunt regulator can dissipate 162 watts continuous

power. Some applications such as an overhauling load have excessive

regenerative energy to dissipate. For these applications, an external

shunt regulator resistor rated at 386 watts continuous can be supplied for

user mounting on 22.5A controllers. This is selectable by removing the

jumper on TB5 and using an external resistor. The shunt has integral

fusing accessible from the outside of 15 and 22.5A controllers. The 45A

controller has an externally mounted resistor and fuse.

Important: An external shunt regulator resistor is included as standard

equipment on 45A units. An additional unit is not required.

- Tach Output

A voltage equal to 2.0V DC/1000 RPM is available at TB2. 1.2V

DC/1000 RPM on units set for 6000 RPM operation.

- Torque or Current Monitor

A voltage equal to 3.0V DC=100% scaled current is available at TB2.

- Anti-Backlash

Provisions to use the 1388 Anti-Backlash module are provided.

Controller Layout Figure 1.1 provides an exterior view of the 1391B-ES AC Servo

Controller, showing accessibility of various components.

Introduction

Chapter 1

1-5

Figure 1.1

1391B-ES AC Servo Controller

TB2

Ground Stud

TB4

Circuit Breaker

Fuse

SW1

TB1

Diagnostic LED’s

Introduction

Chapter 1

1-6

End of Chapter

Chapter

2-7

Specifications

Chapter Objectives Chapter two contains the electrical and environmental specifications for the

1391B-ES. Dimensions are provided in Appendix A.

Controller Specifications The general specifications of the 1391B-ES are provided in the listing

below. The specifications are divided when necessary for the various

controller ratings.

Specific Controller Ratings 1391B-ESAA15 1391B-ESAA22 1391B-ESAA45

Nominal Bus Output Voltage 300V DC 300V DC 300V DC

Continuous Current (RMS) 15A 22.5A 45A

Peak Current (RMS) 30A 45A 90A

Continuous Power Output 5.0 kW 7.5 kW 15.0 kW

Peak Power Output 10.0 kW 15.0 kW 30.0 kW

Input Circuit Breaker Rating 17A RMS 26A RMS 38A RMS

Circuit Breaker Interrupt Rating

(Symmetrical Amperes) 1300A 1300A 1300A

Unit Weight in lbs. (kg) 22 (9.97) 28 (12.69) 34 (15.40)

All Controller Ratings

Static Gain (A/RMS) 1.5 x Rated Motor Current / rpm

Form Factor 1.03 or less

Peak Current Limit Adjust 20 to 300% of Rated Motor Current (to 2 times continuous

rating of drive, maximum)

Controller Efficiency

(Minimum at Rated Load) 85%

Modulation Frequency 2500 Hz ±10%

Drift (Referred to Tach) 0.07 rpm /Degrees C. Maximum

Ambient Temperature 0 to 60°C (32 to 140°F)

Storage Temperature 0 to 65°C (32 to 149°F)

Input Voltage (from Transformer) Power: 230V AC, Three-Phase, 50/60

Hz ±3 Hz Control: 36V AC CT, Single-Phase

Relative Humidity 5 to 95% Non-Condensing

Deadband Zero

Altitude 1000 meters (3300 feet)

Integral Fan Output 50 CFM (Unloaded)

Max. RMS Short Circuit Current

(Symmetrical Amperes) 1300A

Transformer Input Tolerance +10%, –15%

Specifications

Chapter 2

2-8

Specifications are for reference only and are subject to change without notice.

Environmental Specifications The 1391B-ES must be mounted in an enclosure that is clean, dry and

ventilated by filtered or cooled air. Enclosures vented with ambient air

must have appropriate filtering to protect against contamination caused by

oils, coolants, dust, condensation etc. The ambient air temperature must be

kept between 0 to 60°C (32 to 140°F) and the humidity between 5 and

95%, non-condensing.

The 1391B-ES is equipped with an integral cooling fan. The general flow

of air through the unit must be maintained by following the recommended

spacing guidelines found in Chapter 6. The 1391B-ES can operate at

elevations to 3300 feet (1000 meters) without derating, however, the

current rating must be derated by 3% for each additional 1000 feet (305

meters) up to 10,000 feet (3050 meters). Consult with your local

Allen-Bradley Sales Representative prior to operation over 10,000 feet

(3050 meters).

Controller Power Dissipation The 1391B-ES dissipation characteristics are approximated in Table 2.A.

Table 2.A

Controller Power Dissipation

Rated Power

Output

(%)

100

1391B-ESAA

(watts)

114

152

190

1391B-ESAA

(watts)

110

165

220

275

1391B-ESAA

(watts)

104

208

312

416

520

Transformer Power Dissipation The power dissipation characteristics of the 1391 Isolation Transformer are

shown in Table 2.B.

Table 2.B

1391 Isolation Transformer Power Dissipation

Rated Power

Output

(%)

100

1.5kV

(watts)

3.5kV

(watts)

105

140

175

5.0kV

(watts)

100

150

200

250

10.0kV

(watts)

100

200

300

400

500

12.5kV

(watts)

125

250

375

500

625

15.0kV

(watts)

150

300

450

600

750

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