1394 SERCOS Interface Multi-Axis Motion Control System: (Catalog Numbers 1394C-SJT05-D, 1394C-SJT10-D, 1394C-SJT22-D)

1394 SERCOS
Interface
Multi-Axis Motion
Control System
(Catalog Numbers
1394C-SJT05-D,
1394C-SJT10-D,
1394C-SJT22-D)
Integration Manual
Important User Information Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations, charts, sample programs and layout examples

shown in this guide are intended solely for purposes of example.
Since there are many variables and requirements associated with any
particular installation, Allen-Bradley does not assume responsibility
or liability (to include intellectual property liability) for actual use
based upon the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the

Application, Installation and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in

whole or part, without written permission of Rockwell Automation,
is prohibited.
Throughout this manual we use notes to make you aware of safety

considerations:
Identifies information about practices or

ATTENTION
circumstances that can lead to personal injury or
death, property damage or economic loss.
!
Attention statements help you to:
• identify a hazard
• avoid a hazard
• recognize the consequences
IMPORTANT Identifies information that is critical for successful

application and understanding of the product.
Allen-Bradley is a registered trademark of Rockwell Automation.

ControlLogix, DriveExplorer, Logix, RSLogix, SoftLogix, and SCANport are trademarks of Rockwell Automation.
SERCOS interface is a trademark of the Interests Group SERCOS interface e.V. (IGS).
Table of Contents
Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . P-1

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . P-3
Product Receiving and Storage Responsibility . . . . . . . . . . . P-3
Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-4
Comments Regarding this Manual . . . . . . . . . . . . . . . . . P-4
Chapter 1
Commissioning Your 1394 SERCOS Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Interface System General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Understanding 1394 Connectors . . . . . . . . . . . . . . . . . . . . . 1-3
System Module Connectors . . . . . . . . . . . . . . . . . . . . . . 1-3
Axis Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Locating System Module Connectors and Indicators . . . . . . 1-4
Locating Axis Module Connectors and Indicators . . . . . . . . 1-6
Locating SERCOS Interface Fiber-Optic Connectors . . . . . . . 1-7
Configuring Your 1394 SERCOS interface System . . . . . . . . 1-7
Configuring Your 1394 System Module . . . . . . . . . . . . . 1-8
Configuring Your Logix SERCOS interface Module . . . . . . 1-11
Configuring Your Logix Controller. . . . . . . . . . . . . . . . 1-11
Configuring Your Logix Module . . . . . . . . . . . . . . . . . 1-13
Configuring Your 1394 System Module . . . . . . . . . . . . 1-15
Configuring the Motion Group . . . . . . . . . . . . . . . . . . 1-17
Configuring Axis Properties. . . . . . . . . . . . . . . . . . . . . 1-18
Downloading Your Program . . . . . . . . . . . . . . . . . . . . 1-19
Applying Power to the 1394 SERCOS interface System. . . . 1-20
Testing and Tuning Your Axes . . . . . . . . . . . . . . . . . . . . . 1-22
Testing Your Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Tuning Your Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Chapter 2
Troubleshooting Your 1394 Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SERCOS Interface System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Understanding How to Detect a Problem . . . . . . . . . . . . . . 2-2
Troubleshooting System and Axis Module LEDs . . . . . . . . . 2-3
Troubleshooting the SERCOS Network Status LED. . . . . . . . 2-5
Troubleshooting System and Axis Module Faults . . . . . . . . . 2-6
System Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Axis Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Troubleshooting General System Problems . . . . . . . . . . . . 2-12
Understanding Logix/Drive Fault Behavior . . . . . . . . . . . . 2-14
System Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Axis Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
i Publication 1394-IN024B-EN-P — February 2004
ii Table of Contents
Supplemental Troubleshooting Information. . . . . . . . . . . . 2-18

Tools for Changing Parameters . . . . . . . . . . . . . . . . . . 2-18
Using Analog Test Points to Monitor System Variables . 2-20
Changing Default Digital Output Settings . . . . . . . . . . . 2-22
Replacing System and Axis Modules . . . . . . . . . . . . . . . . . 2-23
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Removing an Axis Module. . . . . . . . . . . . . . . . . . . . . . 2-24
Installing a Replacement Axis Module . . . . . . . . . . . . . 2-25
Removing a System Module. . . . . . . . . . . . . . . . . . . . . 2-26
Installing a Replacement System Module . . . . . . . . . . . 2-27
Appendix A
Interconnect Diagrams Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
1394 SERCOS Interface Interconnect Diagram Notes . . . . . . A-2
Power Interconnect Diagrams. . . . . . . . . . . . . . . . . . . . . . . A-3
Shunt Module Interconnect Diagrams . . . . . . . . . . . . . . . . . A-4
Axis Module/Motor Interconnect Diagrams . . . . . . . . . . . . . A-6
Thermal Switch and Brake Interconnect Diagrams . . . . . . . . A-9
Understanding Motor Thermal Switches . . . . . . . . . . . . . A-9
How Your Feedback Cable Affects Thermal Switch
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Thermal Switch Interconnect Diagrams . . . . . . . . . . . . . A-9
Brake Interconnect Diagrams . . . . . . . . . . . . . . . . . . . A-14
Publication 1394-IN024B-EN-P — February 2004

Preface
Read this preface to familiarize yourself with the rest of the manual.
The preface covers the following topics:
• Who Should Use this Manual

• Purpose of this Manual
• Contents of this Manual
• Related Documentation
• Conventions Used in this Manual
• Product Receiving and Storage Responsibility
• Allen-Bradley Support
Who Should Use this This manual is intended for engineers or programmers directly
involved in the operation, field maintenance, and integration of the
Manual 1394 SERCOS interface system with the Logix SERCOS interface
module.
If you do not have a basic understanding of the 1394, contact your

local Allen-Bradley representative for information on available training
courses before using this product.
Purpose of this Manual This manual provides the startup, configuring, and troubleshooting
procedures for the 1394 SERCOS interface system. The purpose of this
manual is to assist you in the startup of your 1394 and the integration
of your 1394 with the ControlLogix 1756-MxxSE SERCOS interface
module or SoftLogix 1784-PM16SE SERCOS interface PCI card.
1 Publication 1394-IN024B-EN-P — February 2004

P-2 Preface
Contents of this Manual

Chapter Title Contents
Describes the purpose, background, and scope of this
Preface manual. Also specifies the audience for whom this
manual is intended.
Provides steps to follow when configuring your 1394
1 Commissioning Your 1394 with the Logix SERCOS interface module and
SERCOS Interface System describes how to apply power to your 1394 SERCOS
interface system for the first time.
Troubleshooting Your 1394 Provides diagnostic aids that help isolate problems
2 SERCOS Interface System with your 1394 SERCOS interface system.
Appendix A Interconnect Diagrams Provides interconnect diagrams for the 1394 SERCOS
interface system.
Related Documentation The following documents contain additional information concerning

related Allen-Bradley products. To obtain a copy, contact your local
Allen-Bradley office, distributor, or download them from
TheAutomationBookstore.com.
For: Read This Document: Publication Number:

The instructions needed for the installation and wiring 1394 SERCOS interface Installation Manual 1394-IN002x-EN-P
of the 1394 SERCOS interface system
A description and specifications for the Ultra3000
family including motors and motor accessories Motion Control Selection Guide GMC-SG001x-EN-P
Application sizing and configuration information Motion Book Servo Sizing CD Motion Book-mmmyy
More detailed information on the use of ControlLogix
motion features and application examples ControlLogix Motion Module Programming Manual 1756-RM086x-EN-P
ControlLogix SERCOS interface module installation 8 or 16 Axis SERCOS interface Module Installation
instructions Instructions 1756-IN572x-EN-P
SoftLogix SERCOS interface PCI card installation 16 Axis PCI SERCOS interface Card Installation 1784-IN041x-EN-P
instructions Instructions
The instructions needed to program a motion Logix Controller Motion Instruction Set Reference
application Manual 1756-RM007x-EN-P
Information on configuring and troubleshooting your ControlLogix Motion Module Setup and
ControlLogix motion module Configuration Manual 1756-UM006x-EN-P
Information on configuring and troubleshooting your SoftLogix Motion Card Setup and Configuration 1784-UM003x-EN-P
SoftLogix PCI card Manual
Information on proper handling, installing, testing, Fiber Optic Cable Installation and Handling
and troubleshooting fiber-optic cables Instructions 2090-IN010x-EN-P
Information, examples, and techniques designed to System Design for Control of Electrical Noise
minimize system failures caused by electrical noise Reference Manual GMC-RM001x-EN-P
For declarations of conformity (DoC) currently Rockwell Automation Product Certification website www.ab.com/
available from Rockwell Automation certification/ce/docs
Published by the National
An article on wire sizes and types for grounding National Electrical Code Fire Protection Association
electrical equipment of Boston, MA.
A glossary of industrial automation terms and
abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1

Preface P-3
Conventions Used in this The following conventions are used throughout this manual:
Manual • Bulleted lists such as this one provide information, not procedural
steps.
• Numbered lists provide sequential steps or hierarchical
information.
• Words that you type or select appear in bold.
• When we refer you to another location, the section or chapter
name appears in italics.
Product Receiving and You, the customer, are responsible for thoroughly inspecting the
equipment before accepting the shipment from the freight company.
Storage Responsibility Check the item(s) you receive against your purchase order. If any
items are obviously damaged, it is your responsibility to refuse
delivery until the freight agent has noted the damage on the freight
bill. Should you discover any concealed damage during unpacking,
you are responsible for notifying the freight agent. Leave the shipping
container intact and request that the freight agent make a visual
inspection of the equipment.
Leave the product in its shipping container prior to installation. If you

are not going to use the equipment for a period of time, store it:
• in a clean, dry location

• within an ambient temperature range of 0 to 65° C (32 to 149° F)
• within a relative humidity range of 5% to 95%, non-condensing
• in an area where it cannot be exposed to a corrosive atmosphere
• in a non-construction area

P-4 Preface
Allen-Bradley Support Allen-Bradley offers support services worldwide, with over 75 Sales/
Support Offices, 512 authorized Distributors and 260 authorized
Systems Integrators located throughout the United States alone, plus
Allen-Bradley representatives in every major country in the world.
Local Product Support
Contact your local Allen-Bradley representative for:
• sales and order support

• product technical training
• warranty support
• support service agreements
Technical Product Assistance
If you need to contact Allen-Bradley for technical assistance, please

review the information in Chapter 2 first, then call your local Allen-
Bradley representative or Rockwell Automation Technical Support at
(440)-646-5800. For the quickest possible response, please have the
catalog numbers of your products available when you call. For
Rockwell Automation Technical Support on the web, go to
www.ab.com/support.
Comments Regarding this Manual
To offer comments regarding the contents of this manual, go to

www.ab.com/manuals/gmc and download the Motion Control
Problem Report form. Mail or fax your comments to the address/fax
number given on the form.

Chapter 1
Commissioning Your 1394 SERCOS Interface

System
Chapter Objectives This chapter provides you with the information to set up, configure,
and apply power to your 1394 system. This chapter includes:
• General Startup Precautions

• Understanding 1394 Connectors
• Locating System Module Connectors and Indicators
• Locating Axis Module Connectors and Indicators
• Locating SERCOS Interface Fiber-Optic Connectors
• Configuring Your 1394 SERCOS interface System
• Configuring Your Logix SERCOS interface Module
• Applying Power to the 1394 SERCOS interface System
• Testing and Tuning Your Axes
These procedures assume you have completed mounting, wiring, and

connecting your 1394 system and Logix SERCOS interface module as
described in the 1394 SERCOS Interface Installation Manual
(publication 1394-IN002x-EN-P).
Note: Some of the procedures in this chapter include information

regarding integration with other products.

1-2 Commissioning Your 1394 SERCOS Interface System
General Startup The following precautions pertain to all of the procedures in this
chapter. Be sure to read and thoroughly understand them before
Precautions proceeding.
This product contains stored energy devices. To

ATTENTION
avoid hazard of electrical shock, verify that all
voltages on the system bus network have been
! discharged before attempting to service, repair or

remove this unit. Only qualified personnel familiar
with solid state control equipment and safety
procedures in publication NFPA 70E or applicable
local codes should attempt this procedure.
This drive contains ESD (Electrostatic Discharge)

ATTENTION
sensitive parts and assemblies. You are required to
follow static control precautions when you install,
! test, service, or repair this assembly. If you do not

follow ESD control procedures, components can be
damaged. If you are not familiar with static control
procedures, refer to Allen-Bradley publication 8000-
4.5.2, Guarding Against Electrostatic Damage or any
other applicable ESD Protection Handbook.

Commissioning Your 1394 SERCOS Interface System 1-3
Understanding 1394 The following tables provide a brief description of the 1394
connectors.
Connectors
System Module Connectors
Description Connector Present on this 1394

System Module
Input Power 4-position connector housing
Logic Power 2-position connector housing 1394C-SJT05-D /
1394C-SJT10-D
Shunt Power 3-position connector housing
Logic, Shunt, and Input Power 8-position terminal block 1394C-SJT22-D
Terminal Block
Single Point Bond Bar 5-position grounding bar
Motor/Auxiliary Feedback 13-position connector housing
Relay Outputs 10-position connector housing
1394C-SJT05-D,
Analog Outputs 9-position connector housing 1394C-SJT10-D, or
1394C-SJT22-D
Discrete Input 8-position connector housing (4)
SERCOS Transmit and Receive SERCOS fiber-optic (2)
DPI/SCANport DPI/SCANport
Axis Module Connectors
Description Connector
Motor Power Terminal Block 6-position terminal block
Motor Brake/Thermal (TB1/TB2) 4-position connector housing (2)

Locating System Module Use the figure below to locate the 1394C-SJT05-D and -SJT10-D
System Module connectors and indicators.
Connectors and Indicators
Figure 1.1
1394 System Modules (1394C-SJT05-D and -SJT10-D)
System Module, front view 1394 Digital Servo Controller

! DANGER
RISK OF ELECTRICAL SHOCK.
SERCOS interfaceTM
(1394C-SJT05-D and -SJT10-D is shown) System Module
RELAY OUTPUTS
MORE THAN ONE
DISCONNECT SWITCH
MAY BE REQUIRED TO
DE-ENERGIZE THE
EQUIPMENT BEFORE
SERVICE.
1
DRIVE SYSTEM OK
OUTPUT 3
OUTPUT 2
! DANGER
ELECTRICAL SHOCK HAZARD
FROM ENERGY STROAGE
CAPACITORS.
Arrow on base address switch
10
OUTPUT 1
OUTPUT 0
VERIFY LOW VOLTAGE
DISCHARGE BEFORE
SERVICING.
SEE INSTRUCTIONAL MANUAL.

indicates address setting
Enable3
AXIS 3
1 5 Pos_Otrav3
(factory default setting is 9).
1394 System Module Analog Outputs
Reg3_Com
Home3
Reg3_1 4 8
Neg_Otrav3
I/O_Com
Reg3_2
- Analog_Out_1
- Analog_Out_2
- Analog_Out_3
- Analog_Out_4
- Common
- N/C
Front Cover AXIS 2 - N/C
456
- N/C
- N/C
Connector
Enable2 1 5 Pos_Otrav2
Home2 Neg_Otrav2
Reg2_Com I/O_Com
Reg2_1 4 8 Reg2_2
AXIS 1
23
78
SERCOS Base Node Home1 Neg_Otrav1
4 5
23
Reg1_Com I/O_Com
6 7
SERCOS System Module Reg1_1 4 8 Reg1_2
8 09 1
Address Switch Enable0
Reg0_Com
Home0
AXIS 0
1 5 Pos_Otrav0
Neg_Otrav0
I/O_Com 901
Reg0_1 4 8 Reg0_2
System Module
RELAY OUTPUTS
Status LED
Status
Relay Outputs
Connector
DANGER
RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY
Network Status LED

EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.
AXIS 3
AXIS 2
Discrete Input
Connectors (4)
AXIS 1
- SERCOS
Receive
AXIS 0
SERCOS Receive (Rx) Connector
3
- SERCOS
Transmit
DIP switches set for
Tie Down Anchor 8M baud applications
2
(high power setting)
OFF ON
SERCOS Transmit (Tx) Connector
1
3
2
1
Tie Down Anchor
OFF
ON
SERCOS Baud Rate
and Optical Power Switches Single Point
Bond Bar
System Module, bottom view

(1394C-SJT05-D and -SJT10-D is shown)
Shunt Power Connector
DPI/SCANport Connector Logic Power Connector
Axis 0 Auxiliary Feedback Input Power Connector
Axis 1 Auxiliary Feedback

Axis 3 Motor Feedback
(in four axis system) or Axis 2 Motor Feedback
Axis 2 Auxiliary Feedback (in four axis system) or
(in three axis system) Axis 3 Auxiliary Feedback
(in two axis system)
Cable Clamp Grounding Bracket

(one clamp installed)
Note: Power, feedback, and I/O connectors are shown, however for
wiring information, refer to the 1394 SERCOS Interface
Installation Manual (publication 1394-IN002x-EN-P).

Use the figure below to locate the 1394C-SJT22-D System Module

connectors and indicators.
Figure 1.2
1394 System Modules (1394C-SJT22-D)
1394 Digital Servo Controller
System Module, front view SERCOS interfaceTM

System Module
(1394C-SJT22-D is shown)
RELAY OUTPUTS
1
DRIVE SYSTEM OK
OUTPUT 3
OUTPUT 2
OUTPUT 1
OUTPUT 0
10
AXIS 3
Analog Outputs Home3
Reg3_Com
Neg_Otrav3
I/O_Com
1394 System Module Reg3_1 4 8 Reg3_2
456
Connector Enable2
AXIS 2
1 5 Pos_Otrav2
Front Cover Home2
Reg2_Com
Reg2_1 4 8
Neg_Otrav2
I/O_Com
Reg2_2
AXIS 1
SERCOS Base Node
23
78
Home1 Neg_Otrav1 4 5
23
6 7
Reg1_Com I/O_Com
Address Switch
8 09 1
Reg1_1 4 8 Reg1_2
SERCOS System Module AXIS 0

Home0
Reg0_Com
Reg0_1 4 8
Neg_Otrav0
I/O_Com
Reg0_2
901
Relay Outputs
System Module Status
Connector
Status LED
DANGER
Network Status LED
Discrete Input
Connectors (4) Terminal Block for Logic Power, Input Power,
and External Shunt Connections
SERCOS Receive (Rx) Connector
3
Tie Down Anchor
2
SERCOS Transmit (Tx) Connector OFF ON
3
2
1
1
SERCOS Baud Rate
and Optical Power Switches
Single Point
Bond Bar
System Module, bottom view

(1394C-SJT22-D is shown)
DPI/SCANport Connector
(in four axis system) or
(in four axis system) or
(in two axis system)
(in three axis system)
Cable Clamp Grounding Bracket
(one clamp installed)
Note: Power, feedback, and I/O connectors are shown, however for
wiring information, refer to the 1394 SERCOS Interface

Locating Axis Module Use the figure below to locate the axis module connectors and
indicators. Shown below are typical 1394C-AM03, -AM04, and -AM07
Connectors and Indicators axis modules. Although the physical size of the 1394C-AM50-xx and
AM75-xx model is larger, the location of the connectors and indicators
is identical.
Figure 1.3
1394 Axis Modules (1394C-AMxx and -AMxx-IH)
Axis Module, front view

(typical)
Axis Enabled LED
Terminator
Motor Power Connections

PE1
PE2
PE3
W1
U1
V1
Axis Module, bottom view

(typical)
1
TB1
4
Motor Brake and Thermal Connections

1
TB2
4
Note: Power and filter connectors are shown, however for wiring
information, refer to the 1394 SERCOS Interface Installation
Manual (publication 1394-IN002x-EN-P).

Locating SERCOS Interface Use the figure below to locate the SERCOS interface fiber-optic
connectors. The fiber-optic ring is connected using the SERCOS
Fiber-Optic Connectors Receive and Transmit connectors.
Note: Plastic cable is available in lengths up to 32 m (105.0 ft). Glass

cable is available in lengths up to 200 m (656.7 ft).
Figure 1.4
ControlLogix and SoftLogix SERCOS Connector Locations
SERCOS interfaceTM
ControlLogix
1756-MxxSE SERCOS
CP OK
interface Module 0
F 1
ABCDE
23 6 7
45
RSLogix 5000 89
SoftLogix
OK 1784-PM16SE SERCOS interface PCI Card
(as viewed from the back of your PC)
CP
TX
SERCOS Transmit Connector, Tx
Tx (rear)
Front View Rx (front) RX

SERCOS Receive Connector, Rx
Bottom View SERCOS Receive Connector, Rx (front)
SERCOS Transmit Connector, Tx (rear)
Configuring Your These procedures assume you have completed mounting, wiring, and
connecting your SERCOS interface module and 1394 SERCOS interface
1394 SERCOS interface drive as described in the 1394 SERCOS Interface Installation Manual
System (publication 1394-IN002x-EN-P).
The procedures in this section apply to 1394 SERCOS interface drive

components and describe how to:
• Configure your 1394 system module

• Configure your Logix SERCOS interface module using RSLogix
5000 software
• Download your program to your Logix controller
• Apply power to your 1394 drive components
• Test and tune your motor using RSLogix 5000 software
These procedures assume you have connected the fiber-optic cables

between your 1394 system module and the ControlLogix chassis with
1756-MxxSE interface module or personal computer with 1784-
PM16SE PCI card.

Configuring Your 1394 System Module
To configure your 1394 system module:
1. Verify that there is no 360/480V AC input power or 24V logic

power applied to the system and that the SERCOS fiber-optic
cables are connected to the Tx and Rx connectors. To verify your
fiber-optic cable connections, refer to the 1394 SERCOS Interface
2. Set the base node address for each 1394 controller in your system
by setting the Base Address switch. Refer to the example table
below for switch settings. Refer to figures 1.1 and 1.2 for switch
location. Configurations with up to nine 1394 SERCOS interface
system modules are possible.
For example, if the Set the Base Address switch

number of 1394 for system number:
SERCOS interface 1 to: 2 to: 3 to: 4 to: 5 to: 6 to: 7 to: 8 to: 9 to:
system modules
you have is:
1 1 N/A N/A N/A N/A N/A N/A N/A N/A
2 1 2 N/A N/A N/A N/A N/A N/A N/A
3 1 2 3 N/A N/A N/A N/A N/A N/A
4 1 2 3 4 N/A N/A N/A N/A N/A
5 1 2 3 4 5 N/A N/A N/A N/A
6 1 2 3 4 5 6 N/A N/A N/A
7 1 2 3 4 5 6 7 N/A N/A
8 1 2 3 4 5 6 7 8 N/A
9 1 2 3 4 5 6 7 8 9
Note: Base address 0 is used for troubleshooting and not a valid setting for normal operation.

Refer to Figure 1.5 for an example of the fiber-optic ring connections

between the 1394 system module(s) and the SoftLogix PCI card.
Although Figure 1.5 only illustrates the SERCOS fiber-optic ring with
the SoftLogix PCI card, node addressing for SoftLogix is done the
same way as shown in the ControlLogix example.
Figure 1.5
Fiber-Optic Ring Connection (SoftLogix)
0
SoftLogix
ABCDE
3456 72
89 F 1
OK
CP
1784-PM16SE SERCOS
Transmit TX
interface PCI Card
RX
Receive
SERCOS fiber-optic ring
SERCOS System Module SERCOS System Module
1394 SERCOS 1394 SERCOS

interface System Status
interface System Status
DANGER
DANGER RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY
RISK OF ELECTRICAL SHOCK. HIGH VOLTAGE MAY EXIST UP TO FIVE MINUTES AFTER REMOVING POWER.
Receive Transmit Receive Transmit
Axis 0 of each system module has a node address of the switch setting
times 10 (for example: system number 1 times 10 = 10 and axes 1-3 on
this system are numbered 11, 12, and 13, respectively). Refer to Figure
1.6 for an example of how node addresses are assigned.
Figure 1.6
Axis Module Node Addresses
1756-MxxSE SERCOS interface Module
ControlLogix Chassis 1394 SERCOS interface System

Number 1
SERCOS System Module
DANGER
13 = Axis 3 node address

SERCOS ring = Axis 2 node address
12
1x10=10 = Axis 0 node address
SERCOS System Module

1394 SERCOS interface System
Number 2
DANGER
SERCOS ring 23 = Axis 3 node address

SERCOS ring 22 = Axis 2 node address
2x10=20 = Axis 0 node address

3. Set the baud rate using DIP switches 2 and 3. Refer to the table
below for baud rate switch settings. Refer to figures 1.1 and 1.2 for
DIP switch location.
For this baud rate: Set switch 2: Set switch 3:

2M baud OFF OFF
4M baud OFF ON
8M baud ON OFF
4. Set the SERCOS optical power level to High using DIP switch 1, as
shown in Figure 1.7. Refer to the table below for optical power
level switch settings. Refer to Figure 1.1 for the optical power
switch location.
For this transmit level: Set switch 1:

Low OFF
High ON
Figure 1.7
SERCOS Baud Rate and Optical Power DIP Switches
DIP switches set for DIP switches set for
4M baud applications 8M baud applications
(high power setting) (high power setting)
3
3
2
2
1
1
OFF
ON
OFF
ON
Switch in OFF position
Switch in ON position

Configuring Your Logix This procedure assumes that you have finished wiring your 1394
SERCOS interface system and have finished configuring the 1394
SERCOS interface Module system module switches.
For greater detail on the RSLogix 5000 software as it applies to

ControlLogix and SoftLogix modules, refer to the table below for the
appropriate publication.
For: Refer to this Document Publication Number:

Detailed information on configuring and ControlLogix Motion Module
troubleshooting your ControlLogix motion module Setup and Configuration Manual 1756-UM006x-EN-P
Detailed information on configuring and SoftLogix Motion Card Setup and 1784-UM003x-EN-P
troubleshooting your SoftLogix PCI card Configuration Manual
If you have already configured your Logix module using one of the
setup and configuration manuals listed above, go directly to Applying
Power to the 1394 SERCOS interface System (page 1-20). If not, go to
Configuring Your Logix Controller beginning below.
Configuring Your Logix Controller
To configure your Logix controller:
1. Apply power to your Logix chassis/PC containing the SERCOS

interface module and open your RSLogix 5000 software.
2. Select New in the File menu. The New Controller window opens.
• Select controller type

• Name the file
• Select the ControlLogix chassis size
• Select the ControlLogix processor slot
3. Select OK.
4. Select Controller Properties in the edit menu. The Controller

Properties window opens.

5. Select the Date and Time tab.
6. Check the box Make this controller the Coordinated System

Time master.
IMPORTANT Only one ControlLogix processor can be

assigned as the Coordinated System Time master.
7. Select OK.

Configuring Your Logix Module
To configure your Logix module:
1. Right-click on I/O Configuration in the explorer window and

select New Module. The Select Module Type window opens.
2. Select 1756-MxxSE or 1784-PM16SE as appropriate for your

actual hardware configuration.
3. Select OK. The Module Properties wizard opens.
• Name the module

• Select the slot where your module resides
• Select an Electronic Keying option.
4. Select Next until the following screen opens.

5. Select Data Rate, Cycle Time, and Optical Power settings.
• Ensure the Data Rate setting matches DIP switches 2 and 3

(baud rate) as set on the system module, or use the Auto
Detect setting.
• Set the Cycle Time according to the table below.
Logix SERCOS Data SERCOS Ring Number

1394 SERCOS interface
Module Rate Cycle Time of Axes
System Module Series
Mbit/s ms
0.5 N/A
1756-M08SE C or D 4 1.0 up to 4
(Series A)
2.0 up to 8
0.5 N/A
1756-M08SE D only 8 1.0
(Series B) up to 8
2.0
0.5 N/A
C or D 4 1.0 up to 4
1756-M16SE or 2.0 up to 8
1784-PM16SE 0.5 N/A
D only 8 1.0 up to 8
2.0 up to 16
• Ensure the Optical Power setting (high or low) matches DIP

switch 1 as set on the system module.
6. Select Finish. Your new module appears under the I/O

Configuration folder in the explorer window.
7. Repeat steps 1-6 for each Logix module.

Configuring Your 1394 System Module
To configure your 1394 system module:
1. Right-click on the new module you just created and select New
Module. The Select Module Type window opens.
2. Select your 1394C-SJTxx-D system module.
3. Select OK. The Module Properties window opens.
• Name the module

• Set the Base Node address
Note: Set node address in the software to match the node
setting on the drive. Refer to Configuring Your 1394
System Module, step 2, page 1-8.
• Select an Electronic Keying option
4. Select Next until the following window opens.
5. Select the New Axis button. The New Tag window opens.
6. Provide/Select the following New Tag attributes:
• Axis name
• AXIS_SERVO_DRIVE as the Data Type
7. Select OK.
8. Repeat steps 5 and 6 for each axis. The axes appear under the
Ungrouped Axes folder in the explorer window.

9. Assign each axis to a node address (as shown in the window

below).
10. Select Next until the following widow opens.
11. Select the Bus Regulator Catalog Number (shunt option) as

appropriate for your actual hardware configuration.
If your hardware configuration Then select:

includes this shunt option:
1394C-SJT05-D or -SJT10-D with internal
Internal or <none>
shunt only
1394C-SJT05-D or -SJT10-D with optional 1394-SR10A
external shunt
1394C-SJT22-D with required external 1394-SR9A, -SR9AF,
shunt -SR36A, or -SR36AF
12. Select Finish.
13. Repeat steps 1-12 for each 1394 system module. The axes appear
under the Ungrouped Axes folder in the explorer window.

Configuring the Motion Group
To configure the motion group:
1. Right-click Motion Groups in the explorer window and select New

Motion Group. The New Tag window opens.
2. Name new motion group.
3. Select OK. New group appears under Motion Groups folder.
4. Right-click on the new motion group and select Properties. The

Motion Group Properties window opens.
5. Select the Axis Assignment tab and move your axes (created
earlier) from Unassigned to Assigned.
6. Select the Attribute tab and edit the default values as appropriate
for your application.
7. Select OK.

Configuring Axis Properties
To configure axis properties:
1. Right-click on an axis in the explorer window and select

Properties. The Axis Properties window opens.
2. Select the Drive/Motor tab.
• Set the Amplifier (system module) Catalog Number

• Set the Motor Catalog Number
• Set Loop Configuration to Position Servo
Note: For amplifier and motor catalog numbers refer to the
amplifier and motor name plate.
3. Select the Motor Feedback tab and verify the Feedback Type
shown is appropriate for your actual hardware configuration.
4. Select the Units tab and edit default values as appropriate for your
application.
5. Select the Conversion tab and edit default values as appropriate

for your application.

6. Select the Fault Actions tab and click on the Set Custom Stop
Action... tab. The Custom Stop Action Attributes window opens.
• Set the Brake Engage Delay Time (refer to Brake Interconnect

Diagrams in Appendix A for specific values).
• Set the Brake Release Delay Time (refer to Brake Interconnect
Diagrams in Appendix A for specific values).
• Select Close.
7. Select OK.
8. Repeat steps 1-7 for each 1394 axis module.
9. Verify your Logix program and save the file.
Downloading Your Program
After completing the Logix configuration you must download your

program to the Logix processor.

Applying Power to the 1394 This procedure assumes that you have wired your 1394 SERCOS
interface system, your SERCOS interface module and verified the
SERCOS interface System wiring. To apply power to your 1394 system:
1. Apply 24V logic power to the system module and verify that the
logic power voltage at the input terminals of the system module is
24V AC (or 24V DC) ±10%.
2. Observe the status LED on the system module.
If the system module Do This:

LED:
System module ready.
Alternates red and green
Go to step 3.
Does not alternate red Go to the chapter Troubleshooting
and green Your 1394 SERCOS Interface System.
3. Observe the three SERCOS LEDs on the SERCOS interface module.
If the three SERCOS Then:

LEDs:
Establishing communication (wait
Flash green and red
for steady green on all three LEDs).
Communication ready.
Illuminates steady green
Go to step 4.
Go to the appropriate Logix motion
Is not flashing or steady module setup and configuration
green manual for specific instructions and
troubleshooting.
4. Observe the network status LED on the system module.
If the network status Then:

LED:
Establishing communication (wait
Flashes green
for steady green).
Communication ready.
Illuminates steady green
Go to step 5.
Is not flashing or steady Go to the chapter Troubleshooting
green Your 1394 SERCOS Interface System.

5. Observe the status LEDs on the axis modules.
If the axis module Then:

LED:
Alternates red and
Axis module ready. Go to step 7.
green
Does not alternates red Go to the chapter Troubleshooting Your
and green 1394 SERCOS Interface System.
6. Disconnect the load from the motor(s).
To avoid personal injury or damage to

ATTENTION equipment, disconnect the load from the
motor(s). Ensure each motor is free of all
! linkages when initially applying power to the

system.
7. Apply main input power.
8. Verify that the main input phase-to-phase voltage is present at the

input terminals of the system module or at the user-supplied input
contactor.
If the voltage Is: Then:

measured between
terminals:
324-528V ac Go to step 9.
Go to the chapter
U and W Not within Troubleshooting Your
324-528V ac 1394 SERCOS Interface
System.
9.
If the voltage Is: Then:
measured between
terminals:
324-528V ac Go to step 10.
Go to the chapter
V and W Not within Troubleshooting Your
324-528V ac 1394 SERCOS Interface
System.

10. Observe the status LED on the system module.
If the system module Then:

LED:
System module is ready.
Is flashing green
Go to step 11.
Go to the chapter Troubleshooting
Is not flashing green Your 1394 SERCOS Interface System.
11. Observe the status LED on the axis modules.
If the axis module LED: Then:

Axis module is ready.
Is flashing green Go to the section Testing and
Tuning Your Axes.
Go to the chapter Troubleshooting
Is not flashing green
Your 1394 SERCOS Interface System.
Testing and Tuning Your This procedure assumes that you have configured your 1394 SERCOS
interface system, your SERCOS interface module, and applied power
Axes to the system.
IMPORTANT Before proceeding with testing and tuning your axes,

verify that the system and axis status LEDs are as
described in the table below.
Status LED: Must be: Status:

System Module (on front cover) Flashing green System module is ready.
Axis Module Flashing green Axis module is ready.
Network (inside front cover) Illuminates steady green Communication ready.
For greater detail on the RSLogix 5000 software as it applies to

ControlLogix and SoftLogix modules, refer to the table below for the
appropriate publication.
For: Refer to this Document Publication Number:

Detailed information on configuring and ControlLogix Motion Module
troubleshooting your ControlLogix motion module Setup and Configuration Manual 1756-UM006x-EN-P
Detailed information on configuring and SoftLogix Motion Card Setup and 1784-UM003x-EN-P
troubleshooting your SoftLogix PCI card Configuration Manual
If you have already tested and tuned your axes using one of the setup
and configuration manuals listed above, you are finished
commissioning your 1394 SERCOS interface system. If not, go to
Testing Your Axes beginning below.

Testing Your Axes
To test your axes:
1. Verify the load was removed from each axis.
2. Right-click on an axis in your Motion Group folder in the explorer

window and select Axis Properties. The Axis Properties window
appears.
3. Select the Hookup tab.
4. Select 2.0 as the number of revolutions for the test (or another
number more appropriate for your application).
This Test: Performs this Test:

Verifies marker detection capability
Test Marker as you manually rotate the motor
shaft.
Verifies feedback connections are
Test Feedback wired correctly as you manually
rotate the motor shaft.
Verifies motor power and feedback
Test Command & connections are wired correctly as
Feedback you command the motor to rotate.
Also, allows you to define polarity.

5. Apply ENABLE input signal (Axis_x pin 1) for the axis you are
testing.

ATTENTION equipment, apply 24V ENABLE signal (Axis_x
pin 1) only to the axis you are testing.
!
6. Select the Test (Marker/Feedback/Command & Feedback) button
to verify connections. The Online Command window opens.
Follow the on-screen test instructions. When the test completes,
the Command Status changes from Executing to Command
Complete.
7. Select OK.
8. The Online Command - Apply Test window opens (Feedback and

Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.

9. Select OK.
If: Then:
Your test completes successfully, this window 1. Select OK.
appears:
2. Remove the ENABLE input signal
(Axis_x pin 1) applied earlier.
3. Go to Tuning Your Axes.
1. Select OK.
Your test failed, this widow appears: 2. Verify that the main three-phase
bus power is up.
3. Verify that the ENABLE input
signal (Axis_x pin 1) is applied to
the axis you are testing.
4. Verify conversion constant entered
in the Conversion tab.
5. Return to step 6 and run the test
again.

Tuning Your Axes
To tune your axes:
1. Verify the load is still removed from the axis being tuned.
To reduce the possibility of unpredictable motor

ATTENTION
response, tune your motor with the load
removed first, then re-attach the load and
! perform the tuning procedure again to provide

an accurate operational response.
2. Select the Tune tab.
3. Enter values for Travel Limit and Speed. In this example, Travel
Limit = 5 and Speed = 2.
Note: Actual value of programmed units depend on your
application. For more information, contact Allen-Bradley
technical support.
4. Check Tune boxes as appropriate for your application.
5. Apply ENABLE input signal (Axis_x pin 1) for the axis you are
tuning.

ATTENTION equipment, apply 24V ENABLE signal (Axis_x
pin 1) only to the axis you are tuning.
!
6. Select the Start Tuning button to auto-tune your axis. The Online
Command - Tune Servo window appears. When the test
completes, the Command Status changes from Executing to
Command Complete.
7. Select OK. The Tune Bandwidth window opens.
Note: Actual bandwidth values (Hz) depend on your application

and may require adjustment once motor and load are
connected.
Record your bandwidth data for future reference.
8. Select OK.
9. The Online Command - Apply Tune window opens. When the test
completes, the Command Status changes from Executing to
Command Complete.

10. Select OK.
If: Then:
Your test completes successfully, this window 1. Select OK.
appears:
2. Remove the ENABLE input signal
(Axis_x pin 1) applied earlier.
3. Go to step 11.
1. Select OK.
Your test failed, this widow appears:
2. Make an adjustment to motor
velocity.
3. Refer to appropriate Logix motion
module setup and configuration
manual for more information.
4. Return to step 6 and run the test
again.
11. Repeat Testing and Tuning Your Axes for each axis.

Chapter 2
Troubleshooting Your 1394 SERCOS Interface

System
Chapter Objectives This chapter covers:
• Safety Precautions
• Understanding How to Detect a Problem
• Troubleshooting System and Axis Module LEDs
• Troubleshooting the SERCOS Network Status LED
• Troubleshooting General System Problems
• Troubleshooting System and Axis Module Faults
• Troubleshooting General System Problems
• Understanding Logix/Drive Fault Behavior
• Supplemental Troubleshooting Information
• Replacing System and Axis Modules

2-2 Troubleshooting Your 1394 SERCOS Interface System
Safety Precautions Observe the following safety precautions when troubleshooting your
1394 SERCOS interface system.
DC bus capacitors may retain hazardous voltages

ATTENTION
after input power has been removed, but will
normally discharge in several seconds. Before
! working on the drive, measure the DC bus voltage to

verify it has reached a safe level or wait the full time
interval listed on the warning on the front of the
drive. Failure to observe this precaution could result
in severe bodily injury or loss of life.
Do not attempt to defeat or override the drive fault
circuits. You must determine the cause of a fault and
correct it before you attempt to operate the system. If
you do not correct a drive or system malfunction, it
could result in personal injury and/or damage to
equipment as a result of uncontrolled machine
system operation.
If you use an oscilloscope (or chart recorder) for
troubleshooting, you must properly ground it. The
oscilloscope chassis can be at a potentially fatal
voltage if you do not properly ground it. Always
connect the oscilloscope chassis to an earth ground.
Understanding How to When a drive fault occurs, the LED on the front panel changes and a
fault message is transmitted to the position controller.
Detect a Problem
The majority of 1394 faults cause the Drive System OK contact to
open. If a drive fault occurs, you can reset the fault detection circuitry
by removing and reapplying logic power. However, if it is a hardware
fault, you need to correct the fault before restarting.
IMPORTANT You can also reset a fault condition using RSLogix

5000 software.
This material, along with the diagnostic/troubleshooting information

included with the position controller, will help you identify most
common system malfunctions and determine which module that
problem pertains to.

Troubleshooting Your 1394 SERCOS Interface System 2-3
Troubleshooting System The system module Status LED is visible from the front of the module.
Refer to figures 1.1 and 1.2 for the location of the system module
and Axis Module LEDs status LED.
If the System Module LED is: Potential Cause is: Possible Resolution is:
Terminator not installed. • Install terminator.
• Verify wiring.
• Secure wiring connections.
Steady red • Replace the module.
Malfunctioning system module.
• Check logic supply ratings.
• Contact your local Allen-Bradley
Support Representative.
• Reset faults.
A fault has occurred in the system • Verify wiring.
Flashing red (check for faults through the RSLogix • Secure wiring connections.
5000, DriveExplorer, or the HIM). • Check SERCOS fiber-optic
connections.
DC bus is not up. Apply three-phase power.
• Check wiring to start/stop circuitry.
Open fuse or malfunctioning contactor
Alternating red and green on user-supplied 3 phase input. • Check the user program.
• Check fuse.
Malfunctioning system module. Replace the module.
Steady green The bus is up and axes are enabled. None needed.
• Check axes and enable them, if
necessary.
The bus is up, but no axis is enabled.
• Verify that enable wiring is correct
and not open.
necessary.
Flashing green Enable signal from position controller • Verify that enable wiring is correct
is not present. and not open.
• Check I/O connections on control
board.
Controller has detected a machine • Check controller.
system malfunction and will not enable • Check the machine.
the 1394.
• Check 24V ac/dc logic power
Not illuminated There is no power to the system supply.
module.
• Check main ac input power supply.

The axis module status LED is visible from the front of the module.
Refer to Figure 1.3 for the location of the axis module status LED.
If the Axis Module LED is: Potential Cause is: Possible Resolution is:
• Verify wiring.
• Verify that the slider and
Steady red Malfunctioning axis module. terminator connections are secure.
• Replace the module.
• Verify wiring.
• Check fault status on the
controller.
Flashing red Axis fault has occurred.
• Check main ac input power.
• Check axis status on the controller.
• Verify that the terminator is
present on the last axis.
• Check the system module LED.
Alternating red and green DC bus is not up. • Check slider connections to verify
that they are properly seated.
Steady green The bus is up and axes are enabled. None needed.
necessary.
Axis is not enabled.
• Verify that enable wiring is correct
and not open.
Enable signal from controller is not necessary.
Flashing green present. • Verify that enable wiring is correct
and not open.
Check I/O connections on the control
Incorrect wiring or loose connections. board.
• Verify that axis definitions are
Axis setups may not be correct for the correct.
application.
• Check tuning parameters.
• Verify that the slider connections
are secure.
There is no power to the axis module.
• Verify that the terminator is secure
on the last axis.
Not illuminated
• Check system module power
supply.
There is no power to the system.
• Verify that the terminator is
present on the last axis.

Troubleshooting the The SERCOS Network Status LED is located on the system module
control board and visible with the system module door open. Refer to
SERCOS Network Status figures 1.1 and 1.2 for the location of the SERCOS Network Status
LED LED.
If the SERCOS
Network Status Status is: Potential Cause is: Possible Resolution is:
LED is:
Steady Green Communication ready No faults or failures. System is ready.
• Cycle power.
Control board failure.
Steady Orange Control board failure • Replace system module.
Hardware failure. Replace system module.
System is still in the process of establishing Wait for steady green LED status.
SERCOS communication.
Flashing Green Establishing
communication Verify proper SERCOS base address switch
Node address setting on the 1394 system module setting (refer to figures 1.1 and 1.2 for switch
does not match SERCOS controller configuration. location).
Loose fiber-optic connection. Verify proper fiber-optic cable connections.
Dirty fiber-optic cable connectors. Remove foreign material from connector.
Broken fiber-optic cable. Replace fiber-optic cable.
Flashing Red No communication 1 Weak fiber-optic signal due to long fiber-optic cable. Set SERCOS transmit level to HIGH.
Distorted fiber-optic signal due to short fiber-optic Decrease SERCOS transmit level of previous
cables. device in SERCOS ring.
Receive fiber-optic cable connected to SERCOS Check proper SERCOS fiber-optic cable
transmit connector and visa versa. connections.
1
Refer to Fiber Optic Cable Installation and Handling Instructions (publication 2090-IN010A-EN-P) for more
information.

Troubleshooting System Fault messages are transmitted to the SERCOS controller through the
SERCOS ring and/or SCANport. The tables on the following pages
and Axis Module Faults provide a description of system and axis module faults, the potential
cause, and possible resolutions.
Note: Fault messages are shown as seen in RSLogix software (bold)

and when using the HIM or DriveExplorer (not bold).
System Module Faults
Use the table below for troubleshooting system module faults.
Fault Message
RSLogix (HIM): Description: Potential Cause is: Possible Resolution is:
• Check for proper motor sizing.

DriveOvercurrent Motor or transmission malfunction. • Check/replace transmission device.
Fault System module exceeded • Check/replace motor.
current rating.
(Bus Overcurrent) • Check for proper system module sizing.
System module not properly sized.
• Install larger kW rated system module.
If this fault occurs when you power up the system • Perform line conditioning.
module with the M-contactor, the power
distribution impedance might be stiff or line • Verify that line voltage is within
voltage might be too high. specifications.
The position controller acceleration / deceleration Change the command profile to reduce speed
The DC bus voltage is above rate is incorrectly set. or increase time.
limits. If it exceeds (830V
dc), a fault is sensed and • Change the command profile to reduce
the power supply is The system inertia is too high causing excessive speed or increase time.
disabled. energy to be returned to the power supply bus.
• Use a larger external shunt resistor.
Bus Voltage Operation A vertical axis with insufficient counterbalancing
DriveOvervoltage Shunt turns on at • Use the external shunt resistor.
Fault is overdriving the servo motor and causing
805V dc. excessive energy to be returned to the power • Increase the mechanical
(Bus Overvoltage) Shunt turns off at supply bus. counter-balance on the machine.
750V dc.
Over voltage trip point is Input line voltage exceeds the maximum input Verify incoming main ac input voltage and
825V dc. voltage rating. change the supply source, if needed.
Under voltage trip point is
275V dc. Power Driver Board is malfunctioning and is
Under voltage fault clears Replace the system module.
incorrectly sensing the bus voltage.
at 300V dc.
The shunt regulator or transistor has
malfunctioned. Replace the system module.
External shunt regulator fuse has blown. Check and possibly replace the shunt resistor.
Shunt type not selected properly. Select proper shunt type.
DriveUndervoltage • Check main ac line voltage.

Fault The system module pre- The precharge circuit has malfunctioned. • Check fusing.
charge cycle has failed.
(Bus Precharge) • Replace the system module.
DriveUndervoltage The DC power bus activates • Verify incoming AC voltage and change
Fault undervoltage limit when the The voltage on the main ac input power is low. the supply source, if needed.
bus drops to 275V dc or
(Bus Undervoltage) less. It will clear at 300V dc. • Check fusing.
DriveHardFault SCANport hardware • Cycle all input power.

initialization fault detected. Control board hardware failure.
(Can Init) • If fault persists, replace system module.

Fault Message
Three-phase power is either • Correct wiring.

DriveHardFault detected when it shouldn’t The contactor is welded or failed to open.
• Replace the contactor.
(Contactor Fault) be or not detected when it
should be. The input wiring to your contactor is incorrect. Correct wiring.
MotFeedbackFault A feedback hardware or • Cycle all input power.

The feedback processor has faulted.
(Fdbk Watch Dog) software fault detected. • If fault persists, replace system module.
• Verify motor and ground wiring.

Incorrect wiring.
• Replace cables.
Check the resistance of each motor winding
Motor malfunction. phase to case ground with an ohm meter.
GroundShortFault Excessive ground current in Readings should be in mega ohms.
the system module was
(Ground Short) detected. Axis Module IGBT malfunction. Replace the axis module.
• Replace the system or axis module.
Short to ground. • Check grounding and incoming power
wiring.
DriveHardFault Motor feedback hardware • Cycle all input power.

Control board hardware failure.
(IDMA Load) initialization fault detected. • If fault persists, replace system module.
Incorrect motor feedback wiring. • Load default parameters, save to non-

volatile memory, and recycle power.
DriveHardFault Memory hardware Improper feedback cable clamp attachment. • Reset the drive.
(Memory Init) initialization fault detected. • Replace the system module.
• Cycle all input power.
• If fault persists, replace system module.
• Load default parameters, save to non-
DriveHardFault Non-volatile memory is volatile memory, and recycle power.
corrupt. Control board software error.
(NV Mem Init) • Reset the drive.
• Replace the system module.
• Load default parameters, save to non-
DriveHardFault Non-volatile memory is volatile memory, and recycle power.
corrupt. Control board hardware failure.
(Objects Init) • Reset the drive.
• Replace the system module.
One or more input line fuses have opened. Check fuses and replace, as necessary.
PowerPhaseLoss The three-phase input line
Fault is monitored and a fault will • Correct wiring.
Input line contactor malfunction.
be issued whenever a • Replace contactor.
(Phase Loss Flt) phase loss is detected.
Incorrect wiring. Check main ac input power at system module.
DriveHardFault SCANport/DPI The SCANport/DPI device or cable is faulty. Check SCANport/DPI connections.
(SCANport Comm) Communication Failed.
• Check fiber optic cable connections.

SERCOS ring not active SERCOS ring is physically broken.
SERCOSFault • Replace fiber optic cable.
after being active and
(SERCOS Ring Flt) operational. ControlLogix program is downloaded during Wait for SERCOS ring to cycle and fault to
operation (this causes SERCOS ring to cycle). reset.
DriveHardFault SERCOS hardware • Cycle all input power.

initialization fault detected. Control board hardware failure.
(SERCOS Init) • If fault persists, replace system module.
• Verify that the slider and terminator

DriveHardFault Intermodule serial Terminator is not installed.
connections are secure.
(Serial Ring Init) communication failed.
System module failure. Replace the system module.

Fault Message
SERCOSFault Verify that each SERCOS drive is assigned a

Duplicate node address detected on SERCOS ring. unique node address.
(SERCOS Same Addr)
DriveOvervoltage • Use a properly sized shunt or modify duty

Fault Shunt resistor continuous The regenerative energy produced by the motor cycle of the application.
rating exceeded. exceeded the limit of the shunt resistor. • System uses internal shunt and requires
(Shunt Time Out) external shunt for additional capacity.
The fan on the system module or an axis module Replace the system or axis module.
failed.
The cabinet ambient temperature is above rating. Check the cabinet temperature.
DriveOvertemp The 1394 thermal sensor The machine duty cycle requires an RMS current Change the command profile to reduce speed
Fault tripped when internal exceeding the continuous rating of the controller. or increase time.
ambient temperature
(Sys Overtemp) exceeded rating. Changes in mechanics have occurred causing an • Check mechanics for improper operation.
increased torque output for the application move
profiles. • Verify operating torque.
The airflow access to the 1394 is limited or Check airflow and re-route cables away from
blocked. the 1394.
DriveHardFault Active when serial ring

detects unknown system Unknown system module. Replace the system module.
(Sys Mod Unknown) module.
DriveHardFault Software initialization fault • Cycle all input power.

(Task Init) detected. • If fault persists, replace system module.
DriveHardFault Fault is detected but source Wrong version of software for the hardware or • Check system terminator.
(Unknown Fault) is unknown. loose internal or external connection. • Reset drive.

Axis Module Faults
Use the table below for troubleshooting axis module faults.
Fault Message Description: Potential Cause is: Possible Resolution is:

RSLogix (HIM):
No Fault Message
(condition indicated
by on-screen Auto tune procedure failed • Check motor power/feedback wiring.
to complete successfully. Motor or feedback device malfunction.
message) • Refer to on-screen message for resolution.
(Ax: ATune Flt)
No Fault Message
(condition indicated
by on-screen Hookup procedure failed to • Check motor power/feedback wiring.
message) Motor or feedback device malfunction.
complete successfully. • Refer to on-screen message for resolution.
(Axis x Hookup
Fault)
DriveHardFault Active when serial ring • Check the slider connections.

detects unknown axis Unknown axis module.
(Axis x Unknown) module. • Replace the axis module.
• Use shielded cables with twisted pair

wires.
AuxFeedbackFault Auxiliary Encoder State Auxiliary encoder has encountered an illegal • Route the feedback away from potential
Error state transition. noise sources.
(Ax: Aux Fdbk AQB)
• Check the system grounds.
• Replace the motor/encoder.
Drive unable to
AuxFeedbackFault communicate with • Check auxiliary feedback wiring.
auxiliary Smart feedback The auxiliary encoder feedback signal is lost.
(Ax: Aux Fdbk Comm) • Reset faults.
device.
Open or short circuit has occurred on feedback Check the feedback cable connectors/wiring
wiring. to the system module and motor.
AuxFeedbackFault The feedback wiring is
open, shorted, or missing. The feedback wiring or termination to system Check the feedback cable connectors/wiring
(Ax: Aux Fdbk Loss) module is incorrect. to the system module and motor.
Motor feedback failure. Replace the motor feedback.
AuxFeedback
NoiseFault Excessive noise detected • Check ground clamp connectors.
Poor grounding.
on feedback signals. • Check system module grounding.
(Ax: Aux Fdbk Noise)
DriveUndervoltage The slider connections may not be secure. Check slider connections.
Fault The DC bus supply to the
axis module was lost. An axis module’s bus link fuse has blown. Replace the axis module.
(Ax: Bus Loss)
DriveOvercurrent
Fault Too much current in the Power module malfunction. Replace the axis module.
axis module.
(Ax: Desat)
• An attempt was made to enable the axis • Disable the Drive Enable Input fault.
DriveEnableInput through software while the Drive Enable
Missing Drive Enable Input hardware input was inactive. • Verify that Drive Enable hardware input is
Fault active whenever the drive is enabled
Signal
(Drive Enable Flt) • The Drive Enable input transitioned from through software.
active to inactive while the axis was enabled.

Fault Message
Axis position error limit • Check motor load for binding.

PositionErrorFault has been exceeded. This The motor cannot keep up with the position • Increase position loop proportional gain.
(Ax: Follow Error) fault can be configured for command.
status only. • Increase the allowable following error.
Accel/decel command from position controller is Change the command profile to reduce speed
requiring peak current for an excessive amount of or increase time.
time.
• Change the command profile to reduce
The machine friction, inertial load, and/or viscous speed or increase time.
load is excessive. • Check for mechanical problems on the
machine.
• Check motor size for your application.
DriveOvercurrent The output current is The motor has been improperly sized. • Contact your Allen-Bradley Support
Fault exceeding the time-current
rating. Representative.
(Ax: I(t) Fault)
A short circuit exists across the drive output Check wiring between the axis and the motor.
terminals.
• Check wiring between the axis and the
motor.
Logic supply circuits have malfunctioned or AC • Check power wiring between the axis and
output is incorrectly wired. the motor.
• Check resolver wiring between the system
module and the motor.
PosSoftOvertravel Axis position exceeded

Fault • Jog motor to within limits.
maximum software Positive travel limit set too high.
positive travel limit. • Increase travel range limits.
(Ax: +Soft Ovrtrvl)
NegSoftOvertravel Axis position exceeded

Fault • Jog motor to within limits.
maximum software Negative travel limit set too low.
negative travel limit. • Increase travel range limits.
(Ax: -Soft Ovrtrvl)
PosHardOvertravel • Disable checking and jog motor to within

Fault Axis tripped positive hard Axis moved beyond the physical travel limits. limits.
overtravel limit switch.
(Ax: +Hard Ovrtrvl) • Move motor manually to within limits.
NegHardOvertravel • Disable checking and jog motor to within

Fault Axis tripped negative hard limits.
overtravel limit switch. Axis moved beyond the physical travel limits.
(Ax: -Hard Ovrtrvl) • Move motor manually to within limits.
• Use shielded cables with twisted pair

wires.
MotFeedbackFault Motor encoder has encountered an illegal state • Route the feedback away from potential
Motor Encoder State Error noise sources.
(Ax: Mtr Fdbk AQB) transition.
• Check the system grounds.
• Replace the motor/encoder.
Communication was not
MotFeedbackFault established with an • Check motor feedback wiring
intelligent (i.e. Stegmann) The encoder feedback signal is lost.
(Ax: Mtr Fdbk Comm) • Reset faults
encoder.
Open or short circuit has occurred on feedback Check the feedback cable connectors/wiring
wiring. to the system module and motor.
MotFeedbackFault The feedback wiring is The feedback wiring or termination to system Check the feedback cable connectors/wiring
(Ax: Mtr Fdbk Loss) open, shorted, or missing. module is incorrect. to the system module and motor.
The motor feedback might be bad. Replace the motor feedback.

Fault Message
MotFeedback
NoiseFault Excessive noise detected • Check ground clamp connectors.
on feedback signals. Poor grounding.
• Check system module grounding.
(Ax: Mtr Fdbk Noise)
MotorOvertemp
Fault • Allow motor to cool down and investigate
The motor thermal switch the cause of the motor overload.
was tripped. Motor overload.
(Ax: Motor x • Motor not sized properly.
Overtemp)
Axis speed has reached 150% of the maximum

OverSpeedFault Motor velocity exceeded rated setting. The 100% trip point is dictated by • Verify operating parameters.
(Ax: Overspeed) the overspeed trip limit. the lesser of the user velocity limits or the motor • Verify application requirements.
maximum speed rating.
The fan on the system module or an axis module
failed. Replace the system or axis module.
DriveOvertemp The cabinet ambient temperature is above rating. Check the cabinet temperature.
Fault Axis module temperature
limit exceeded The machine duty cycle requires an RMS current Change the command profile to reduce speed
(Ax: Overtemp) exceeding the continuous rating of the controller. or increase time.
The airflow access to the 1394 is limited or Check airflow and re-route cables away from
blocked. the 1394.
• Check the motor cable.
• Check the resistance of each power phase
The motor lead has shorted. wire to ground. It should be Mega ohms.
• Make sure ferrite cores are not installed
DriveOvercurrent The current through any on motor power conductors.
Fault one of the power IGBTs has
exceeded 300% of the • Check the resistance of each motor
(Ax: Power Fault) 1394’s current rating. winding phase to case ground with an
The motor is malfunctioning. ohm meter. Readings should be in Mega
ohms.
• Return motor for repairs.
Power IGBTs are malfunctioning. Replace the axis module.

Troubleshooting General Use the tables below for troubleshooting general system faults.
System Problems
Condition: Potential Cause is: Possible Resolution is:
The position feedback device is incorrect or open. Check wiring.
Axis or System runs Check to see what primary operation mode
uncontrollably Unintentionally in torque mode. was programmed.
An internal malfunction exists. Replace system or axis module.
Motor tuning parameters are set too high. Run auto tune.
Position loop gain or position controller accel/decel rate is
improperly set. Run auto tune.
Axis or System is unstable Improper grounding or shielding techniques are causing noise to
be transmitted into the position feedback or velocity command Check wiring and ground.
lines, causing erratic axis movement.
Motor Select parameter is incorrectly set (servo motor is not • Check setups.
matched to 1394). • Run auto tune.
Torque Limit parameters are set too low. Verify that current limits are set properly.
Motor Select parameter is incorrectly set. Program the correct motor and run auto tune
again.
• Check motor size vs. application need.
The system inertia is excessive.
• Review servo system sizing.
You cannot obtain the motor The system friction torque is excessive. Check motor size vs. application need.
acceleration/deceleration
that you want Available current is insufficient to supply the correct accel/decel • Check motor size vs. application need.
rate. • Review servo system sizing.
Verify parameter settings and correct them,
Acceleration parameter is incorrect. as necessary.
Verify parameter settings and correct them,
Velocity Limit parameters are incorrect. as necessary.
Check for possible faults. Verify parameter settings and correct them,
as necessary.
Disable the axis, wait for 1.5 seconds, and
The axis cannot be enabled for 1.5 seconds after disabling. enable the axis.
Enable signal has not been applied or the enable wiring is • Check the controller.
incorrect. • Check the wiring.
The motor wiring is open. Check the wiring.
Motor does not respond to a • Check for a fault.
Velocity Command The motor thermal overload has tripped.
• Check the wiring.
The motor has malfunctioned. Repair or replace the motor.
The coupling between motor and machine has broken (i.e., the Check and correct the mechanics.
motor moves, but the load/machine doesn’t).
Primary operation mode is set incorrectly. Check and properly set the parameter.
Velocity limit parameters are set incorrectly. Check and properly set the parameter(s).
The axis module has a malfunction. Replace the axis module.

Condition: Potential Cause is: Possible Resolution is:

Recommended grounding per installation instructions and • Verify grounding.
Appendix A has not been followed. • Route wire away from noise sources.
• Verify grounding.
External 50/60 Hz line frequency may be present.
• Route wire away from noise sources.
External 100/120 Hz from a single phase logic supply may be • Verify grounding.
Presence of noise on present. • Route wire away from noise sources.
Command or resolver signal
wires External180 or 360 Hz from other adjustable speed drives may • Verify grounding.
be present. • Route wire away from noise sources.
Variable frequency may be velocity feedback ripple or a • Decouple the motor for verification.
disturbance caused by gear teeth or ballscrew balls etc. The • Check and improve mechanical
frequency may be a multiple of the motor power transmission
components or ballscrew speeds resulting in velocity performance of the gearbox, ballscrew,
disturbance. etc.
The motor connections are loose or open. Check motor wiring and connections.
Foreign matter is lodged in the motor. Remove foreign matter.
The motor load is excessive. Size the servo system.
No Rotation The bearings are worn. Return the motor for repair.
• Check brake wiring and function.
The motor brake is engaged (if supplied).
• Return the motor for repair.
The motor is not connect to the load. Check coupling.
Change the command profile to reduce accel/
The duty cycle is excessive. decel or increase time.
Overheating
The rotor is partially demagnetized causing excessive motor Return the motor for repair.
current.
Motor tuning parameters are set too high. Run auto tune again.
• Return motor for repair.
Loose parts are present in the motor.
• Replace motor.
Abnormal Noise
Mounting bolts are loose. Tighten bolts.
Shaft key loose. Check coupling.
The bearings are worn. Return motor for repair.
Phases U1 and V1, U1 and W1 or V1 and W1 reversed. Check and correct motor power wiring.
Erratic Operation - Motor
locks into position, runs Sine, Cosine or Rotor leads are reversed in the feedback cable
without control or with connector. Check and correct motor feedback wiring.
reduced torque
Sine, Cosine, Rotor lead sets of resolver feedback are reversed. Check and correct motor feedback wiring.

Understanding Logix/Drive This section provides the drive fault actions and indicates whether the
fault action is programmable.
Fault Behavior
The following drive fault action definitions apply:
Drive Fault Action Definition
Shutdown The drive disables and the contactor enable relay opens. Uncontrolled
stop, motor coasts to a stop.
Disable Drive The drive is disabled. Uncontrolled Stop, motor coasts to a stop.
The drive switches internally to velocity mode and sets the command to 0.
Logix configuration for velocity loop Kp/Ki is followed. When zero speed is
Stop Motion reached or stopping time is exceeded, the drive is disabled.
Note: Stopping time and stopping torque are configurable parameters in
RSLogix 5000.
Status Only Drive continues to operate. Status is provided by System Module Status
LED and SCANport/DPI (if used).
System Module Faults
RSLogix
Fault Message Description: Drive Fault Programmable
RSLogix (HIM): Action Fault Action?
DriveOvercurrent
Fault System module exceeded current rating. SHUTDOWN No
(Bus Overcurrent)
DriveOvervoltage
Fault The DC bus voltage is above limits. If it exceeds (830V dc), a fault is SHUTDOWN No
sensed and the power supply is disabled.
(Bus Overvoltage)
DriveUndervoltage
Fault The system module pre-charge cycle has failed. SHUTDOWN No
(Bus Precharge)
DriveUndervoltage
Fault The DC power bus activates undervoltage limit when the bus drops
to 275V dc or less. It will clear at 300V dc. SHUTDOWN No
(Bus Undervoltage)
DriveHardFault
SCANport hardware initialization fault detected. SHUTDOWN No
(Can Init)
DriveHardFault Three-phase power is either detected when it shouldn’t be or not

detected when it should be. SHUTDOWN No
(Contactor Fault)
MotFeedbackFault
A feedback hardware or software fault detected. DISABLE No
(Fdbk Watch Dog)
GroundShortFault
Excessive ground current in the system module was detected. SHUTDOWN No
(Ground Short)
DriveHardFault
Motor feedback hardware initialization fault detected. SHUTDOWN No
(IDMA Load)

RSLogix
DriveHardFault
Memory hardware initialization fault detected. SHUTDOWN No
(Memory Init)
DriveHardFault
Non-volatile memory is corrupt. SHUTDOWN No
(NV Mem Init)
DriveHardFault
Non-volatile memory is corrupt. SHUTDOWN No
(Objects Init)
PowerPhaseLoss
Fault The three-phase input line is monitored and a fault will be issued
whenever a phase loss is detected. SHUTDOWN/ STOP No
2
(Phase Loss Flt )
DriveHardFault
SCANport/DPI Communication Failed STOP No
(SCANport Comm)
SERCOSFault
SERCOS ring not active after being active and operational. STOP No
(SERCOS Ring Flt)
DriveHardFault
SERCOS hardware initialization fault detected. SHUTDOWN No
(SERCOS Init)
DriveHardFault
Intermodule serial communication failed. SHUTDOWN No
(Serial Ring Init)
SERCOSFault
Duplicate node address detected on SERCOS ring. STOP No
(SERCOS Same Addr)
DriveOvervoltage
Fault Shunt resistor continuous rating exceeded. SHUTDOWN No
(Shunt Time Out)
DriveOvertemp
Fault The 1394 thermal sensor tripped when internal ambient temperature
exceeded rating. SHUTDOWN No
(Sys Overtemp)
DriveHardFault
Active when serial ring detects unknown system module. SHUTDOWN No
(Sys Mod Unknown)
DriveHardFault
Software initialization fault detected. SHUTDOWN No
(Task Init)
DriveHardFault
Fault is detected but source is unknown STOP No
(Unknown Fault)

Axis Module Faults
Fault Message Drive Fault RSLogix

RSLogix (HIM): Description: Action Programmable
Fault Action?
No Fault Message
(condition indicated by
on-screen message) Auto tune procedure failed to complete successfully. DISABLE No
(Ax: ATune Flt)
No Fault Message
(condition indicated by
on-screen message) Hookup procedure failed to complete successfully. DISABLE No
(Axis x Hookup
Fault)
DriveHardFault
Active when serial ring detects unknown axis module. SHUTDOWN No
(Axis x Unknown)
AuxFeedbackFault
Auxiliary encoder has encountered an illegal state transition. DISABLE No
(Ax: Aux Fdbk AQB)
AuxFeedbackFault
Drive unable to communicate with auxiliary Smart feedback device. STOP No
(Ax: Aux Fdbk Comm)
AuxFeedbackFault
The feedback wiring is open, shorted, or missing. DISABLE No
(Ax: Aux Fdbk Loss)
AuxFeedback
NoiseFault Excessive noise detected on feedback signals. DISABLE Yes
(Ax: Aux Fdbk Noise)
DriveUndervoltage
Fault The DC bus supply to the axis module was lost. SHUTDOWN No
(Ax: Bus Loss)
DriveOvercurrent
Fault Too much current in the axis module. STOP No
(Ax: Desat)
DriveEnableInput
Fault Missing Drive Enable Input Signal STOP Yes
(Ax: Drive Enable Flt)
PositionErrorFault Axis position error limit has been exceeded. This fault can be DISABLE Yes
(Ax: Follow Error) configured for status only.
DriveOvercurrent
Fault The output current is exceeding the time-current rating. SHUTDOWN No
(Ax: I(t) Fault)
SoftOvertravel
Fault Axis position exceeded maximum software positive/negative travel STOP Yes
limit. This fault can be configured for status only.
(Ax: ±Soft Ovrtrvl)

RSLogix
HardOvertravel
Fault Axis moved beyond the physical travel limits in the positive/negative
direction. This fault can be configured for status only. STOP Yes
(Ax: ±Hard Ovrtrvl)
MotFeedbackFault
Motor encoder has encountered an illegal state transition. DISABLE No
(Ax: Mtr Fdbk AQB)
MotFeedbackFault Communication was not established with an intelligent (i.e.

Stegmann) encoder. STOP No
(Ax: Mtr Fdbk Comm)
MotFeedbackFault
The feedback wiring is open, shorted, or missing. DISABLE No
(Ax: Mtr Fdbk Loss)
MotFeedback
NoiseFault Excessive noise detected on feedback signals. DISABLE Yes
(Ax: Mtr Fdbk Noise)
MotorOvertemp
Fault The motor thermal switch was tripped. STOP Yes
(Ax: Motor x Overtemp)
OverSpeedFault
Motor velocity exceeded the overspeed trip limit. DISABLE No
(Ax: Overspeed)
DriveOvertemp
Fault Axis module temperature limit exceeded DISABLE Yes
(Ax: Overtemp)
DriveOvercurrent
Fault The current through any one of the power IGBTs has exceeded 300%
of the 1394’s current rating. SHUTDOWN No
(Ax: Power Fault)

Supplemental This section provides information for accessing and changing

parameters not accessible through RSLogix 5000 software.
Troubleshooting
Information
Tools for Changing Parameters
Most parameters are accessible through RSLogix 5000 software.

Alternatives to RSLogix 5000 software for changing parameters include
the Human Interface Module (HIM) and DriveExplorer software. Refer
to the table below for catalog numbers.
Method: Description: Catalog Numbers: Firmware Revision:
DriveExplorer Software1 9306-4EXP02ENE 2.01 or later

DriveExplorer
Serial to SCANport Adapter 1203-SSS (Series B) 3.004 or later
Programmer Only 1201-HAP N/A
HIM
(series B required) Analog Speed Potentiometer 1201-HA1 N/A
Digital Up-Down Speed Control 1201-HA2 N/A
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001x-EN-E) for instructions.
Changing Parameters Using DriveExplorer
To navigate using DriveExplorer, refer to the figure below. In this

example, the I/O Interface group folder is open, the Analog Outputs
parameter is selected, and the parameter elements are displayed in the
box to the right.
Figure 2.1
DriveExplorer Example

Changing Parameters Using the HIM
To navigate using the HIM, refer to the programming flowchart in the

figure below.
Figure 2.2
HIM Programming Flowchart
OPERATOR LEVEL Power-Up Mode &

Status Display
ESC SEL
or or or or
"Choose Mode"
MODE LEVEL
Display Program EEProm Search Control Status Password

(Read Only) (Read and Write)
FILE LEVEL
Choose File Choose File Choose File

Axis x System Module I/O Interface
GROUP LEVEL Choose Group
Digital Outputs Analog Outputs Linear List
661 Output Image 681 AnaOut Ch1 Selec

662 Output 01 Source 682 AnaOut Ch1 Scale
663 Output 02 Source 683 AnaOut Ch2 Selec
665 Output 04 Source 685 AnaOut Ch3 Selec
687 AnaOut Ch4 Selec
688 AnaOut Ch4 Scale
PARAMETER LEVEL

Using Analog Test Points to Monitor System Variables
There are four analog output test points accessible from the connector
on the front of the system module (refer to the figure below for the
connector location).
Figure 2.3
Analog and Relay Output Connectors
1394C-SJTxx-D 1394 Digital Servo Controller

SERCOS interfaceTM
! DANGER
RISK OF ELECTRICAL SHOCK.
MORE THAN ONE
(5 and 10 kW) System Module

RELAY OUTPUTS
1
DISCONNECT SWITCH
MAY BE REQUIRED TO
DE-ENERGIZE THE
EQUIPMENT BEFORE
SERVICE.
DRIVE SYSTEM OK
OUTPUT 3
! DANGER
ELECTRICAL SHOCK HAZARD
FROM ENERGY STROAGE
OUTPUT 2 CAPACITORS.
1
VERIFY LOW VOLTAGE
10
OUTPUT 1
OUTPUT 0
DISCHARGE BEFORE
SERVICING.
SEE INSTRUCTIONAL MANUAL.

Analog_Out_1
AXIS 3
Enable3
Reg3_Com
Home3
1 5 Pos_Otrav3
Neg_Otrav3
I/O_Com
- Analog_Out_1
- Analog_Out_2
Analog_Out_2
- Analog_Out_3
Reg3_1 4 8 Reg3_2
- Analog_Out_4
Enable2
Home2
AXIS 2
1 5 Pos_Otrav2
Neg_Otrav2
- Common
- N/C
- N/C
- N/C
Analog_Out_3
- N/C
Reg2_Com I/O_Com
Reg2_1
Enable1
4 8
AXIS 1
1 5
Reg2_2
Pos_Otrav1
- Control Reset Analog_Out_4
Home1 Neg_Otrav1
45 - SERCOS
Base Address
Common
678
Reg1_Com I/O_Com
23
1 Reg1_1 4 8
AXIS 0
Reg1_2 90 1 x10
Reg0_Com
Home0 Neg_Otrav0
I/O_Com N/C
DRIVE SYSTEM OK Reg0_1 4 8 Reg0_2
N/C See Attention statement

below.
OUTPUT 3 N/C
9
RELAY OUTPUTS
N/C
OUTPUT 2
OUTPUT 1 SERCOS
Network Status
AXIS 3
Analog Output Connector (9-pin)

AXIS 2
OUTPUT 0
AXIS 1
10 - SERCOS
Receive
AXIS 0
Relay Output Connector (10-pin)

- SERCOS
(Feedback and I/O connector kit Transmit
part number 1394C-CCK-D)

OFF ON
3
2
1
To avoid damage to the system, do not short

ATTENTION the unused pins (6-9) on the Analog Output
connector (shown above) together or to
! ground.

To use the four analog output test points to monitor system variables,
refer to the table below.
Analog Controlling Default Parameter Scale Parameter:

Output: Parameter Number: Number:
1 681 40 682
2 683 1040 684
3 685 2040 686
4 687 3040 688
The value entered in Scale Parameter will scale the analog output so
that you can get a full scale reading of the specific parameter for the
dynamic range or values you are testing.
To monitor dynamic system variables on analog outputs, use the

values shown in the table below.
Attribute: Parameter Number Parameter Number Parameter Number Parameter Number

(axis 0): (axis 1): (axis 2): (axis 3):
Velocity Feedback1 40 1040 2040 3040
Velocity Commanded1 36 1036 2036 3036
Torque Feedback2 84 1084 2084 3084
Torque Commanded2 80 1080 2080 3080
Following Error3 189 1189 2189 3189

1 Velocity Command and Feedback scaling value is 1V = 1000 rpm (using default scaling).
2 Torque Command and Feedback scaling value is 1V = 100% rated motor current or amplifier rating (whichever is
less) using default scaling.
3 Output scaling is dependant on feedback device and drive resolution.

Changing Default Digital Output Settings
Change the system module parameters listed below by using either

the HIM or DriveExplorer software. To locate the relay output
connector, refer to Figure 2.3.
Digital Output Controlling Default Parameter Default Parameter Delay Parameter

Number: HIM Display: Parameter: Number: Description: (on/off):
Drive System OK Output01 Source 662 617 Drive System OK
Output 0 Output02 Source 663 528 Axis 0 brake control 2061/2072
1
When the axis is enabled, there is a delay (ms) (Drive On Delay) between the axis having torque commanded
(brake releasing) and the axis following reference.
2
When the axis is disabled, there is a delay (ms) (Drive Off Delay) between the axis reaching zero speed or the
stopping time (brake engaging), and torque removed).
To monitor dynamic system variables on digital outputs, use the

values shown in the table below.
Parameter Number
Attribute: Axis 0 Parameter Axis 1 Parameter Axis 2 Parameter Axis 3 Parameter
(Threshold Setting (Threshold Setting (Threshold Setting (Threshold Setting
Parameter) Parameter) Parameter) Parameter)
331 1331 2331 3331
At Zero Speed (124) (1124) (2124) (3124)
330 1330 2330 3330
At Programmed Speed (157) (1157) (2157) (3157)
Velocity Command 335 1335 2335 3335

Above Limit (38+) (1038+) (2038+) (3038+)
(39-) (1039-) (2039-) (3039-)
332 1332 2332 3332
Velocity Below Limit (125) (1125) (2125) (3125)
334 1334 2334 3334
Torque Above Limit (82+) (1082+) (2082+) (3082+)
(83-) (1083-) (2083-) (3083-)
Torque Above 333 1333 2333 3333
Threshold (126) (1126) (2126) (3126)
336 1336 2336 3336
In Position (57) (1057) (2057) (3057)

Replacing System and Axis Use these procedures to:

Modules • Determine what you need to replace modules
• Remove an axis module
• Install a replacement axis module
• Remove a system module
• Install a replacement system module
Note: If you are replacing the fuse in 1394-SRxxxx shunt modules
refer to 1394 Shunt Modules Fuse Replacement Kit Installation
Instructions (publication 1394-6.6).
Note: If you are replacing the cooling fan in the 1394x-AM50 or -AM75
axis modules refer to Replacing the 10 and 15 kW Axis Module
Fan Installation Instructions (publication 1394-5.15).
This drive contains ESD (Electrostatic Discharge)

ATTENTION sensitive parts and assemblies. You are required to
follow static control precautions when you install,
! test, service, or repair this assembly. If you do not

follow ESD control procedures, components can be
damaged. If you are not familiar with static control
procedures, refer to Allen-Bradley publication 8000-
4.5.2, Guarding Against Electrostatic Damage or any
other applicable ESD Protection Handbook.
Before You Begin
Before you replace modules, be sure to have the following:
• A phillips screw driver

• A standard screw driver
• A voltmeter
• A nutdriver
• A wrench

Removing an Axis Module
To remove an axis module:
1. Remove 24V control power and main input power from the
system.
To avoid shock hazard or personal injury, assure

ATTENTION that all power has been removed before
proceeding. This system may have multiple
! sources of power. More than one disconnect

switch may be required to de-energize the
system.
2. Allow five minutes for the DC bus to completely discharge before

proceeding.
To avoid hazard of electrical shock, verify that all

ATTENTION voltage on the capacitors has been discharged
before attempting to service, repair, or remove
! this unit. This product contains stored energy

devices. You should only attempt the procedures
in this document if you are qualified to do so and
familiar with solid-state control equipment and
the safety procedures in publication NFPA 70E.
3. Remove connectors (TB1 and TB2) from the bottom of the axis
module.
4. Label and remove the motor leads and ground wiring from the
terminal block on the axis module.
5. Disconnect the slide-and-lock mechanism on the module you plan

to remove and all modules to the right of it.
6. Remove the bottom fastener on the axis module you plan to

remove.
7. Loosen the top fastener on the axis module you plan to remove.
8. Lift the axis module and pull it out.
9. If you are removing the right-most axis module, remove the

terminator.

Installing a Replacement Axis Module
To install a replacement axis module:
1. Install the top mounting fastener on the system panel for the axis
module. The head of the fastener should be at least 6.35 mm (0.25
in.) from the panel. Refer to the 1394 SERCOS Interface
Installation Manual (publication 1394-IN002x-EN-P) for more
information.
2.
If you are mounting: Do this:
A 1394x-AM03, Go to main step 3.
-AM04, -AM07
-AM50-IH, or
-AM75-IH axis module
A 1394x-AM50 or 1. Remove the paper backing from
-AM75 axis module with the gasket that came with the
the heat sink through AM50/75 axis module.
the back of the
enclosure 2. Position the gasket so that the
small hole side is on top.
3. Slide the gasket over the heat sink
and attach it to the back of the
axis module.
4. Go to main step 3.
3. Hang the axis module on the next mounting fastener.
4. Engage the alignment tab.
5. Slide the slide-and-lock mechanism on the axis module to the left

until it locks into place.
6. Install the lower fastener for all axis modules.
7. If not already attached, attach the terminator to the last axis

module slide-and-lock mechanism until it locks in place.
8. Tighten all mounting fasteners.
9. Reconnect TB1, TB2, motor, and ground wires.
If you are replacing a Series B axis module with a

ATTENTION Series C axis module you must use 24V dc in the
thermal switch circuit to avoid damage to the
! filter components between TB1 and TB2. Refer to

the interconnect diagrams in Appendix A for
examples.

10. Apply power to the system.
11. Verify that the system is operating properly.
Note: Because system and axis parameters reside in the system

module software, you do not need to perform any tuning or
setup at this time.
Removing a System Module
To remove a system module:
1. Remove the main input power from the system.
To avoid shock hazard or personal injury, assure

ATTENTION that all power has been removed before
proceeding. This system may have multiple
! sources of power. More than one disconnect

switch may be required to de-energize the
system.
2. Remove all 24V control input power from the system.
3. Allow five minutes for the DC bus to completely discharge before

proceeding.
To avoid hazard of electrical shock, verify that all

ATTENTION voltage on the capacitors has been discharged
before attempting to service, repair, or remove
! this unit. This product contains stored energy

devices. You should only attempt the procedures
in this document if you are qualified to do so and
familiar with solid-state control equipment and
the safety procedures in publication NFPA 70E.
4. Label and remove the 24V control power wiring from the system
module.
5. Label and remove the main input power wiring from the system
module.
6. Label and remove the ground wire and the external shunt
connections (if applicable).
7. Label and remove the feedback and communication connectors

from the bottom of system module.

8. Disconnect the slide-and-lock mechanism on the system module.
9. Open the system module door.
10. Label and remove any feedback and/or communication

connectors from the control board.
11. Loosen the top and bottom fasteners that hold the module in
place.
12. Lift the module up and pull it out.
Installing a Replacement System Module
To install a replacement system module:
1. Install the top mounting fasteners on the system panel for the
system module. The heads of the fasteners should be at least 6.35
mm (0.25 in.) from the panel. Refer to the 1394 SERCOS Interface
Installation Manual (publication 1394-IN002x-EN-P) for more
information.
2. Hang the 1394 System Module on the two mounting fasteners on

the left side of the panel.
3. Install the lower fasteners for the system module.
4. Open the system module door.
5. Connect the slide-and-lock mechanism on the system module to

the axis modules.
6. Reconnect feedback and communication connectors to the system

module. Refer to Appendix A for connection information.
7. Connect the ground wire and if used, the external shunt resistor
connections.
8. Connect the 24V control power and main input power to the
system module.
9. Connect all shunt wiring (if applicable).
10. Apply 24V control power to the system module.

11. Apply main input power to the system module.
IMPORTANT If you are replacing a Series C system module

with a Series D system module, you must auto
tune each axis to ensure proper operation. Refer
to Testing and Tuning Your Axes beginning on
1-22 for more information.
12. Verify that your system is operating properly.

Appendix A
Interconnect Diagrams
Chapter Objectives This appendix covers the following:
• Power Interconnect Diagrams

• Shunt Module Interconnect Diagrams
• Axis Module/Motor Interconnect Diagrams
• Understanding Motor Thermal Switches
• Brake Interconnect Diagrams

A-2 Interconnect Diagrams
1394 SERCOS Interface This section provides interconnect diagrams to assist you in wiring the
1394 system. The notes in the table below apply to the interconnect
Interconnect Diagram diagrams on the pages that follow.
Notes
Note: Information:
1 For power wiring specifications, refer to the 1394 SERCOS Interface Installation Manual (publication 1394-IN002x-EN-P).
2 For input fuse and circuit breaker sizes, refer to the 1394 SERCOS Interface Installation Manual (publication 1394-IN002x-EN-P).
3 For AC line filter specifications, refer to the 1394 SERCOS Interface Installation Manual (publication 1394-IN002x-EN-P).
4 Contactor coil (M1) needs integrated surge suppressors for AC coil operation.
5 Drive Enable input must be opened when main power is removed, or a drive fault will occur. A delay of at least 1.0 second must be observed
before attempting to enable the drive after main power is restored.
6 Cable shield clamp must be used in order to meet CE requirements. No external connection to ground required.
7 Jumper is factory set, indicating grounded system at user site. Ungrounded sites must jumper the bleeder resistor to prevent high electrostatic
buildup. Refer to the 1394 SERCOS Interface Installation Manual (publication 1394-IN002x-EN-P) for more information.
8 Implementation of safety circuits and risk assessment is the responsibility of the
ATTENTION machine builder. Please reference international standards EN1050 and EN954
estimation and safety performance categories. For more information refer to
9
! Understanding the Machinery Directive (publication SHB-900).
The recommended minimum wire size for wiring the safety circuit to the contactor enable connector is 1.5 mm2 (16 AWG).
10 If an external shunt resistor is used, remove the jumper between INT and COL.
11 There is no internal shunt resistor in the 22 kW system module. An external shunt resistor module (1394-SRx Ax) must be used.
12 The thermal switch and brake circuits are a source of conducted noise. Isolation from customer control devices may be required. A separate 24V
dc supply or relay can be used. Axis modules (Series C or later) include a thermal switch and motor brake filter to eliminate the need for a
separate 24V dc supply.
13 Use a flyback diode for noise suppression of the motor brake coil. For more information, refer to System Design for Control of Electrical Noise
Reference Manual (publication GMC-RM001x-EN-P).
14 For motor cable specifications, refer to Motion Control Selection Guide (publication GMC-SG001x-EN-P).
15 User supplied auxiliary contact is recommended. Use safety rated, mechanically linked contactor for M1.

Interconnect Diagrams A-3
Power Interconnect The power interconnect wiring for the 1394 SERCOS interface system
module is shown in the figures below.
Diagrams
Figure A.1
1394C-SJT05-D or -SJT10-D Interconnect Diagram
1394 SERCOS interface SYSTEM MODULE

1394C-SJT05-D or -SJT10-D
LOGIC POWER
DC MINUS BUS & SIGNALS
J4 J5 J6
Notes 4, 9
DC BUS POS.
Note 7
STOP* START* DC BUS NEG.
24V ac/dc CR1* SLIDER INTERCONNECT
or
120V ac
50/60 Hz M1* CR1*
1 Input Fusing*
CR1* 2 Drive System OK
Logic Power W1 24V ac RMS or
3
Refer to Attention statement (Note 8) Relay Output 3 Connector W2 24V dc (non-polarized)
4 Notes 1, 2
5
Relay Output 2
6
DC+ External Shunt Bonded Cabinet Ground Bu
7 Shunt Power
Relay Output 1 INT Connections (optional)
8 Connector
COL Note 10
Brake cable (2090-UXNBMP-18Sxx) for 9 Relay Output 0
MP-Series and 1326AB (M2L/S2L) motors 10
(refer to Brake Interconnect Diagrams PE
Relay Outputs Three-Phase
beginning on page A-14). Input Power W Three-Phase Input
Connector AC Line Filter
Connector V 360-380V ac RMS
Note 3
To TB2-1 and TB2-2 for U Notes 1, 2
1326AB/AS (resolver) motors. M1* Input Fusing *
(refer to Thermal Switch Interconnect Diagrams System Module Notes 4, 5
beginning on page A-9). Single Point Bond Bar
Bonded Cabinet A to 1394 Axis Module PE1 terminal

Ground Bus* * INDICATES USER-SUPPLIED COMPONENT
Figure A.2
1394C-SJT22-D Interconnect Diagram
1394 SERCOS interface SYSTEM MODULE

1394C-SJT22-D
LOGIC POWER
& SIGNALS
DC MINUS BUS J4 J5 J6
Notes 4, 9
DC BUS POS.
Note 7
START* DC BUS NEG.
STOP*
24V ac/dc CR1*
or SLIDER INTERCONNECT
120V ac
50/60 Hz M1* CR1*
1 Input Fusing*
CR1* 2 Drive System OK
Logic Power W1 24V ac RMS or
3 24V dc (non-polarized)
Refer to Attention statement (Note 8) Relay Output 3 Terminal Blocks W2
4 Notes 1, 2
5
Relay Output 2
6
Shunt Power DC+ External Shunt Bonded Cabinet Ground Bus
7 Relay Output 1 Connections
Terminal Blocks COL
8 Note 11
Brake cable (2090-UXNBMP-18Sxx) for 9 Relay Output 0
MP-Series and 1326AB (M2L/S2L) motors 10
(refer to Brake Interconnect Diagrams Relay Outputs PE
beginning on page A-14). Connector Three-Phase
Input Power W Three-Phase Input
AC Line Filter
Terminal Blocks V 360-380V ac RMS
Note 3
To TB2-1 and TB2-2 for U Notes 1, 2
1326AB/AS (resolver) motors.
(refer to Thermal Switch Interconnect System Module M1* Input Fusing *
Diagrams beginning on page A-9). Single Point Bond Bar Notes 4, 5
Bonded Cabinet A to 1394 Axis Module PE1 terminal

Ground Bus* * INDICATES USER-SUPPLIED COMPONENT

Shunt Module Interconnect In the figure below, the 1394 system module is shown wired for
internal shunt operation. This is the factory default jumper setting.
Diagrams
IMPORTANT Internal shunt operation is only present on the 1394
system modules listed in Figure A.3.
Figure A.3
Internal Shunt Interconnect Diagram
1394 System Modules

1394C-SJT05-D or
1394C-SJT10-D
DC+
Shunt Power
INT Connector
COL
In the figure below, the 1394C-SJT05-D and -SJT10-D system modules

are shown wired with the optional external shunt resistor.
Figure A.4
External Shunt Module Interconnect Diagram (optional)
1394 System Modules

1394C-SJT05-D or
External Passive 1394C-SJT10-D
Shunt Module
1394-SR10A
DC+
DC+ Shunt Power
INT Connector
COL
COL

In the figure below, the 1394C-SJT22-D system module is show wired

with an external shunt resistor.
IMPORTANT All 1394 configurations with 22 kW system modules

require an external shunt module.
Figure A.5
External Shunt Module Interconnect Diagram (required)
External Passive 1394 System Module

Shunt Module 1394C-SJT22-D
1394-SR9A,
1394-SR9AF, DC+ DC+ Shunt Power
1394-SR36A, Terminal Blocks
1394-SR36AF COL COL
Thermal To customer-defined
Switch 1 control string
Fan To customer-supplied
Connections 1 fan supply
1 The thermal switch and fan connections are only included with the 1394-SR36A and -SR36AF shunt modules.

Axis Module/Motor This section contains the motor power, brake, and feedback signal
interconnect diagrams between an Axis Module and MP-Series,
Interconnect Diagrams 1326AB, and 1326AS servo motors.
In the figure below, the 1394 axis module is shown connected to MP-
Series Low Inertia (460V) motors.
Figure A.6
Axis Module to MP-Series Low Inertia Motors Interconnect Diagram
TERMINATOR CONNECTED TO
LAST AXIS MODULE
1394 AXIS MODULE
1394C-AMxx-xx
LOGIC POWER
& SIGNALS
DC BUS POS.
Motor Power Terminal Blocks
DC BUS NEG.
SLIDER INTERCONNECT
SLIDER INTERCONNECT TO ADDITIONAL AXIS MODULES
U1 V1 W1 PE1 PE2 PE3
To
4.0 mm2 (12 AWG) System Module
A Single Point
Axis Module 2090-XXNPMP-xxSxx or Bond Bar
Cable Clamp 2090-CDNBPMP-xxSxx
Note 6 Motor Power Cable Motor Feedback
A B C D Note 14
Connector
(System Module)
U V W PE
A BLACK SIN+ 1
2090-UXNBMP-18Sxx Brake Cable Three-Phase
Note 14 Motor Power Ground B WHT/BLACK SIN- 2
Black C C RED COS+ 3

BR-
D WHT/RED COS- 4
White A BR+ Motor Brake Motor Feedback
E GREEN DATA+ 8
F WHT/GREEN DATA- 9
COM +24V
N ORANGE +9VDC 6
User-Supplied P WHT/ORANGE COM 5
+24V Power Supply
(1A max.) R BLUE TS+ 12
Note 13 MPL-Bxxxx (460V) Thermostat
S WHT/BLUE TS- 13
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
2090-CDNFDMP-xxSxx Feedback Cable System Module
Note 14
Cable Clamp
Note 6
A B C D Motor Feedback
Connector
(System Module)
U V W PE
Three-Phase A BLACK S2 1
2090-UXNBMP-18Sxx Brake Cable Motor Power B WHT/BLACK S4 2
Note 14
Ground
Black C C RED S1 3
BR-
Motor Feedback D WHT/RED S3 4
White A BR+
Motor Brake
G YELLOW R1 10
H WHT/YELLOW R2 11
COM +24V
R BLUE TS+ 12
User-Supplied MPL-Bxxxx (460V)
+24V Power Supply SERVO MOTORS WITH Thermostat
S WHT/BLUE TS- 13
(1A max.) RESOLVER FEEDBACK
Note 13 2090-CDNFDMP-xxSxx Feedback Cable
Note 14 System Module
Cable Clamp Note 6

In the figure below, the 1394 axis module is shown connected to

1326AB (460V) servo motors.
Figure A.7
Axis Module to 1326AB Motors Interconnect Diagram
1394 AXIS MODULE LAST AXIS MODULE
1394C-AMxx-xx
Thermostat and Brake Noise Filtering
Note 12
LOGIC POWER Motor Thermal Switch Motor Brake
& SIGNALS Filter (Series C) Filter (Series C)
TB1 TB2
DC BUS POS. Motor Power SLIDER INTERCONNECT
DC BUS NEG. Terminal Blocks TO ADDITIONAL AXIS MODULES
SLIDER INTERCONNECT
PE3
W1
PE2
PE1
U1
V1
1 2 3 4 1 2 3 4
To
4.0 mm2 (12 AWG) System Module
A
Single Point
Bond Bar
2090-XXNPMP-xxSxx or
Axis Module 2090-CDNBPMP-xxSxx Motor Feedback
Cable Clamp Motor Power Cable Connector
A B C D
Note 6 Note 14 (System Module)
U V W PE 1
A BLACK SIN+
Ground B WHT/BLACK SIN- 2
Three-Phase
Motor Power C RED COS+ 3
2090-UXNBMP-18Sxx Brake Cable
Motor Feedback D WHT/RED COS- 4
Note 14
E GREEN DATA+ 8
Black A BR+ WHT/GREEN DATA-
F 9
White C BR-
Motor Brake N +9VDC 6
ORANGE
P WHT/ORANGE COM 5
COM +24V R BLUE TS+ 12
User-Supplied Thermostat
+24V Power Supply S WHT/BLUE TS- 13
1326AB (M2L/S2L) 460V
(1A max.)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK Cable Clamp
2090-CDNFDMP-xxSxx Feedback Cable Note 6
Note 14
Note 12
TB1 TB2
Motor Power
Terminal Blocks
Refer to Thermal Switch and Brake
PE3
W1
PE2
PE1
U1
V1
Interconnect Diagrams beginning on

To 1 2 3 4 1 2 3 4 page A-9 for connections.
Motor Feedback
System Module 4.0 mm2 (12 AWG) Connector
Single Point A
(System Module)
Bond Bar
Axis Module
Cable Clamp TS+ 12
Note 6 TS- 13
1 2 3 8 7 9 5 4 6
1326-CPx1-xxx
Motor Power Cable
Note 14 PE K2 K1 B2 B1 1
T1 T2 T3 G GREEN S2
H BLACK S4 2
Three-Phase
Motor Power D BLACK S1 3
Ground Brake E RED S3 4
Thermostat A BLACK R1 10
Motor Feedback WHITE 11
B R2
1326AB (460V) SERVO MOTORS
WITH RESOLVER FEEDBACK 1326-CCU-xxx Feedback Cable
System Module
Note 14
Cable Clamp
Note 6

In the figure below, the 1394 axis module is shown connected to

1326AS (460V) servo motors.
Figure A.8
Axis Module to 1326AS Motors Interconnect Diagram
1394 AXIS MODULE LAST AXIS MODULE
1394C-AMxx-xx
Note 12
LOGIC POWER Motor Thermal Switch Motor Brake
& SIGNALS Filter (Series C) Filter (Series C)
TB1 TB2
DC BUS POS. Motor Power SLIDER INTERCONNECT
DC BUS NEG. Terminal Blocks TO ADDITIONAL AXIS MODULES
SLIDER INTERCONNECT
PE3
W1
PE2
PE1
U1
V1
1 2 3 4 1 2 3 4 Motor Feedback
To
Connector
Refer to Thermal Switch and Brake
System Module 4.0 mm2 (12 AWG) Interconnect Diagrams beginning on (System Module)
Single Point A
page A-9 for connections.
Bond Bar
TS+ 12
Axis Module 13
TS-
Cable Clamp
Note 6
1 2 3 8 7 9 5 4 6
1326-CPx1-xxx
Motor Power Cable
Note 14 T1 T2 T3 PE K2 K1 B2 B1
Three-Phase G GREEN S2 1
Motor Power H BLACK S4 2
Ground Brake D BLACK S1 3
Thermostat E RED S3 4
A BLACK R1 10
Motor Feedback WHITE
B R2 11
1326AS (460V) SERVO MOTORS
WITH RESOLVER FEEDBACK 1326-CCU-xxx Feedback Cable
Cable Clamp
Note 6

Thermal Switch and Brake This section provides thermal switch and brake interconnect diagrams.
Interconnect Diagrams
Understanding Motor Thermal Switches
Thermal switches, internal to each servo motor, can be wired in series

to protect the motor from overheating. In the event of a fault
condition, the switch opens and the motor responds to the system
configuration. The explanation and example diagrams that follow
show how to wire motor thermal switches to your system module.
Depending on the series of your 1394 axis module, your customer

control devices may require isolation from the motor’s conducted
noise. When using 1394 (Series A and B) axis modules, an isolated
24V dc power supply and relay is recommended. 1394 (Series C) axis
modules contain internal motor brake and thermal switch filtering and
do not require the isolation power supply and relay.
Individual thermal fault monitoring can be achieved by wiring each of

the motor thermal switches from the motor, through TB1/TB2 on the
axis module, or directly from the motor to one of four dedicated
thermal fault inputs on the system module. Your 1394 system can then
be configured to monitor and disable one or all four of the axes. As an
alternative, you can wire the thermal switches into the start/stop string
to disable all axes when a fault occurs.
How Your Feedback Cable Affects Thermal Switch Wiring
The examples shown on the following pages are for 1326AB/AS servo
motors with resolver feedback (using 1326-CCU-xxx feedback cables).
The motor thermal switch leads are in the motor power cable and
attach to TB1 of the axis module (refer to figures A.7 and A.8 for
motor/axis module interconnect diagrams).
1326AB (M2L/S2L) motors and MP-Series motors (both resolver and

high resolution feedback) use 2090-CDNFDMP-Sxx feedback cables.
The motor thermal switch wires are in the motor feedback cable and
attach directly to the feedback connector on the bottom of the 1394
system module. Refer to figures A.6 and A.7 for motor/system module
interconnect diagrams).
Thermal Switch Interconnect Diagrams

The example in Figure A.9 shows 1394 (Series C) axis modules with
internal brake and thermal switch filtering. Separate isolation power
supply and relay are not required. Using this start/stop string
configuration all axes are disabled when any one motor faults.

Figure A.9
Non-Isolated Series Start/Stop String
Axis 0 Axis 1 Axis 2 Axis 3
1394C-AMxx 1394C-AMxx 1394C-AMxx 1394C-AMxx

Motor thermal Motor thermal Motor thermal Motor thermal
switch filter Motor brake switch filter Motor brake switch filter Motor brake switch filter Motor brake
(Series C) filter (Series C) (Series C) filter (Series C) (Series C) filter (Series C) (Series C) filter (Series C)
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
TB1 TB2 TB1 TB2 TB1 TB2 TB1 TB2
3 4 3 4 3 4 3 4
Motor thermal switch wiring for

1326AB/AS motor resolver feedback
Drive System OK 1
Relay 2
START STOP
1394 SERCOS Interface 3 CR1
4
Control Board 5 24V AC/DC
6 CR1
1394C-SJTxx-D 7 M1
8
Relay Output 9 CR1
Connector 10
Refer to Attention statement below
IMPORTANT The thermal circuit includes filtering on the TB1/TB2

connector board that is rated for 24V only. For TB1/
TB2 wiring alternatives, refer to the table below.
If: Then:
Option 1: Install a 24V pilot relay on the
thermal switch circuit.
120V ac is used on the start/stop string
Option 2: Bypass the TB1/TB2 terminations 1.
24V is used on the start/stop string Follow the wiring shown in Figure A.9 above.
1
When bypassing the TB1/TB2 terminations, ensure that unshielded motor power conductors are kept as short as
possible at the drive, as they will radiate high levels of electrical noise.
Note: Refer to Figure 1.3 for the location of the TB1/TB2 connectors
and pin-out diagram.
Implementation of safety circuits and risk assessment

ATTENTION is the responsibility of the machine builder. Please
reference international standards EN1050 and EN954
! estimation and safety performance categories. For

more information refer to Understanding the
Machinery Directive (publication SHB-900).

The example below shows 1394 (Series C) axis modules wired for
thermal fault monitoring. Depending on how the 1394 system is
configured, the fault can be used to disable one or all of the four axis
modules.
Figure A.10
Non-Isolated with Thermal Fault Monitoring
Motor thermal Motor thermal Motor thermal Motor thermal

switch filter Motor brake switch filter Motor brake switch filter Motor brake switch filter Motor brake
(Series C) filter (Series C) (Series C) filter (Series C) (Series C) filter (Series C) (Series C) filter (Series C)
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
3 4 3 4 3 4 3 4

12 13 Axis 0 12 13 Axis 1 12 13 Axis 2 12 13 Axis 3

TS+ TS+ TS+ TS+
TS- TS- TS- TS-
Motor Feedback Connector
1394 SERCOS Interface

Control Board
1394C-SJTxx-D

The example below shows 1394 (Series A and B) axis modules (no
internal brake or thermal switch filter). Separate 24V dc isolation
power supply and relay (CR2) are recommended. Using this start/stop
string configuration all axes are disabled when any one motor faults.
Figure A.11
Isolated Series Start/Stop String
1394-AMxx 1394-AMxx 1394-AMxx 1394-AMxx
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
3 4 3 4 3 4 3 4

24V dc +24V dc
CR2
Power Supply 1
24V dc com
START STOP
CR1
24V AC/DC
CR2 or
Drive System OK 1 CR1 120V AC,
Relay 2 M1 50/60 HZ
1394 SERCOS Interface 3 CR1
Control Board 4
5
6
1394C-SJTxx-D 7 Refer to Attention statement below
Relay Output 8
9
Connector 10
1
120V ac (50/60 Hz) power may be used in place of 24V dc for motor thermal switch circuits in Series A and B axis
modules.
Implementation of safety circuits and risk assessment

ATTENTION is the responsibility of the machine builder. Please
reference international standards EN1050 and EN954
! estimation and safety performance categories. For

more information refer to Understanding the
Machinery Directive (publication SHB-900).

The example below shows 1394 (Series A and B) axis modules wired
for thermal fault monitoring. Depending on how the 1394 system is
configured, the fault can be used to disable one or all of the four axis
modules. Two separate 24V dc power supplies and four relays (CR2-
CR5) are included to isolate the thermal inputs from conducted noise.
Figure A.12
Isolated with Thermal Fault Monitoring
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
3 4 3 4 3 4 3 4

CR2 CR3 CR4 CR5
24V dc +24V DC
Power Supply 1
24V DC com
CR2 CR3 CR4 CR5
12 13 Axis 0 12 13 Axis 1 12 13 Axis 2 12 13 Axis 3

TS+ TS+ TS+ TS+
TS- TS- TS- TS-
Motor Feedback Connector

Control Board
1394C-SJTxx-D
1
120V ac (50/60 Hz) power may be used in place of 24V dc for motor thermal switch circuits in Series A and B axis
modules.

Brake Interconnect Diagrams
The relay outputs (Output 0-3) are linked to the Brake Enable/Disable
configuration in RSLogix 5000 axis properties to allow control of a
motor brake for each axis. When an axis is enabled, the configured
output relay contact will close to disengage the associated motor
brake. At the same time, the axis will command sufficient torque to
hold the motor's position while the brake is disengaging. The length
of time that the axis will apply this torque is set by the Brake Off
Delay parameter for each axis. When an axis is disabled and the
motor has reached zero velocity, the configured output relay contact
will open to engage the associated motor brake. At the same time, the
axis will command sufficient torque to hold the motor's position while
the brake is engaging. The length of time that the axis will apply this
torque is set by the Brake On Delay parameter for each axis. Refer to
Configuring Axis Properties beginning on page 1-18 to set delay times
in RSLogix 5000.
Depending on the series of your 1394 axis module, your brake

circuitry may require isolation from the motor's conducted noise.
When using 1394 Series B axis modules, an isolated 24V dc power
supply and relay is recommended. 1394 Series C axis modules contain
an internal motor brake filter and do not require the isolation power
supply and relay. The Series C brake filter also contains a bi-
directional snubber diode to protect the user-supplied 24V dc brake
power supply.
IMPORTANT The output relay contacts are rated to control a 24V

dc motor brake rated up to 1A. Motor brakes rated
greater than 1A require an additional relay or
contactor with sufficient rating to handle the higher
current.

The example below shows 1394 series C axis modules with internal
brake filtering. Each axis is connected to a motor with a brake rated at
less than 1A. A separate pilot relay is not required. Motor brakes that
do not require a pilot relay are shown in the table below.
Note: Suppression devices and pilot relays impact motor brake

response time.
Brake Response Time

Motor Series: Brake Option: Pickup/Dropout
mSec
1326AB-B4 K4 120/20
1326AS-B3 K3 38/10
1326AS-B4 K4 44/13
MPL-B3 (460V) 4 50/20
MPL-B4 (460V) 4
110/25
MPL-B45 (460V) 4
Figure A.13
Brake Interconnect Diagram
Motor brake Motor brake Motor brake Motor brake

filter (Series C) filter (Series C) filter (Series C) filter (Series C)
Brake current rated Brake current rated Brake current rated Brake current rated
less than 1.0A less than 1.0A less than 1.0A less than 1.0A
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 2 1 2 1 2 1 2
I <1A I <1A I <1A I <1A

Motor Brake
9 Relay 8 Relay 6 Relay 4 Relay
10 Output 0 7 Output 1 5 Output 2 3 Output 3

Control Board
1394C-SJTxx-D
24V DC + DC
Power Supply
DC com
Note: Refer to figures 1.1 and 1.2 for the location of the 10-pin relay
output connector.

The example below also shows 1394 series C axis modules with
internal brake filtering. Each axis is connected to a motor with a brake
rated at greater than 1A. A separate pilot relay is required for brake
current handling.
Note: Suppression devices and pilot relays impact motor brake
response time.
Brake Response Time

Motor Series: Brake Option: Pickup/Dropout
mSec
1326AB-B5 K5 150/25
1326AB-B7 K7 120/30
1326AS-B6 K6 114/11
1326AS-B8 K8 200/12
MPL-B5 (460V) 4 70/50
MPL-B6 (460V) 4 200/120
MPL-B8 (460V) 4 250/200
MPL-B9 (460V) 4 300/200
Figure A.14
Isolated Brake (with pilot relay) Interconnect Diagram

Motor brake Motor brake Motor brake Motor brake
filter (Series C) filter (Series C) filter (Series C) filter (Series C)
Brake current rated Brake current rated Brake current rated Brake current rated
greater than 1.0A greater than 1.0A greater than 1.0A greater than 1.0A
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 2 1 2 1 2 1 2
CR6 CR7 CR8 CR9

Motor Brake I >1A I >1A I >1A I >1A
24V DC + DC
Power Supply
DC com
CR6 CR7 CR8 CR9
10 9 8 7 6 5 4 3
Relay Relay Relay Relay
Output 0 Output 1 Output 2 Output 3
1394 SERCOS Interface Control Board 1394C-SJTxx-D
output connector.

The example below shows 1394 Series B axis modules without

internal brake filtering. Any axis connected to a motor with a brake
requires a separate pilot relay for noise isolation.
Figure A.15
Isolated Brake (with pilot relay) Interconnect Diagram
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 2 1 2 1 2 1 2
CR6 CR7 CR8 CR9
Motor Brake
24V DC + DC
Power Supply
DC com
CR6 CR7 CR8 CR9
10 9 8 7 6 5 4 3
Relay Relay Relay Relay
Output 0 Output 1 Output 2 Output 3
1394 SERCOS Interface Control Board 1394C-SJTxx-D
output connector.


Index
Numerics 1394 SERCOS 1-7

1326AB (M2L/S2L) Logix 1-11
interconnect diagram A-7 optical power level 1-10
1326AS connector
interconnect diagram A-8 analog 2-20
1394 SERCOS relay 2-20
commissioning 1-1 connector designators
configuring 1-7 axis module 1-3
1394 system system module 1-3
troubleshooting 2-1 connector locations
1756-MxxSE P-1 axis module 1-6
1756-MxxSE interface module Logix 1-7
1-7 system module 1-4, 1-5
1784-PM16SE P-1 contents of manual P-2
1784-PM16SE PCI card 1-7 controller properties 1-11
ControlLogix P-1
ControlLogix Motion Module
A Setup and Configuration
analog connector 2-20 Manual 1-11, 1-22
analog test points 2-20 conventions used in this manual
applying power P-3
24V 1-20 conversion tab 1-18
360/480V 1-21 cycle time 1-14
attribute tab 1-17
axis assignment tab 1-17
axis module
D
connector designators 1-3, 1-6 data rate 1-14
installing replacement 2-25 data type 1-15
removing 2-24 date and time tab 1-12
status LED 2-4 detecting a problem 2-2
axis module status LED 1-21, digital output settings 2-22
1-22 dip switches 1-14
axis properties 1-18 disable drive 2-14
documentation P-2
download program 1-19
B drive system ok 2-22
base node address 1-8, 1-15 drive tab 1-18
baud rate 1-10 DriveExplorer 2-18
bus regulator 1-16
F
C fault actions tab 1-19
cables fault behavior 2-14
fiber-optic cable length 1-7 faults
certifications axis module
Rockwell Automation Product +hard ovrtrvl 2-10
Certification P-2 +soft ovrtrvl 2-10
changing parameters 2-18 ATune Flt 2-9
comments regarding this manual Aux Fdbk AQB 2-9
P-4 Aux Fdbk Loss 2-9
commissioning 1-1 Aux Fdbk Noise 2-9
configuring axis hookup fault 2-9

I-2 Index
axis unknown 2-9 SERCOS same address

Bus Loss 2-9 2-8
desat 2-9 Serial Ring Init 2-7
drive enable 2-9 shunt time out 2-8
Follow Error 2-10 sys mod unknown 2-8
-hard ovrtrvl 2-10 Sys Overtemp 2-8
I(t) Fault 2-10 task Init 2-8
Motor Overtemp 2-11 unknown fault 2-8
Mtr Fdbk AQB 2-10 system module (Logix)
Mtr Fdbk comm 2-9, 2-10 DriveHard 2-6, 2-7, 2-8
Mtr Fdbk Loss 2-10 DriveOvercurrent 2-6
Mtr Fdbk Noise 2-11 DriveOvertemp 2-8
Overspeed 2-11 DriveOvervoltage 2-6,
Overtemp 2-11 2-8
Power Fault 2-11 DriveUndervoltage 2-6
-soft ovrtrvl 2-10 GroundShort 2-7
axis module (Logix) MotFeedback 2-7
AuxFeedback 2-9 PowerPhaseLoss 2-7
AuxFeedbackNoise 2-9 SERCOS 2-7
DriveEnableInput 2-9 SERCOSFault 2-8
DriveHard 2-9 feedback tab 1-18
DriveOvercurrent 2-9, fiber-optic cables
2-10, 2-11 receive and transmit
DriveOvertemp 2-11 connectors 1-7
DriveUndervoltage 2-9
MotFeedback 2-10
H
MotFeedbackNoise 2-11
MotorOvertemp 2-11 HIM 2-18
NegHardOvertravel 2-10 programming flowchart 2-19
NegSoftOvertravel 2-10 hookup tab 1-23
OverSpeed 2-11 human interface module (HIM)
PosHardOvertravel 2-10 2-18
PositionError 2-10
PosSoftOvertravel 2-10 I
system module interconnect diagrams
bus overcurrent 2-6 1326AB (M2L/S2L) A-7
Bus Overvoltage 2-6 1326AS A-8
Bus Precharge 2-6 motor brake
Bus Undervoltage 2-6 Series B axis modules
Can Init 2-6 A-17
contactor fault 2-7 Series C axis modules
Fdbk Watch Dog 2-7 A-15, A-16
Ground Short 2-7 MP-Series low inertia A-6
IDMA load 2-7 notes A-2
Memory Init 2-7 power A-3
NV Mem Init 2-7 shunt module A-4, A-5
Objects Init 2-7 thermal switch
Phase Loss Flt 2-7 Series A and B axis
SCANport Comm 2-7 modules A-12, A-13
SERCOS Init 2-7 Series C axis modules
SERCOS ring flt 2-7 A-10, A-11

Index I-3
L P
LED parameters, changing 2-18
axis module status 1-21, 1-22, power
2-4 control 24V 1-20
network status 1-20, 2-5 input 1-21
SERCOS module 1-20 interconnect diagrams A-3
system module status 1-20, precautions
1-22, 2-3 general startup 1-2
local support P-4 safety 2-2
Logix problem report form P-4
connector designators 1-7
Logix interface module 1-11
R
loop configuration 1-18
receiving and storage P-3
related documentation
M Motion Book Servo Sizing CD
manuals on-line P-4 P-2
modules relay connector 2-20
installing replacement axis RSLogix 5000 software 1-11, 2-18
2-25
installing replacement system
S
2-27
removing axis 2-24 safety precautions 2-2
removing system 2-26 SERCOS module LED 1-20
Motion Book Servo Sizing CD P-2 shunt module
motion control problem report configuring 1-16
form P-4 interconnect diagram A-4, A-5
Motion Control Selection Guide shutdown 2-14
P-2 SoftLogix P-1
motion group properties 1-17 SoftLogix Motion Card Setup and
motor and feedback tab 1-18 Configuration Manual 1-11,
motors 1-22
testing 1-22 software
tuning 1-22 RSLogix 5000 1-11, 2-18
MP-Series low inertia status LEDs 1-22
interconnect diagram A-6 status only 2-14
stop motion 2-14
storage P-3
N supplemental troubleshooting
network status LED 1-20 information 2-18
node address switches support
configuring comments regarding this
base node address 1-8 manual P-4
baud rate 1-10 local product P-4
noise P-2 technical product assistance
P-4
switches
O base node address 1-8
optical power level 1-10, 1-14 baud rate 1-10
dip 1-14
optical power level 1-10, 1-14

I-4 Index
System Design for Control of shutdown 2-14

Electrical Noise Reference status only 2-14
Manual P-2 stop motion 2-14
system module supplemental troubleshooting
connector designators 1-3 information 2-18
connector locations 1-4, 1-5 changing digital output
installing a replacement 2-27 settings 2-22
removing 2-26 changing parameters
system module status LED 1-20, 2-18
1-22, 2-3 using analog test points
2-20
system module faults 2-6
T system module status LED 2-3
technical product assistance P-4 tune tab 1-26
testing axes tuning axes
hookup tab 1-23 tune tab 1-26
testing motors 1-22 tuning motors 1-22
troubleshooting 2-1
axis module faults 2-9
axis module status LED 2-4 U
disable drive 2-14 understanding
fault behavior 2-14 motor brake A-14
general system problems 2-12 motor thermal switches A-9
how to detect a problem 2-2 units tab 1-18
network status LED 2-5

For more information refer to our web site: www.ab.com/motion
For Rockwell Automation Technical Support information refer to: www.rockwellautomation.com/support or Tel: (1) 440.646.3434

Supersedes Publication 1394-IN024A-EN-P — July 2001 Copyright © 2004 Rockwell Automation. All rights reserved. Printed in USA.

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1394 SERCOS

The illustrations, charts, sample programs and layout examples

Allen-Bradley publication SGI-1.1, Safety Guidelines for the

Reproduction of the contents of this copyrighted publication, in

Throughout this manual we use notes to make you aware of safety

Identifies information about practices or

IMPORTANT Identifies information that is critical for successful

Allen-Bradley is a registered trademark of Rockwell Automation.

Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . P-1

Supplemental Troubleshooting Information. . . . . . . . . . . . 2-18

Publication 1394-IN024B-EN-P — February 2004

• Who Should Use this Manual

If you do not have a basic understanding of the 1394, contact your

1 Publication 1394-IN024B-EN-P — February 2004

Contents of this Manual

Related Documentation The following documents contain additional information concerning

For: Read This Document: Publication Number:

Publication 1394-IN024B-EN-P — February 2004

Leave the product in its shipping container prior to installation. If you

• in a clean, dry location

Publication 1394-IN024B-EN-P — February 2004

Local Product Support

Contact your local Allen-Bradley representative for:

• sales and order support

Technical Product Assistance

If you need to contact Allen-Bradley for technical assistance, please

Comments Regarding this Manual

To offer comments regarding the contents of this manual, go to

Publication 1394-IN024B-EN-P — February 2004

Commissioning Your 1394 SERCOS Interface

• General Startup Precautions

These procedures assume you have completed mounting, wiring, and

Note: Some of the procedures in this chapter include information

1 Publication 1394-IN024B-EN-P — February 2004

This product contains stored energy devices. To

! discharged before attempting to service, repair or

This drive contains ESD (Electrostatic Discharge)

! test, service, or repair this assembly. If you do not

Publication 1394-IN024B-EN-P — February 2004

System Module Connectors

Description Connector Present on this 1394

Axis Module Connectors

Publication 1394-IN024B-EN-P — February 2004

System Module, front view 1394 Digital Servo Controller

SEE INSTRUCTIONAL MANUAL.

Front Cover AXIS 2 - N/C

Address Switch Enable0

Network Status LED

SERCOS Receive (Rx) Connector

Tie Down Anchor

System Module, bottom view

Shunt Power Connector

DPI/SCANport Connector Logic Power Connector

Axis 0 Auxiliary Feedback Input Power Connector

Axis 1 Auxiliary Feedback

Cable Clamp Grounding Bracket

Publication 1394-IN024B-EN-P — February 2004

Use the figure below to locate the 1394C-SJT22-D System Module

1394 Digital Servo Controller