PAM & SAM

System User’s
Manual
Part 2 - System Design
and Integration
Ordering Number: 9032 011 982
Issue October 6, 2000
This version replaces all
previous versions of this
document. It also replaces
the SAM System Designer’s
Guide (1995-1996).
Inmotion Technologies and
ACC Motion have made
every effort to insure this
document is complete and
accurate at the time of
printing. In accordance with
our policy of continuing
product improvement, all
data in this document is
subject to change or
correction without prior P/n 9032 011 982
notice. Issue October 6, 2000

ACC Motion SA © 1995 - 2000

Zone industrielle La Rippe by ACC Motion SA
CH-1303 Penthaz All rights reserved
Switzerland
PART 2 - SYSTEM DESIGN AND INTEGRATION TABLE OF CONTENTS

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PART 2 - SYSTEM DESIGN AND INTEGRATION TABLE OF CONTENTS

Table of Contents
Table of Contents....................................................................................................3
List of Figures .........................................................................................................5
List of Tables...........................................................................................................6
Grounding and Shielding ........................................................................................7
About Protective Earth and Functional Earth Grounds .......................................7
Protective Earth Grounding Requirements..........................................................8
Grounding for Electro-magnetic Compatibility.....................................................9
Enclosure Layout ..................................................................................................12
Concept for an Entire Machine Control System ................................................12
Rules for Enclosure Layout ...............................................................................12
Recommended Layout for a PAM with SAM System ........................................13
Rules for Placement of EMC Line Filter ............................................................14
Back Panel Layout.............................................................................................14
PAM ......................................................................................................................16
PAM Full System ...............................................................................................16
PAM-ISA ............................................................................................................18
PAM for Simatic Module ....................................................................................18
EasyBus................................................................................................................19
General ..............................................................................................................19
Installation..........................................................................................................19
SAM Drive.............................................................................................................20
Mounting a SAM Drive.......................................................................................20
Interfacing AC Servomotors ..............................................................................24
Interfacing Standard Resolvers .........................................................................29
Interfacing Sine-Cosine Encoders and Rulers ..................................................32
Interfacing Multi-turn Resolvers.........................................................................34
Safety I/O & 24 VDC Supply..............................................................................35
User I/O .............................................................................................................35
Connector Pin Assignment ................................................................................38
SAM Supply ..........................................................................................................41
AC Supply Input.................................................................................................42
DC Output..........................................................................................................43
External Dynamic Braking Resistor ...................................................................43
Safety, Status and 24 VDC Supply....................................................................45
Connector Locations and Pin Assignments.......................................................47
DC Bus..................................................................................................................49
General ..............................................................................................................49
DC Bus Bar Assembly .......................................................................................49
Low Power Applications ....................................................................................51
Feeding Section ....................................................................................................52

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PART 2 - SYSTEM DESIGN AND INTEGRATION TABLE OF CONTENTS

Basic Circuit.......................................................................................................52
Installing an EMC Line Filter..............................................................................52
Interfacing a Transformer ..................................................................................53
24 VDC Supply .....................................................................................................55
Functions ...........................................................................................................55
24 VDC Power Distribution................................................................................55

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PART 2 - SYSTEM DESIGN AND INTEGRATION LIST OF FIGURES

List of Figures
Figure 1 Symbols for Protective Earth Ground ......................................................7
Figure 2 Symbol for Functional Earth Ground........................................................7
Figure 3 AC Supply with a Grounded Neutral ........................................................8
Figure 4 Machine to System Enclosure PE Conductor ..........................................9
Figure 5 Mesh Earthing Network Using Building Structure..................................10
Figure 6 Mesh Earthing Network Using Conduits and Cable Trays.....................11
Figure 7 Enclosure Layout Concept.....................................................................12
Figure 8 Enclosure Layout for a Large System....................................................13
Figure 9 Recommended Spacing and Clearances for SAM Drives and Supplies
...............................................................................................................15
Figure 10 PAM Full System....................................................................................16
Figure 11 PAM Chassis Mounting Dimensions and Clearances ...........................17
Figure 12 EMI/RFI Requirements when Installing PAM Chassis...........................17
Figure 13 The PAM-ISA .........................................................................................18
Figure 14 PAM Modules for Simatic S5-115 (left), S5-135 and S5-155 (right) ......18
Figure 15 Dimensions for SAM Drive 7 amp Models .............................................21
Figure 16 Dimensions for SAM Drive 14 & 28 amp Models...................................22
Figure 17 Dimensions for SAM Drive 50 amp Models ...........................................23
Figure 18 Shields Termination in Cable Gland ......................................................25
Figure 19 Wiring Diagram for “AC Servomotors” with Terminal Boxes (“C33”
option) ....................................................................................................26
Figure 20 Motor Windings Cable Configurations ...................................................27
Figure 21 Wiring Diagram for motors with Integral Mating Connectors .................28
Figure 22 Plug-fitted Motor Winding Cable Assembly............................................29
Figure 23 Resolver Feedback Interface for AC Servomotors with Terminal Boxes
...............................................................................................................30
Figure 24 Resolver Feedback Interface for ACC & Bautz Motors with Integral
Connectors.............................................................................................31
Figure 25 Wiring Diagram for Sine-cosine Encoders .............................................33
Figure 26 Wiring Diagram for Multi-turn Resolvers ................................................34
Figure 27 Safety I/O and 24 VDC Power Wiring Diagram .....................................35
Figure 28 User Interface to Standard I/O Configuration ........................................36
Figure 29 User Interface to Expanded I/O Configuration.......................................37
Figure 30 DC Bus, Motor Windings, Thermal Protector and Brake Control
Connectors.............................................................................................38
Figure 31 24 VDC Power, Safety and Position Feedback Connectors (The 14, 28
and 50 amp models are wider than shown in this figure) ......................39
Figure 32 EasyBus and User I/O Connectors (The 14, 28 and 50 amp models are
wider than shown in this figure) .............................................................40
Figure 33 Dimensions for SAM Supply 30 amp Models ........................................41
Figure 34 Dimensions for SAM Supply 80 amp Models ........................................42
Figure 35 AC Supply and DC Bus Connections to SAM Supply............................43
Figure 36 Dynamic Braking Resistors Dimensions (all dimensions in mm)...........44
Figure 37 Dynamic Braking Resistor Cable Assembly...........................................45
Figure 38 DB Resistor Circuit Wiring .....................................................................45
Figure 39 SAM Supply Status, Safety and 24 VDC Supply Connections ..............46
Figure 40 Connector Locations and Pin Assignments for 30 amp SAM Supply
Models (X2 connector is available only on SAM-PA-xxx-30-E type) .....47
Figure 41 Connector Locations and Pin Assignments for 80 amp SAM Supply
Models....................................................................................................48
Figure 42 DC Bus bar outlines ...............................................................................49

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PART 2 - SYSTEM DESIGN AND INTEGRATION LIST OF TABLES

Figure 43 Wiring Diagram for DC Bus Bar Assembly ............................................50

Figure 44 DC Bus Arrangement for Small Systems...............................................51
Figure 45 EMC Filter Dimensions ..........................................................................53
Figure 46 Isolation Transformer Configurations.....................................................54
Figure 47 Auto-transformation Wiring Configuration..............................................54
Figure 48 24 VDC Power Distribution ....................................................................55

List of Tables
Table 1 EMC Filter Information ...........................................................................52

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PART 2 - SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING

Grounding and Shielding

About Protective Earth and Functional Earth Grounds
Protective Earth Ground
Protective earth ground is primarily a safety function. Physically, a protective earth
ground is a wire connected on one end to some points in a circuit or to the exterior
metal surfaces of devices. The other end is connected to the earth. In the event
that a short circuit occurs within the device, current flows in the protective earth
ground, preventing the voltage at the grounded point from reaching a dangerous
level with respect to the earth.
In this manual, one or both of the following symbols indicate protective earth
ground connections:

PE
Figure 1 Symbols for Protective Earth Ground

EMC practices and safety requirements have common aspects such as earthing
(grounding), over-voltage protection and lightning protection. Occasionally, the two may
seem to conflict. In such cases, safety requirements must always have precedence
over EMC practices and alternate EMC measures must be sought.

Functional Earth Ground

Functional earth grounds serve primarily to neutralize the electrical charge that
develops in the shields and metal cases enclosing system components. The
currents flowing in functional earth grounds are high frequency; therefore,
conductors with a large surface area such as flat braided cable must be used for
making high quality, low impedance functional earth ground connections.
In this manual, functional earth ground connections are indicated by the following
symbol:

Figure 2 Symbol for Functional Earth Ground

Functional earth grounding is not simply connecting a wire to ground. Since

perturbations are high frequency, current flow is concentrated at the outside surface of
STOP the conductor. Therefore, to have a good functional earth ground connection, a
conductor with a large surface area (such as flat braided cable) must be used.

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PART 2 - SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING

Protective Earth Grounding Requirements

General
This section describes the protective earth (PE) grounding requirements for a PAM
with SAM system. Local, national and international regulations may specify
additional PE grounding requirements. These regulations also specify other
aspects of protective earth grounds including conductor cross-section and color,
connection means at the device and manner of connecting to the earth. PAM with
SAM system users must be aware of and comply with any additional PE grounding
requirements.

AC Supply with Grounded Neutral

Operating a PAM with SAM system from an ungrounded AC Supply is prohibited.

AC Supply system grounding is a crucial consideration. The AC Supply must have

a grounded neutral (see Figure 3).
AC supply PAM with SAM system
L1

L2 Feeding
section SAM
L3 supply

PE

PE Sag014_a.Cdr

Figure 3 AC Supply with a Grounded Neutral

If a three phase, 4 wire, grounded neutral AC Supply is not available, an isolation

transformer with “Wye” connected secondary must be used (see Figure 46). The
secondary neutral (star point) must be solidly connected to protective earth ground
in accordance with applicable regulations.

For additional information on AC Supply grounding, refer to IEC 664-1: 1992-10, Table
i B2 “Three phase, four wire systems with earthed neutral”

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PART 2 - SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING

System, Cabinet and Machine

1. All SAM Drives and SAM Supplies must be connected to PE ground using the
designated PE terminal on each unit (see Figure 4).
2. The 24 VDC supply (negative side) must be connected to PE ground.
3. The PE conductor in each motor winding cable must be connected to PE
ground in the cabinet and to a PE grounding screw at the motor.
Motor cable

PE Conductor
2

Cabinet (min. 10 mm ) Machine

SAM-P SAM-D

Motor
L L

PE
Bus Bar
DC Bus Bar PE Motor
LOAD

EMC Filter
LINE

From Main Supply SAG013_A.CDR

Figure 4 Machine to System Enclosure PE Conductor

Grounding for Electro-magnetic Compatibility

Electro-magnetic compatibility (EMC) is the capability of a part of a system to work
without perturbing (emission) - and being perturbed by (immunity) - the rest of the
system with electromagnetic phenomena. There are a few basic rules.
4. The system cabinet must be designed for EMI/RFI attenuation.
5. The backpanel (equipment mounting panel) must be bare (unpainted). The
areas beneath where the PAM, SAM Drives, SAM Supplies and EMI filters are
mounted, provide intimate metallic contact between the units and backpanel.
When using Aluminum backpanel, avoid surface oxidation treatments.
6. The back panel must be connected to functional earth ground with a high
quality ground connection. Normally the best way to achieve this is with a large
area of metal to metal contact between the back panel and the metal structure

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PART 2 - SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING

of the cabinet. Otherwise, connect the back panel to functional earth ground
using braided wire cable with large surface area.
7. The system cabinet and the machine on which the motors are mounted must
be connected to the functional earth network of the building as illustrated in
Figure 5. If this is not possible, metallic conduits and cable trays carrying motor
and feedback cables may be utilized to create a meshed grounding network
(see Figure 6).
8. Motor windings cables shields must be properly terminated and connected to
functional earth ground (see "Interfacing AC Servomotors" on page 23). On the
motor end, the motor windings cable shields are connected to the motor case
and to the machine's functional earth ground. A large area of metal to metal
contact between the motor and the machine structure is required.

Motor windings cable shields may carry strong, capacitively induced high frequency
currents. These currents are normally routed to earth ground and therefore pose no
danger. Should the user fail to connect a motor cable shield to earth ground, a voltage
potentially dangerous to humans may be present at places that are not at least IP20
protected.

A mesh functional earth network throughout the machine and even throughout the
building is recommended. Each room should have earthing network conductors to
i which the machine structures, enclosures, cable trays, etc. are bonded. Ground loops
are not only allowed, they are an effective EFI/RFI mitigation measure.

Refer also to IEC 1000-5-2 “Installation and Mitigation Guidelines, Earthing and
i Cabling”. This technical report provides valuable information.

Control cabinet
Machine structure

Mesched earthing network EMC003_b.CDR

Figure 5 Mesh Earthing Network Using Building Structure

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PART 2 - SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING

Control Arial conduits

cabinet & cable trays Machine
structure

EMC004_b.CDR

Figure 6 Mesh Earthing Network Using Conduits and Cable Trays

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PART 2 - SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT

Enclosure Layout
Concept for an Entire Machine Control System
Figure 7 illustrates a general concept for an enclosure housing a complete machine
control system where power and control as well as high frequency and low
frequency parts of the system are located in separate areas of the enclosure. In
addition, the cables carrying power, control, high frequency and low frequency
should be separated in the same manner.

Power
Power Power
Low Frequency High Frequency

Control
Control Control
Low Frequency High Frequency

LF HF EMC001_b.cdr

Figure 7 Enclosure Layout Concept

Rules for Enclosure Layout

The following are some general rules for enclosure layout:
1. Power and control devices as well as high and low frequency parts must be
separated and placed in different areas which are a minimum of 30 cm apart
(see Figure 7).
2. To be an effective ground plane, the back panel on which devices are mounted
must not be painted (nor oxidized if Aluminum is used).
3. The contact area between all devices and the ground plane (back panel) must
be as large as possible. When SAM Drives and SAM Supplies are mounted on
the back panel, their cases become part of the ground plane.
4. Power cables must not cross the control area and control cables must not cross
power area.
5. If not shielded, power and the control cables must be minimum of 30 cm apart.
They must be as close as possible to the ground plane (back panel) in order to
reduce the area of the loop they make with it.
6. Shields must be connected to the ground plane or directly to the device with
360° contact (using a cable gland and strain relief, for example). The shield
must not be twisted in “pig tail” fashion and connected to a terminal.

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PART 2 - SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT

7. Where possible, place devices that generate a large quantity of heat toward the
top of the enclosure.

Recommended Layout for a PAM with SAM System

Figure 8 illustrates an implementation of the enclosure layout concept for a seven-
axes PAM with SAM system. The mating connectors for the SAM Drive and SAM
Supply are strategically located to simplify wiring and cable routing with this
arrangement.
For large systems requiring more than one SAM Supply, the DC Bus output (and
associated DC Bus distribution network) for each SAM Supply must remain
electrically isolated from the DC Bus of all other SAM Supplies in the system.
DBR

SAM SAM SAM SAM

PLC
Drive Drive Drive Drive

Aux.
Supply
DC Bus bar

Low frequency
low power
SAM SAM SAM
EMC Filter

machine controls
Supply Drive Drive

DC Bus bar

Fuses

Psg017_b.Cdr

Figure 8 Enclosure Layout for a Large System

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PART 2 - SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT

Rules for Placement of EMC Line Filter

When placing an EMC line filter in the enclosure, use the following guidelines:
1. Keep the length of wiring between filter and SAM Supply as short as possible.
2. The input (line side) of the EMC filter must be as close as possible to the point
where the AC Supply cable enters the enclosure.
3. The EMC Line Filter relies on capacitance between AC Supply conductors and
functional earth. Therefore, the EMC Line Filter must have metal to metal
contact with the ground plane (back panel) over the largest possible area.

Back Panel Layout

Unit Mounting Dimensions and Spacing
Figure 9 illustrates the recommended horizontal and vertical spacing between SAM
Drives/Supplies and adjacent units. The vertical dimensions in Figure 9 indicate the
minimum clearance required for connecting/removing mating connectors (including
cable bend radius). The 1.0-mm horizontal spacing accommodates normal
tolerances in unit width.

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PART 2 - SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT

Other equipment

1.0 mm
60 mm
W Cable Conduit

SocapelSAM SocapelSAM SocapelSAM SocapelSAM SocapelSAM SocapelSAM

L L L L L L

DC-Bus bar
100 mm
1.0 mm Cable Conduit
W

SocapelSAM SocapelSAM

L L

DC-Bus bar
60 mm
Cable Conduit

Other equipment

PSU2_009.CDR

Figure 9 Recommended Spacing and Clearances for SAM Drives and Supplies

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PART 2 - SYSTEM DESIGN AND INTEGRATION PAM

PAM
PAM Full System
General
The PAM Full System (See Figure 10) is housed in a panel-mountable chassis
which requires a single 24 VDC power source. An integral DC/DC converter
provides all other voltages required internally. If the PAM Full Systems includes a
fieldbus interface, the system is supplied with the interface hardware and software
pre-installed in the chassis.
Normally, the 24 VDC power source providing power for the remainder of the PAM
with SAM system is used. For PAM Full System input voltage and current
requirements refer to Part 1 - “Selecting System Components”.
24V DC
supply

Run Indicator (green)

Alphanumeric
Display
Fieldbus/PC104
Interface boards Reset button

Service connector
PAM Module

EasyBus IN
Power Converter
unit EasyBus OUT

(Not used)

RS 422 connector

PAH015_a.CDR

Figure 10 PAM Full System

Fieldbus Interface
Details on interfacing the PAM to a fieldbus are beyond the scope of this manual.
Refer to the technical manual for the selected fieldbus interface, which provides
hardware and software interfacing information.

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PART 2 - SYSTEM DESIGN AND INTEGRATION PAM

Chassis Installation in System Cabinet

The PAM chassis is designed to be panel mounted. Figure 11 shows the chassis
mounting dimensions and recommended clearances. The back panel in the area
beneath the chassis must paint free as illustrated in Figure 12 to provide intimate
contact between the chassis and back panel for EMI/RFI mitigation.
157
139

38
3 free 2TE 3U
front panels

All dimensions are mm

190
Allow min. 50 mm clearance
287

above and below chassis

for air flow

Allow min. 70 mm clearance

in front of chassis for
connectors

Power Supply

3
24
116
PAH008_d.cdr

Figure 11 PAM Chassis Mounting Dimensions and Clearances

Cabinet's back panel

No paint here !!!

24V DC
Source For EMC rack must
be securely attached
to back panel at these
four mounting points

For EMC PAM Module

must be securely attached
to chassis with four
attaching screws

PAH020_a.CDR

Figure 12 EMI/RFI Requirements when Installing PAM Chassis

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PART 2 - SYSTEM DESIGN AND INTEGRATION PAM

PAM-ISA
General
The PAM-ISA (see Figure 13) is intended for direct installation in an ISA Bus slot of
a PC. For installation and interfacing information, refer to Part 4 - “PAM Technical
Information”.
Fault Indicator
(red)

Run Indicator
(green)

Address
jumpers

FATAL ERROR Service

output connector
EasyBus IN EasyBus OUT

Pah013_a.cdr

Figure 13 The PAM-ISA

PAM for Simatic Module

General
The PAM for Simatic module (see Figure 14) is intended for direct installation into
Siemens’ Simatic S5 PLC chassis. Two configurations of PAM module are
available. The PAM module integrated into a plastic housing is for use in the
Simatic S5-115. The PAM module with no plastic housing is for use with Simatic
S5-135 and S5-155 models.

Run indicator (green)

Run indicator (green) Alphanumeric

Display
Alphanumeric
Display Reset button

Reset button Service connector

Service connector
EasyBus IN
EasyBus IN
EasyBus OUT
EasyBus OUT
(Not used)
(Not used)
RS 422 connector RS 422 connector
PAH016_b.cdr PAH016_a.CDR

Figure 14 PAM Modules for Simatic S5-115 (left), S5-135 and S5-155 (right)

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PART 2 - SYSTEM DESIGN AND INTEGRATION EASYBUS

EasyBus
General
The EasyBus is constructed of fiber optic cable assemblies that link a PAM and all
SAM Drives in a PAM with SAM system. Three types of EasyBus cable assemblies
are used including:
− Standard duty plastic fiber cables
− Long distance fiber cables
− Kevlar reinforced plastic fiber cables
Refer to Part 1 - “Selecting System Components” for more information

Installation
The following guidelines should be observed when handling and installing EasyBus
Cables:
1. Handle the cables carefully. Kinks and bends below the minimum bend radius
can destroy the cable.
2. When making EasyBus connections, finger-tighten the connectors only. Never
use a wrench as the tightening torque would be too great.

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

SAM Drive
Mounting a SAM Drive
General
SAM Drives are designed for panel mounting. Mounting tabs above and beneath
the unit are provided for securing the unit to the back panel. The mounting tabs are
pre-punched with slots for M4 screws.

Setting the EasyBus Node Address

Each SAM Drive must have a unique node address, which assigns a physical drive
to logical axis references in the application program. Two sixteen position rotary
switches "Node Address (LSB)" and "Node Address (MSB)" (See Figure 32 on
page 40) set the Node Address. It is generally easier to set the Node Address
switches prior to mounting the SAM Drive.

Chassis Installation in System Cabinet

See “Back Panel Layout” (page 14) for details on laying out the mounting panel for a
PAM with SAM system.
STOP For effective EMI-RFI shielding, the SAM Drive must make metal to metal contact with
the back panel over the largest possible area. Therefore, the back panel must be
unpainted beneath the area where the SAM Drive contacts the back panel.

SAM Drive dimensions are illustrated in Figure 15, Figure 16, and Figure 17. The
mounting tabs for all model SAM Drives and Supplies are slotted for M4 screws.

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

260
229
202
178
136

38
47

20
202 61
250

30
49

SocapelSAM
283

357
379
L

23

137
47

2
285 30

X33(Rx) X17
218 X35(Tx)
22 X32
X31 X23
Socapel SAM
X24

l X29
111
15
39

16
202 X12 X11
234 X13
X14 Sah076_a.cdr

Figure 15 Dimensions for SAM Drive 7 amp Models

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

2 0
229
202
178
136

202 140
38
47

20
2 0
105
70
49

SocapelSAM
283

379

357
L

23

137
36
47

2 70
285
105

X33(Rx)
X17
X35(Tx)
X32
93

X31 X23
75

Socapel SAM
X24

122 l X29
190
02
X13
234 X11 X12 X14
Sah077_a.cdr

Figure 16 Dimensions for SAM Drive 14 & 28 amp Models

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

2 0
229
202
178
136

269
202 234
38
47

20

2 0
105
70 70
49

SocapelSAM
283

379

357 L

23

137
36
47

2
70 70
285
105
234
221

X33(Rx)
208

X17
X35(Tx)
X32 X23
X31 X24
Socapel SA M

X29
l

122
1 0
02 X13
X11 X12 X14
234
Sah078_a.cdr

Figure 17 Dimensions for SAM Drive 50 amp Models

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Interfacing AC Servomotors
General
This section includes instructions and wiring diagrams specific to servomotor
families that were offered together with the PAM and SAM System in the beginning
of 1999, namely the “AC Servomotors” and the “Bautz” motors.
For interfacing other motors, the information in this section may be useful but not
completely applicable.

Motor-mounted Thermal Protector

The thermal protector is optional and not provided in all motors. When the thermal
protector is either not present or not used other steps must be taken to prevent the
SAM Drive operating software from interpreting no thermal protector as a motor
over-temperature error. The following solutions are available:
− Simulate the thermal protector closed (motor temperature in range) by
inserting a wire jumper from X13-2 to X13-3
− In software, modify the SAM Drive Action Masks to prevent the motor thermal
protection input (Status B7) from initiating a Stop action

Thermal modeling of the axis motor by the SAM Drive operating software is the primary
motor overload protection mechanism. The thermal protector mounted in the motor
provides secondary protection in the event that the thermal model is incorrect due to
i environmental factors such as heavy accumulation of dust on the motor, high ambient
temperature, poor air circulation, etc.

Brake Control
An external 24 VDC source is required for powering a motor-mounted brake. In
some applications, additional user interlocks are inserted in the brake control
circuit. The brake control (connector X14) and associated wiring are options that
are not present in every configuration.

Interfacing Servomotor types with “C33”-type Terminal Boxes

Figure 19 is applicable for interfacing to all “AC Servomotors” that use a terminal
box for motor winding connections (“C33” option). This includes motor types
AHD92, AHD115, AHD142, AHD190, AHR92, AHR115, AHR142 and AHR190.
Two motor windings cable configurations (see Figure 20) are used depending on
the SAM Drive model. The wire colors shown in Figure 19 are for motor windings
cables that are supplied together with the PAM and SAM System. The cable gland
on the motor end is easily removable when necessary to pull cables through
conduit or bulkheads.
For safety, compliance with EMC regulations and satisfactory performance, it is
imperative that SAM Drive to motor wiring be exactly as illustrated in Figure 19.

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Please note and observe the following instructions and precautions when
performing SAM Drive to motor wiring.
1. On the motor flange end, there should be a large area of metallic contact (bare
metal) where the motor’s mounting face contacts the machine.
2. The motor end of the motor windings cable shields must be properly terminated
in a cable gland and the cable gland must make good metallic contact with the
terminal box. Figure 18 shows correct preparation of the cable shields for
termination in a cable gland.
3. On the SAM Drive end, the screws that secure the cable bracket (and in some
cases connector X12) to the SAM Drive must be threaded into the captive nuts
on the SAM Drive and tightened because they serve to ground the shield at the
SAM Drive end.
Outer metal Inner plastic Outer nut
sleeve sleeve

EMC005_B.cdr

Figure 18 Shields Termination in Cable Gland

There must be metallic contact between the cable shield and cable gland around the
whole circumference of the shield. Pigtails degrade the high frequency noise
! suppression considerably and are not permitted.

The shield must be earthed (grounded) at both ends. High voltage may be present on
the shield if either end is left ungrounded.

Machine builders who prefer to fabricate their own motor winding cables should refer to
i Part 1 - Selecting System Components, which provides some recommendations
regarding cable and mating plug selection.

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 25
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Protective earth rail Cable braket

Motor earth
grounded through attaching screw
machine structure

Green & Yellow

X12
U Black 1 U

V Black 2 V IGBT
Driver
W Black 3 W

Θ X13
K1 Yellow 2
Temperature
Θ sensor
K2 Green 3
Thermal protector interface

Braun

White X14
5 Brake
control
(option)
Feedback Cable gland
4

Terminal box

Cable gland Driver

W V U Temp.ctrl Brake & bracket
2
Brake
1
PE
User
interlocks

+24 VDC
Feedback Supply
connector
- + SAH055_b.Cdr

Motor windings - feedback cable

cable

Figure 19 Wiring Diagram for “AC Servomotors” with Terminal Boxes (“C33” option)

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

SAM-DA-...-07 & 14

SAM-DA-...-28 & 50

Sah061_b.cdr

Figure 20 Motor Windings Cable Configurations

Interfacing Servomotor types with Integral Mating Connectors

Figure 21 is applicable for interfacing Servomotor types with integral mating
connectors for motor winding connections. This includes motor types AHD55,
AHD70, M254 and M506. The wire colors shown in Figure 21 are for motor winding
cables that are supplied with the PAM and SAM System.
The plug-fitted motor windings cable configuration (see Figure 22) is used for
interfacing to the SAM SA-400-07 & 14 models. The connector assembly on the
SAM Drive end is removable when necessary to pull cables through conduit or
bulkheads. For safety, compliance with EMC regulations and satisfactory
performance, it is imperative that SAM Drive to motor wiring is exactly as illustrated
in Figure 21.

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 27
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

On the motor end, there should be a large area of metallic contact (bare metal)
where the motor’s mounting face contacts the machine. On the SAM Drive end, the
screws that secure the cable bracket (and in some cases connector X12) to the
SAM Drive must be threaded into the captive nuts on the SAM Drive and tightened
because they serve to ground the shield at the SAM Drive end.

The shield must be earthed (grounded) at both ends. High voltage may be present on
the shield if either end is left ungrounded.

Protective earth rail Cable braket

Motor earth
grounded through attaching screw
machine structure

2 Green & Yellow

X12
1 Black 1 U

3 Black 2 V IGBT
Driver
4 Black 3 W

Θ X13
A Yellow 2
Temperature
Θ sensor
B Green 3
Thermal protector interface

D Braun

C White X14
5 Brake
control
(option)
Feedback Connector
shell 4
Connector

Cable gland Driver

& bracket
B C (as seen from the 2
A D crimp side of the
4 mating plug) Brake
1 2 3 1

User
interlocks

+24 VDC
Supply
- + SAH073_b.Cdr

Figure 21 Wiring Diagram for motors with Integral Mating Connectors

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

to PE bar

Sah082_b.cdr

Figure 22 Plug-fitted Motor Winding Cable Assembly

Interfacing Standard Resolvers

General Information
This section includes instructions and wiring diagrams specific to servomotor
families that were offered together with the PAM and SAM System in the beginning
of 1999, namely the “AC Servomotors” and the “Bautz” motors.
For interfacing other motors, the information in this section may be useful but not
completely applicable.

Interfacing Servomotor types with “C33”-type Terminal Boxes

Figure 23 shows the resolver cable configuration for all “AC Servomotors” that use
a terminal box for motor winding connections (“C33” option). This includes motor
types AHD92, AHD115, AHD142, AHD190, AHR92, AHR115, AHR142 and
AHR190. On the motor end, the resolver connections are terminated in an eight (8)
pin connector in a separate compartment of the terminal box. To make the resolver
connections on the motor end, perform the following steps:
1. Remove the cable gland outer metal sleeve (see Figure 18) from the feedback
cable.
2. Insert the cable gland outer metal sleeve into the mating hole in the terminal
box and secure it to the terminal box with the locking nut.
3. Insert the rectangular connector of the feedback cable through the cable gland
outer metal sleeve and mate it with the resolver feedback connector.
4. Insert the cable gland inner plastic sleeve into the cable gland outer sleeve. For
satisfactory performance and compliance with EMC regulations, it is imperative
that the feedback cable shield is terminated as illustrated in Figure 18.

There must be metallic contact between the cable shield and cable gland around the
whole circumference of the shield. Pigtails degrade the high frequency noise
! suppression considerably and are not permitted.

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P/n 9031 011 982, October 6, 2000 Page: 29
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

5. Tighten cable gland outer nut.

6. On the SAM Drive end, plug the mating connector into X24.

Cable gland

Shield connected to SAM drive

case via copper banding, connector
shell and mounting screw

Terminal Shield connected

box to terminal box X24
via cable gland
5 Ua -

Resolver 4 Ua+

3
1 Green 9 Sin a2
8 Yellow 8 Sin a1
4 Pink 7
3 Grey 6
Cos a1

1 Brown 2 U Gen a1
2 White 1 U Gen a2

terminal box Resolver

W V U Temp.ctrl Brake
Feedback
connector
SAH062_b.Cdr

PE
7 1
8 2
(motor-side connector;
pin arrangement is the
same when looking
from the crimp side
of the mating plug)
- feedback cable

Figure 23 Resolver Feedback Interface for AC Servomotors with Terminal Boxes

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Interfacing Servomotor types with Integral Mating Connectors

For interfacing Servomotor types with integral mating connectors (motor types
AHD55 & AHD70 and M254 & M506), simply connect the resolver feedback cable
to its mating connectors on the motor and SAM Drive as illustrated in Figure 24.

9 (as seen from the

8 1 crimp side of the
12 10 mating plug)
7 2
6 11 3 Shield connected to SAM drive
5 4 case via copper banding, connector
shell and mounting screw

Shield connected
to motor case via
cable gland and
X24
connector shell
5 Ua -

Resolver 4 Ua+

3
3 Green 9 Sin a2
4 Yellow 8 Sin a1
Pink
1 7
Gray
2 6
Cos a1

5 Brown 2 U Gen a1
6 White 1 U Gen a2

SAH063_b.cdr

Figure 24 Resolver Feedback Interface for ACC & Bautz Motors with Integral Connectors

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 31
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Interfacing Sine-Cosine Encoders and Rulers

Guidelines for Mechanical Integration
Several motors with Sine-Cosine Encoders are available together with the PAM and
SAM System. When using a linear motor, or a direct-drive, “torque” motor, the user
has to assemble the encoder by himself. These recommendations cover this kind of
applications, and are valid for Rulers as well as for Encoders.

Users performing their own integration of a feedback device with a motor must pay
close attention to the mechanical interface. Misalignment, backlash and other
! interfacing errors translate to position error at the motor shaft. Any resonance should be
carefully damped.
In order to realize the high precision and high servo stiffness possible with high
resolution sine-cosine encoders, particular care and attention must be paid to the
mechanical interface with the motor. ACC offers the following recommendations:
− Often, the best solution is to install the encoder rotating and stationary parts
directly onto the motor shaft and into the motor housing respectively.
− When using a coupling between motor end encoder, select a very stiff, zero
backlash coupling. Belt coupling is to be avoided.
− A statoric coupling is preferred over a rotoric type coupling such as a bellows.
− Mechanical misalignment between motor shaft end encoder induces a periodic
positioning error proportional to the severity of misalignment. Design the
mechanical interface to minimize misalignment and maintain the encoder
securely in alignment with the motor shaft.
− For applications requiring very high servo stiffness, please contact ACC for
application assistance.

Electrical Interface
Figure 25 shows the wiring diagram for interfacing sine-cosine encoders that are
supplied together with the PAM and SAM System.

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

11 1 (as seen from the

10 12 2 crimp side of the
16 13 mating plug)
9 15 17 14 3
8 4
7 6 5
c
Shield connected to SAM drive
ase via copper banding, connector
shell and mounting screw
Shield connected
to motor case via
cable gland and
connector shell

X23
7 Gray-Pink 18
A5
1 Gray 17
S5
Encoder 10 Red-Blue 3
Pink 16
4 S0
Green 6
15 Cos C2
Yellow 19
16
Blue 7
12
Sin C2
Red 20
13 Sin C1
14
White 2
Data
Braun 15
17 / Data
Black 1
8 Clk
Violet
9 14
/ Clk

SAH075_b.cdr

Figure 25 Wiring Diagram for Sine-cosine Encoders

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 33
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Interfacing Multi-turn Resolvers

Figure 26 shows the wiring diagram for interfacing multiturn resolvers that are
supplied together with the PAM and SAM System
11 1 (as seen from the
10 12 2 crimp side of the
16 13 mating plug)
9 15 17 14 3
8 4
7 6 5

Shield connected to SAM drive

acase via copper banding, connector
shell and mounting screw

Shield connected
to motor case via
cable gland and X24
connector shell
5 Ua -

4 Ua+

3
15 Green 9 Sin a2
16 Yellow 8 Sin a1
Blue 7
12
13 Red 6
Cos a1

Braun-Green (Brown)
3 2 U Gen a1
2 White-Green (White) 1 U Gen a2

X23
7 Gray-Pink 18
A5
1 Gray 17
S5
Encoder 10 Red-Blue 3
Pink 16
4 S0
Green 6
15 Cos C2
Yellow 19
16
Blue 7
12
Sin C2
Red 20
13 Sin C1
14
White 2
Data
Braun 15
17 / Data
Black 1
8 Clk
Violet
9 14
/ Clk

PSU2_003.cdr

Figure 26 Wiring Diagram for Multi-turn Resolvers

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Safety I/O & 24 VDC Supply

24 VDC power for the SAM Drive and user safety functions interface through
connector X17. Safety inputs are isolated from internal SAM Drive electronics and
share a common return line.
Figure 27 illustrates a typical wiring diagram. Refer to Part 3 - “Safety and
Protective Functions” for a functional description of User Stop inputs and the Fatal
Error output. Refer to Part 5 - “SAM Drive Technical Information” for safety
input/output signal specifications and 24 VDC power requirements.
+24 VDC
Supply
- + X17 SAM Drive
Power Board
1
DC Internal
2 Supply
DC
User STOP0 (Input) 3
No current activates 10 mA Stop0
Stop functions 4 (typ.)

User STOP1 (Input) Stop1

5

Safety chain Fatal Error relay is closed when Fatal Error

no fatal error condition exists 6

SAH031_B.CDR

Figure 27 Safety I/O and 24 VDC Power Wiring Diagram

User I/O
General
Two User I/O configurations, standard and expanded I/O, are available depending
on the SAM Drive model. SAM Drive models SAM-DA-400-…-…-E incorporate the
standard User I/O configuration and SAM-DA-400-…-…-F models have the
expanded User I/O configuration.
All user inputs and outputs are isolated from the internal SAM Drive electronics and
share common power and ground return lines. LED indicators located on the SAM
Drive front panel display the state of each input/output. Refer to Part 5 - “SAM Drive
Technical Information” for user input and output signal specifications.

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 35
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Standard User I/O Configuration (“E” option)

Figure 28 illustrates a typical interface to the standard I/O configuration. For all
signals except USER FAST IN 1, the user connection may be made to either
connector X31 or X32.
Signals applied to USER FAST IN 1 should be high quality, “clean” signals with sharp
rising and falling edges, no bounce and no ringing. They require shielded
connections and can be thus connected only to X32 (D-sub type connector).

X32
User OUT 1 9

User IN 3 8

N/C 7

User IN 2 6

N/C 5

4 0L
GND ext.

User fast IN 1 3
Sensor

GND ext. 2

24 VDC ext. 1

X31
User OUT 1 5

User IN 3 4

User IN 2 3 0L

GND ext. 2
+ -
I/O PWR
24 VDC ext. 1

+24 VDC
Supply
- + SAH065_B.CDR

Figure 28 User Interface to Standard I/O Configuration

PAM with SAM System Users Handbook

Page: 36 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Expanded User I/O Configuration

Figure 29 shows the functional schematic for the expanded user I/O option. With
this configuration, four (4) user I/O (X32-12, 11, 10, and 9) are user-configurable to
function as inputs or outputs.

X32
User OUT 4 16

0L

User OUT 3 15

0L

User OUT 2 14

0L

User OUT 1 13

0L

User OUT 8
User IN 10 12
0L

User OUT 7
User IN 9 11
0L

User OUT 6 10
User IN 8 0L

User OUT 5 9
User IN 7 0L

User IN 6 8

User IN 5 7

User IN 4 6

User IN 3 5

User IN 2 4
0L
3 Fault 4
User IN 1

GND ext. 2
+24 VDC I/O PWR
Supply 24 VDC ext. 1
- +
SAH066_B.CDR

Figure 29 User Interface to Expanded I/O Configuration

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 37
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

Connector Pin Assignment

DA -xxx-07x-xxx-x DA-xxx-14x-xxx-x
X14 Brake option X14 Brake option

24VDC Ext 1 24VDC Ext 1

GND Ext 2 X14
GND Ext 2
n/c 3 n/c 3 X14
Brake 1 4 Brake 1 4
Brake 2 5 Brake 2 5

X13 X13 X13

X13
n/c 1 X12
Mot Temp 1 n/c 1
2 Mot Temp 1
Mot Temp 2 3 2
Mot Temp 2 3
X11 X12
X12 female X11
X11 male
Motor Phase U 1
DC Bus - 3
Motor Phase V 2
DC Bus + 2
Motor Phase W 3
DC Bus PE 1
X11 male
X12 female
DC Bus - 3
Motor Phase U 1
DC Bus + 2 2
Motor Phase V
DC Bus PE 1 3
Motor Phase W

DA-xxx-50x-xxx-x
X14 Brake option

24VDC Ext 1
GND Ext 2
n/c 3 X14
Brake 1 4
Brake 2 5

X13 X13

n/c 1
Mot Temp 1 2 X11/X12
Mot Temp 2 3

X11 / X12
DC Bus - -
DC Bus + +
DC Bus PE
Motor Phase 1 U
Motor Phase 2 V
Motor Phase 3 W

PSU2_004.cdr

Figure 30 DC Bus, Motor Windings, Thermal Protector and Brake Control Connectors

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

DA -xxx-xxx-P4N-x

X17

1 24 VDC Ext.
2 GND Ext. X17 X23 female
3 STOP0
4 STOP1 n/c 1
14 n/c
Fatal Error n/c 2
15 n/c
5 n/c 3
Fatal Error 16 n/c
6 n/c 4
n/c 5 17 n/c
n/c 6 18 n/c
19 n/c
n/c 7
20 n/c
n/c 8
21 n/c
n/c 9
22 n/c
Ua +10V 10
23 Ua -10V
n/c 11 24 n/c
n/c 12 25 n/c
n/c 13

U Gen a2 1
2 6 COS a1
U Gen a1
n/c 3 7 COS a2
8 SIN a1
Ua +10V 4
9 SIN a2
Ua -10V 5

DA-xxx-xxx-P5N-x

X17

1 24 VDC Ext.
GND Ext. X17 X23 female
2
3 STOP0
Clk 1 14 _Clk
4 STOP1 Data 2 15 _Data
5 Fatal Error A0 3
+12 VDC 4 16 S0
6 Fatal Error n/c 5 17 S5
Cos c2 6 18 A5
Sin c2 7 19 Cos c1
Piref 2 8
20 Sin c1
Cos d2 9 21 Piref 1
Sin d2 10 22 Cos d1
Error 11 23 Sin d1
24 En_latch
Pol Piref 12 25 Mux_LR
n/c 13

U Gen a2 1
2 6 COS a1
U Gen a1
n/c 3 7 COS a2
4 8 SIN a1
Ua +10V 9 SIN a2
Ua -10V 5

PSU2_005.cdr

Figure 31 24 VDC Power, Safety and Position Feedback Connectors

(The 14, 28 and 50 amp models are wider than shown in this figure)

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 39
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM DRIVE

DA -xxx-xxx-xxx-E DA-xxx-xxx-xxx-F

Node Address (LSB) Node Address (LSB)

X33 EasyBus Rx X33 EasyBus Rx

Node Address (MSB) Node Address (MSB)

X35 EasyBus Tx X35 EasyBus Tx

X17 X17
X32
X32 Male

n/c 5
9
Gnd Ext. 4 16 OUT 4
8
Fast Input IN 1 3
7 n/c 15 OUT 3
Gnd Ext. 2 14 OUT 2
24 VDC Ext. 1
1 6 IN 2
13 OUT 1
12 IN 10 / OUT 8
11 IN 9 / OUT 7
X31 X32
10 IN 8 / OUT 6
9 IN 7 / OUT 5
8 IN 6
5 OUT 1 7 IN 5
4 IN 3 6 IN 4
3 IN 2 5 IN 3
2 GND Ext. 4 IN 2
1 24 VDC Ext. 3 IN 1
2 GND Ext.
1 24 VDC Ext.

PSU2_006.cdr

Figure 32 EasyBus and User I/O Connectors

(The 14, 28 and 50 amp models are wider than shown in this figure)

PAM with SAM System Users Handbook

Page: 40 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

SAM Supply
Chassis Installation in System Cabinet

See “Back Panel Layout” (page 14) for details on laying out the mounting panel for a
PAM with SAM system.
STOP For effective EMI-RFI shielding, the SAM Supply must make metal to metal contact with
the back panel over the largest possible area. Therefore, the back panel must be
unpainted beneath the area where the SAM Drive contacts the back panel.

Figure 33 and Figure 34 show dimensions for 30 and 80 amp SAM Supply models.

62

122
15

30
48

Socapel SAM
282

377

357

L
47

2
281
X7

22 Socapel SAM

106
X1 X5
15

166
PSU2_001.dsf

Figure 33 Dimensions for SAM Supply 30 amp Models

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 41
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

136

140

48
105
70
48

Socapel SAM
282

377

357
L
36
47

2
281
X7

Socapel SAM

122 X1/X5
140 X2
PSU2_002.dsf

Figure 34 Dimensions for SAM Supply 80 amp Models

AC Supply Input
Figure 35 illustrates three phase AC Supply connections to a SAM Supply. The AC
Supply voltage applied to a SAM Supply must meet the following requirements:
1. The voltage must be within the limits specified for the SAM Supply model (see
Part 1 - “Selecting System Components”).
2. The AC Supply must have a grounded neutral (see Protective Earth Grounding
Requirements on page 8).
3. The Feeding Section must provide the necessary short-circuit and over-current
protections (i.e. fuses or circuit breaker).
4. Necessary safety and interlocks must be built into the AC Supply input circuit
(see Part 3 - “Safety and Protective Functions”).

Operating a PAM with SAM system from an ungrounded AC Supply is prohibited.

PAM with SAM System Users Handbook

Page: 42 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

SAM SAM SAM

Drive Drive Drive

SAM
Supply DC Bus
L1 L1
+
L2 L2 -
Feeding X1
Section L3 L3
PE Rail
PE PE
On 80 amp
X5 models, X1
and X5 are
terminal Sah080_a.cdr
blocks

Figure 35 AC Supply and DC Bus Connections to SAM Supply

DC Output
The SAM Supply produces DC power at high voltage (up to 800 VDC) and current
levels for use by SAM Drives in powering axis motors. Distribution of this DC power
to the SAM Drives is the function of the DC Bus (See DC Bus, page 49).

External Dynamic Braking Resistor

General
SAM Supply models SAM-PA-…-…-E require an external DB resistor for
dissipating excess regenerated energy from motors when it cannot be immediately
reused by other SAM Drives. SAM Supply models SAM-PA…-30-I have an internal
DB resistor. For these models, no external DB resistor is used.

DB Resistor Installation and Mounting

If the average braking power "PBRAKE_AV_TOTAL" (see Part 1 - System Component
Selection”) is high, the DB resistor should be placed outside of the equipment
enclosure in order to reduce the heat load within the enclosure, and thus simplify its
cooling. Heavy wire mesh encloses the top and sides of the DB Resistor assembly
to prevent accidental exposure to high temperature and high voltage present on the
resistors. Figure 36 shows the overall size and mounting dimensions for the various
DB Resistor types.

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 43
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

L B (1600 W)

F E B (400 & 800 W)

l
Cable length: 3m

b FWA
D

D FWDA

Power L B H A D E F b x l Weight
400 W 450 60 85 430 30 404 23 5.5 x 9 2.6 kg

800 W 550 80 116 530 40 504 23 6.5 x 9 4.7 kg

1600 W 550 180 116 530 90 504 23 6.5 x 9 5.6 kg

saa004_b.dsf

Figure 36 Dynamic Braking Resistors Dimensions (all dimensions in mm)

Wiring Information
DB Resistors are supplied with a 3-meter long, shielded cable attached to it, and a
connector kit for attaching to the SAM Supply plug. The SAM Supply end of the
cable is left unterminated to facilitate routing the cable and to permit trimming to
required length before installing the supply end connector. Trim the cable to the
required length, then assemble the connector as follows:
1. Insert the cable gland components onto the cable as shown in Figure 18.
2. Fold the cable shield back over the cable gland inner plastic sleeve as shown in
Figure 18.

There must be metallic contact between the cable shield and cable gland around the
whole circumference of the shield. "Pigtails" degrade high frequency suppression
! considerably and are not permitted.

PAM with SAM System Users Handbook

Page: 44 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

3. Install the cable gland, connector X2 and attaching screws into the bracket as
shown in Figure 37.
4. Terminate the conductors in connector X2 using the wiring diagram in Figure
38.
5. Tighten the cable gland outer nut.
6. Plug the assembled cable into the mating connector X2 on the SAM Supply.
Bracket
to PE bar

Connector X2
Cable gland SAH087_a.CDR

Figure 37 Dynamic Braking Resistor Cable Assembly

Cable gland
& bracket
SAM Supply X2
4 Brown
3 White
RID

DB Resistor
IGBT 2 Black2
Error/Fault
Logic

1 Black1
Green-Yellow
DC Bus +
DC Bus -

PE bar SAH040_b.CDR

Figure 38 DB Resistor Circuit Wiring

Safety, Status and 24 VDC Supply

Status Outputs
The SAM Supply provides four (4) PLC compatible status/error outputs (see Figure
39) including:
− Dynamic Braking Resistor Overload
− Over Temperature
− Over Voltage
− DC Bus Low

PAM with SAM System Users Handbook

P/n 9031 011 982, October 6, 2000 Page: 45
PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

They are normally monitored by a PC/PLC performing overall machine control.

Figure 39 illustrates a typical circuit. The status outputs are isolated from the SAM
Supply internal electronics and share a common connection to 24 VDC power. For
a detailed description and electrical specifications of these status outputs, refer to
Part 6 - “SAM Supply Technical Information”.

Fatal Error Output

Fatal Error is an isolated relay contact intended for use in implementing machine
level safety interlocks. See Part 3 - “Safety and Protective Functions” for further
information.

24 VDC Supply
The SAM Supply requires 24 VDC power for its internal operation. All required
internal voltages are derived from the 24 VDC supply. Refer to Part 1 - “Selecting
System Components” for 24 VDC power supply requirements.
X7 SAM Supply
1
+
+24 VDC DC Internal
Supply 2 Supply
- DC

Safety chain Fatal Error relay is closed when

no fatal error condition exists 5

Over Voltage 3

Reset (Input) 6

DC Bus Low 7

8
n/c

Over Temp
9

DBR Overload 10

Machine
control PC/PLC
SAH038_C.CDR

Figure 39 SAM Supply Status, Safety and 24 VDC Supply Connections

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

Connector Locations and Pin Assignments

PA-xxx-30x-x

X2 DBR Overload 10
Over Temp 9
n/c 8
DC Bus Low 7
Reset In 6
Fatal Error 5
X1 Fatal Error 4 X7
Over Voltage 3
X2 female, optional GND Ext. 2
24 VDC Ext. 1
X5 1 DC+
2 Shunt IGBT
X7
3 ID Res
4 ID Res

- DC Bus -
+ DC Bus +

X5 male
PE PE
L1 Phase L1
Bottom view L2 Phase L2 Top view
L3 Phase L3 PSU2_007.cdr

Figure 40 Connector Locations and Pin Assignments for 30 amp SAM Supply Models
(X2 connector is available only on SAM-PA-xxx-30-E type)

PAM with SAM System Users Handbook

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PART 2 - SYSTEM DESIGN AND INTEGRATION SAM SUPPLY

PA-xxx-80x-E
X2 female
X2 4 ID Res
3 ID Res
2 Shunt IGBT
1 DC+

X5 / X1
X5 / X1
L1 Supply Phase 1 X7
L1 L2 L3 - +
L2 Supply Phase 2
L3 Supply Phase 3
DC Bus PE
- DC Bus -
+ DC Bus +
X7

DBR Overload 10
Over Temp 9
n/c 8
DC Bus Low 7
Reset In 6
Fatal Error 5
Fatal Error 4
Bottom view Over Voltage 3 Top view
GND Ext. 2
24 VDC Ext. 1
PSU2_008.CDR

Figure 41 Connector Locations and Pin Assignments for 80 amp SAM Supply Models

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Page: 48 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION DC BUS

DC Bus
General
The DC Bus distributes DC Power at high voltage and current levels from a SAM
Supply to SAM Drives. The DC Bus voltage (DC Bus + to DC Bus –) can be as high
as 800 VDC and the DC Bus must be totally isolated from ground. In systems with
multiple SAM Supplies, the DC Bus for each SAM Supply must remain totally
isolated from the DC Busses of all other SAM Supplies.

High DC Bus voltage ranging from 550 to 800 at high power level is present at the SAM
Supply and on the DC Bus. This high voltage is stored in large capacitors, which retain
the high voltage after the AC Supply is switched off. Wait 60 seconds after removing AC
Supply before touching any component carrying DC Bus voltage.

DC Bus Bar Assembly

General
This paragraph provides installation and interfacing instructions for the PAM and
SAM System Bus Bar assembly.

Installation

Figure 42 DC Bus bar outlines

Wiring
Figure 43 shows the wiring diagram for the DC Bus Bar assembly. Additional PE
Ground nodes are provided on the DC Bus Bar assembly for the PE ground
conductors of motor winding cables.

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PART 2 - SYSTEM DESIGN AND INTEGRATION DC BUS

L1/2/3

PE

EMC SAM-PA Supply SAM-DA SAM-DA

Filter Drive Drive

X5 X1 X2 X11 X12 X11 X12

DC-bus +-
bar PE

PSU1_005.doc D. B. Resistor Motor Motor

Figure 43 Wiring Diagram for DC Bus Bar Assembly

DC Bus Bar plugs are not keyed. It is physically possible to insert any plug into any
connector. The user must verify by inspection that all connections to the DC Bus Bar
! are correct before applying power to the SAM Supply.

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Page: 50 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION DC BUS

Low Power Applications

For small systems (i.e. a PA-…-30-… and 1 to 3 SAM Drives) a simple DC Bus can
be constructed using daisy chained wiring from the SAM Supply to SAM Drives in
combination with a simple earth ground rail. The PE rail can be a simple Copper
bar; it does not have to be IP20 protected, as it is solidly at earth potential. Figure
44 illustrates the circuit schematically.

SAM SAM SAM

Drive Drive Drive
On 28 and 50
amp SAM Drives,
X11 is a terminal
block - + PE - + PE - + PE
X11 X11 X11
Feeding
Section
SAM
Supply
L1 L1 +
-
L2 L2 X1

L3 L3
PE PE
On 80 amp
X5 models, X1
PE rail
and X5 are
terminal PE grounding conductors
blocks from motor windings cables

Sah068_c.cdr

Figure 44 DC Bus Arrangement for Small Systems

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PART 2 - SYSTEM DESIGN AND INTEGRATION FEEDING SECTION

Feeding Section
Basic Circuit
The Feeding Section includes all components of the AC Supply circuit between the
AC Supply and the SAM Supply. Refer to Part 1 - “Selecting System Components”
and to Part 3 - “Safety and Protective Functions” for details on sizing and selecting
Feeding Section components.

The AC Supply to a PAM with SAM system must have a grounded neutral. Operating a
! PAM with SAM system from an ungrounded AC Supply is prohibited.

Installing an EMC Line Filter

When installing an EMC filter, refer to Rules for Placement of EMC Line Filter on
page 14. The connection method for making load and line side connections is via
wire leads or terminal blocks depending on the model. Table 1 lists the connection
method and conductor cross section for each model. Refer to Figure 45 for EMC
filter dimensions.
The EMC filter relies on capacitance between AC Supply conductors and functional
earth. Therefore, the EMC line filter must have metal to metal contact with the
ground plane (back panel) over the largest possible area.

If a Ground Fault Interrupter is used in the Feeding Section, The leakage current for
STOP
each EMC filter must be taken into account (see Table 1).

p/n model current rating leakage Line side Load side

@ 40°°C (50°°C) current connections connections
9032 011 149 FN 258-30/07 36 (30) ARMS 104 mA Terminals Wires AWG 10
2 2
1 - 10 mm 5.37 mm
9032 011 150 FN 258-75/34 90 (75) ARMS 113 mA Terminals Terminals
2 2
10 - 25 mm 10 - 25 mm
Table 1 EMC Filter Information

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PART 2 - SYSTEM DESIGN AND INTEGRATION FEEDING SECTION

p/n 9032 011 149 p/n 9032 011 150

(FN258-30/07) (FN258-75/34)

60

80
150
220

35 55
1 1 M6
M5

LINE LINE

314

329
320

335

300
305

LOAD LOAD
400

M6

6.5
9

6.5

80

220

saa002_b.dsf
All dimensions in mm

Figure 45 EMC Filter Dimensions

Interfacing a Transformer
When a Transformer is Required
A transformer is required under any of the following circumstances:
− The AC Supply voltage exceeds the maximum rated voltage that may be
applied to a PAM with SAM system (see Part 1 - “Selecting System
Components”).
− The AC Supply is not a three phase, four wire system with grounded neutral
(see AC Supply with Grounded Neutral on page 8).

Operating a PAM with SAM system from an ungrounded AC Supply is prohibited.

Interfacing an Isolation Transformer

Figure 46 illustrates the wiring of isolation transformers. The transformer secondary
(load side) must be wired in a "wye" configuration and the star point, which is the
secondary's neutral, must be solidly grounded with a low-impedance connection to
protective earth ground. The primary may be either “Delta” or “Wye” connected.

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PART 2 - SYSTEM DESIGN AND INTEGRATION FEEDING SECTION

L1a
L1
L2
L2a

L3
L3a
PE PE

OR
L1a
L1

L2 L2a

L3 L3a

PE PE
Sag016_a.cdr

Figure 46 Isolation Transformer Configurations

Interfacing an Auto-transformer
Auto-transformers are always “Wye” connected; their star point must be solidly
grounded with a low impedance connection to protective earth ground as illustrated
in Figure 47.

L1
L2a
L2

L1a

L3a

L3
SAG017_a.CDR

Figure 47 Auto-transformation Wiring Configuration

PAM with SAM System Users Handbook

Page: 54 P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION 24 VDC SUPPLY

24 VDC Supply
Functions
The 24 VDC supply provides a low voltage power source which each SAM Drive,
SAM Supply and PAM (Full system only) utilizes to develop their internal operating
voltages. On units equipped with cooling fans, the fans are powered by 24 VDC.
The 24 VDC supply may also be utilized as a power source for:
− Operating electro-mechanical brakes on motors
− Devices controlled by the User I/O on a SAM Drive
− Other system or machine functions

24 VDC Power Distribution

General System Diagram
Figure 48 is a general system level diagram illustrating distribution of 24 VDC
power in a PAM with SAM system. Refer to the relevant sections of this chapter for
detailed information on interfacing to the PAM, SAM Supply and SAM Drive.
Safety & Protective
Functions

X17 Safety X31/X32

I/o

User I/O
User
outputs
X14 Brake
ctrl.

X17 X31/X32

+
+24 VDC
Supply
-

The negative rail of the

PE PE PE
24 VDC Supply must be X14
grounded
X14
Machine Control
PC/PLC SAM PAM
I/O
Supply (Full System)

SAG018_b.CDR

Figure 48 24 VDC Power Distribution

ACC recommends not removing 24 VDC power during or immediately following a

controlled or uncontrolled machine stop because valuable diagnostic information
! retained by the PAM, Sam Drive and SAM Supply is lost with the removal of 24 VDC
power.

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