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2098-IN003 - Rockwell Automation

1. VENE 9 Q oo El S ren a ren E gr gr Chassis ground IE sh Chassis ground ES on Chassis ground oe J all Jie A Te i Ie h Te TS i Jerg Si x Tegal II E C etse 7 eie J amp eS ten s To Ti Te all lt To i Yer Jl elp 40 i Sex JL eb Tm B i J ZE Bonded ground bar Chassis ground e elh i io optional x torre E Tel Bonded cabinet ooo EH d ground bus TEI TR Ground grid or power distribution ground Always follow NEC and N applicable local codes Publication 2098 INOO3E EN P April 2004 3 10 Connecting Your Ultra3000 Grounding Multiple Subpanels To ground multiple subpanels refer to the figure below Note HF bonding is not illustrated For HF bonding information refer to Bonding Multiple Subpanels on page 1 12 Figure 3 10 Subpanels Connected to a Single Ground Point Always follow NEC and applicable local codes Publication 2098 INOO3E EN P April 2004
2. Publication 2098 INOO3E EN P April 2004 Serial Port Connector Seven Segment Status LED 9 pin CN3 Serial Connector Logic Power LED Module Status LED Pin9 Network Status LED Pin 6 q284 Node Address Switches 15 pin CN2 Data Rate Switch Feedback Connector CN3 9 pin Serial Port Connector gt Pin 10 od Pin 5 Pin 1 CN2 15 pin Motor Feedback Connector 44 pin CN1 1 0 Connector CN1 44 pin Pin 30 User 1 0 ira ee Pin 44 ds Pin 15 DeviceNet Interface Pin 31 A pin 1 Connector RJ Pin 16 7 The following table provides the signal descriptions and pin outs for the CNG serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved 1 0 Connector Ultra3000 Connector Data 2 25 The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector
3. CN1 Pin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 5V EPWR 23 Programmable Analog Output AOUT 2 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Command COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common I0COM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch l IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUT3 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUTA 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUTS 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS3 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUTA 21 Buffered Motor Encoder Ch I IMOUT 43 Normally Op
4. Green Yellow Motor Feedback l CN2 Connector Blue caw GND NEM Black B V i Brown T Three Phase A 7 B ACK aes S IN a 1 A Li Motor Feedback lt Motor Power B gt gt WHT BLACK XX SIN 2 15 pin Connector gt gt en COS IE CN2 V D Edi WHT RED XX COS 4 Motor Feedback E s l GREEN DATA 5 2090 UXNBMP 18Sxx Brake Cable Foss WHT GREEN XX _DATA 10 Note 12 K 5 GRAY 5VDC 14 43 Black C lt lt BR L SS d wee XX_ECOM 8 Control Interface 44 Moe s fA BR 3 Motor Brake N 5 ORANGE 9VDC 7 44 pin Connector White o R WHT ORANGE XX TS 11 CNI COM 24V Thermostat H User Supplied I 24V dc Power Supply Cable Shield 1A max ae lm M OP dE 7 2090 XXNFMP Sxx flying lead or 2090 UXNFBMP Sxx with drive end connector Feedback Cable Notes 12 15 16 17 Motor Feedback MPL B 460V SERVO MOTORS CN2 Connector WITH INCREMENTAL FEEDBACK me jc Wl S C eee nece D lt lt A IS LACK AM 1 C caw l GND B SS WHT BLack XC AM BE B V C 5 gt RED BM 3 C Three Phase D wuyuD XX BM 4 A cant Motor Power gt E 5 GREEN IM 5 F 5 WHT GREEN XX IM 10 Motor Feedback K dits 45VDC 14 L S Sle wuremy XX ECOM 6 N 5 ORANGE R waT orancE XX TS n Oo gt gt Thermostat TY d S syle BLUE TS C 7 BR T SS wayRu
5. CN1 Pin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 5V EPWR 23 Programmable Analog Output AOUT 2 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Command COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common I0COM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch l IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUT3 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUTA 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUTS 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS3 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUTA 21 Buffered Motor Encoder Ch I IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally
6. CNiPin Description Sigal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 5V EPFWR 23 Reserved 2 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Reserved 4 Auxiliary Encoder Ch A AX 26 Reserved 5 Auxiliary Encoder Ch A AX 27 1 0 Common I0COM 6 Auxiliary Encoder Ch B BX 28 1 0 Common IOCOM 7 Auxiliary Encoder Ch B BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch l IX 31 Drive Enable Input ENABLE 10 Unbuffered Motor Encoder Ch A AM 32 Home Sensor Input HOME 11 Unbuffered Motor Encoder Ch A AM 33 Registration Sensor 1 Input REG1 12 Unbuffered Motor Encoder Ch B BM 34 Registration Sensor 2 Input REG2 13 Unbuffered Motor Encoder Ch B BM 35 Reserved 14 Unbuffered Motor Encoder Ch l IM 36 Reserved 15 Unbuffered Motor Encoder Ch l IM 37 Positive Overtravel Input OT_POS 16 Buffered Motor Encoder Ch A AMOUT 38 Negative Overtravel Input OT_NEG 17 Buffered Motor Encoder Ch A AMOUT 39 Drive Ready READY 18 Buffered Motor Encoder Ch B BMOUT 40 Reserved 19 Buffered Motor Encoder Ch B BMOUT 41 Reserved 20 Buffered Motor Encoder Ch l IMOUT 42 Reserved 21 Buffered Motor Encoder Ch l IMOUT 43 Brake Relay Output BRAKE 22 Common ACOM 44 Brake Relay Output BRAKE READY signal only available with firmwa
7. 0 O lt I START stop T R1 CR2 E Ultra3000 g qo 120V AC 50 60 Hz CR1 Mi CR1 Fuse RII Refer to Attention statement above Block M1 MS Single Phase T L1 eW AC Line L2 N was N 50 60 Hz gt IAS HIN 43 NO Relay Output Note 20 ei amp dM N O Relay Output Ze eG td JS 44 seas Bae O From CN1 Breakout Board les a with 24V to 5V Aux Power Sr g Aux Logic Power In 15V lt Converter 2090 U3CBB DMxx Note 21 2 Aux SV Common Publication 2098 INOO3E EN P April 2004 Interconnect Diagrams B 17 The 120V ac control string wired to the Ultra3000 2098 DSD 030x xx drives is shown in the figure below Implementation of safety circuits and risk assessment Did HE M 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 Figure B 17 120V ac Single P
8. co _BLACK28GA__ ACOM ANALOG GRD ACOM ANALOG GRD s BLACK 28GA 2 WHT BLK 286A ANALOG OUT PROG ANALOG OUT PROG WHT BLK 286A m BROWN 28GA ILIMIT ILIMIT BROWN 28GA 2 WHT BRN 28GA EPWR 5 OUT EPWR 5 OUT WHT BRN 28GA 1 2090 U3CC D44xx RED 28GA AX AX RED 28GA 4 2090 U3CC D44xx Controller Interface WHT RED 28GA AX AX WHT RED 28GA 5 Controller Interface Cable ORANGE 28GA BX BX ORANGE 28GA 6 Cable WHT ORG 28GA BX BX WHT ORG 28GA 1 YELLOW 28GA IX IX YELLOW 28GA 8 WHT YEL 28GA IX IX WHT YEL 28GA 9 GRAY 28GA INPUT 2 INPUT 2 GRAY 28GA 32 WHT GRY 28GA INPUT 3 INPUT 3 WHT GRY 28GA 33 7 PINK 28GA INPUT 4 INPUT 4 PINK 28GA 34 WHT PNK 28GA INPUT 5 INPUT 5 WHT PNK 28GA 35 WHT BLK RED 28GA INPUT 6 INPUT 6 WHT BLK RED 28GA 36 Ultra3000 RED BLK 28GA INPUT 7 INPUT 7 RED BLK 28GA 37 Ultra3000 WHT BLK ORG 28GA INPUT 8 INPUT 8 WHT BLK ORG 28GA 38 CN1 Connector cN1 Connector ORG BLK 28GA OUTPUT 2 OUTPUT 2 ORG BLK 28GA 40 Axi Axis 0 WHT BLK YEL 28GA OUTPUT 3 OUTPUT3 WHT BLK YEL 286A HAS YEL BLK 28GA OUTPUT 4 OUTPUT 4 YEL BLK 28GA 42 DRAIN DRAIN 1 1 0 power pins 28 and 30 must be connected to user supplied 12 24V dc 2 Input 1 pin 31 must configured as Drive Enable using Ultraware software 3 Output 1 pin 39 must be configured as Ready using Ultraware software 4 This cable does not carry the unbuffered motor encoder sig
9. CNiPin Description Sigal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 5V EPFWR 23 Reserved 2 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Reserved 4 Auxiliary Encoder Ch A AX 26 Reserved 5 Auxiliary Encoder Ch A AX 27 1 0 Common I0COM 6 Auxiliary Encoder Ch B BX 28 1 0 Common IOCOM 7 Auxiliary Encoder Ch B BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch l IX 31 Drive Enable Input ENABLE 10 Unbuffered Motor Encoder Ch A AM 32 Home Sensor Input HOME 11 Unbuffered Motor Encoder Ch A AM 33 Registration Sensor 1 Input REG1 12 Unbuffered Motor Encoder Ch B BM 34 Registration Sensor 2 Input REG2 13 Unbuffered Motor Encoder Ch B BM 35 Reserved 14 Unbuffered Motor Encoder Ch l IM 36 Reserved 15 Unbuffered Motor Encoder Ch l IM 37 Positive Overtravel Input OT_POS 16 Buffered Motor Encoder Ch A AMOUT 38 Negative Overtravel Input OT_NEG 17 Buffered Motor Encoder Ch A AMOUT 39 Drive Ready READY 18 Buffered Motor Encoder Ch B BMOUT 40 Reserved 19 Buffered Motor Encoder Ch B BMOUT 41 Reserved 20 Buffered Motor Encoder Ch l IMOUT 42 Reserved 21 Buffered Motor Encoder Ch l IMOUT 43 Brake Relay Output BRAKE 22 Common ACOM 44 Brake Relay Output BRAKE READY signal only available with firmware version 1 29
10. Figure 2 10 Ultra3000 Front Panel Connections for 2098 DSD 030 DN and 030X DN 9 pin CN3 Seven Segment z z 4L Status LED Serial Connector Passive Shunt aia 4 F Resistor Connections E E M Logic Power LED sot Pind SX J OF Module Status LED o 7X Network Status LED m 7 pe ode Address Switches Sb m b 15 pin CN2 GE L Data Rate Switch Feedback Connector D CN3 9 pin Pin 10 Hf Serial Port Pin 15 Pin 5 CD g Connector n n Pin 1 Motor Power wa WIT O CN2 15 pin n Connections amp 3 w d lt Motor Feedback lille Connector ee ld DC Bus 3 3 O amp 9 A El CN1 44 pin AC Input P ET um User l 0 S nput Power TON Connector in 44 hoso Connections Sec E ji E 4 3 au 7 DeviceNet Interface Pin 31 Motor Power Connector Cable Shield Clamp Pin 16 q gt N Serial Port Connector The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3 Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data 2 21 1 0 Connector The followi
11. CNiPin Description Sigal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 5V EPFWR 23 Reserved 2 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Reserved 4 Auxiliary Encoder Ch A AX 26 Reserved 5 Auxiliary Encoder Ch A AX 27 1 0 Common I0COM 6 Auxiliary Encoder Ch B BX 28 1 0 Common IOCOM 7 Auxiliary Encoder Ch B BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch l IX 31 Drive Enable Input ENABLE 10 Unbuffered Motor Encoder Ch A AM 32 Home Sensor Input HOME 11 Unbuffered Motor Encoder Ch A AM 33 Registration Sensor 1 Input REG1 12 Unbuffered Motor Encoder Ch B BM 34 Registration Sensor 2 Input REG2 13 Unbuffered Motor Encoder Ch B BM 35 Reserved 14 Unbuffered Motor Encoder Ch l IM 36 Reserved 15 Unbuffered Motor Encoder Ch l IM 37 Positive Overtravel Input OT_POS 16 Buffered Motor Encoder Ch A AMOUT 38 Negative Overtravel Input OT_NEG 17 Buffered Motor Encoder Ch A AMOUT 39 Drive Ready READY 18 Buffered Motor Encoder Ch B BMOUT 40 Reserved 19 Buffered Motor Encoder Ch B BMOUT 41 Reserved 20 Buffered Motor Encoder Ch l IMOUT 42 Reserved 21 Buffered Motor Encoder Ch l IMOUT 43 Brake Relay Output BRAKE 22 Common ACOM 44 Brake Relay Output BRAKE READY signal only available with firmware version 1 29 or above Re
12. Module Seven Segment s Status LED Status LED 1 ule H Sas Network Status LED Logic Power LED x L Peescid CN3 9 pin Serial Port oc Connector M rm uw 6 Node Address DC Bus Connections for eae gm Switches Active Shunt Resistor Kit Ne uU CN2 15 pin 4 T I lt Motor Feedback AC Input Power n us Pom Data Rate Connector Connections ZEI 9 Na x Switch L T T 1 8MB Q SERCOS a Interface o T k SERCOS Interf Rx nterface Motor Power Motor 1 Receive Rx and Connections w Q w Transmit Tx sr Connectors cy CN1 44 pin User 1 0 Motor Power LL Connector Cable Shield Clamp Publication 2098 INOO3E EN P April 2004 Serial Port Connector 9 pin CN3 Serial Connector 15 pin CN2 Feedback Connector Pin 10 Pin 5 Pin 1 44 pin CN1 1 0 Connector Pin31 og Pin 1 Pin 16 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT g Reserved 1 0 Connector Ultra3000 Connector Data The following table provides the signa
13. Ultra3000 Circuit 2 Breaker 24V Contactors g Power Supply E t 3 di AC Ed Line Filter ralje i MI E Elle es e Very dirty power connections segregated not in wireway Motor Power Cable Route Motor Power Route Encoder Analog Registration Shielded Cable Shielded Cables Enclosure Installing Your Ultra3000 1 17 When mounting your shunt module inside the enclosure follow these additional guidelines refer to Figure 1 10 and for an example e Metal clad modules can be mounted anywhere in the dirty zone but as close to the Ultra3000 as possible e Shunt power wires can be run with motor power cables e Keep unshielded wiring as short as possible Keep shunt wiring as flat to the cabinet as possible e Separate shunt power cables from other sensitive low voltage signal cables Figure 1 10 External Shunt Resistor Inside the Enclosure Dirty Wireway Clean Wireway 150 mm 6 0 in of clearance on all sides of the shunt module minimum Shunt Wiring Methods Twisted pair in conduit 1st choice Shielded twisted pair 2nd choice am na ey Twisted pair 2 twists per foot min 3rd choice Maximum Length 3 05 m 10 ft C
14. TI To Ad rr rir od Pd rd nt TH om TE 7 i oo Fri e E 3 Publication 2098 INOO3E EN P April 2004 Serial Port Connector Seven Segment Status LED 9 pin CN3 Serial Connector Logic Power LED o Module Status LED A etwork Status LED ode Address Switches Data Rate Switch 15 pin CN2 Feedback Connector CN3 9 pin Serial Port Connector Pin 10 Pin 5 Pin 1 CN2 15 pin Motor Feedback Connector 44 pin CN1 1 0 Connector CN1 44 pin User 1 0 Connector Pin 30 Pin 44 I Pin 15 SERCOS interface Receive Rx and Transmit Tx Connectors Pin 31 Pin 16 71 Pin 1 The following table provides the signal descriptions and pin outs for the CNS serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved Ultra3000 Connector Data 2 17 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector
15. DC D l Filter VD po _o ll es o ETE i T Ultra3000 o Circuit Breaker 24V Contactors mig 9 Power Supply 24 AC Ta Line Filter Ne D VD sse es amp Fi G Very dirty power connections ad Zn segregated not in wireway D C Motor Power Cable Route Motor Power Route Encoder Analog Registration Shielded Cable Shielded Cables Enclosure Publication 2098 INOO3E EN P April 2004 1 18 Installing Your Ultra3000 Mounting Your Ultra3000 Drive Publication 2098 INOO3E EN P April 2004 The procedures in this section assume you have prepared your panel and understand how to bond your system For installation instructions regarding other equipment and accessories refer to the instructions that came with each of the accessories for their specific requirements ATTENTION This drive contains ESD Electrostatic Discharge 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 To mount your Ultra3000 drive 1 Layout the position for the Ultra3000 and accessories in the enclosure refer to Establishing Noise Zones for p
16. Tanstormer WR Secondary TEE E TI lj Urano Sym A i Filter E l L1 i 2 B IL IP UN TB1 Terminals B MM SEM Input Fusing M2 TB1 L2 Tit um H CIH d Ultra3000 System B f 13 Filter on Single Phase AC Input LZ I n Tt TB1 Terminals L R M3 2 L3 I I Ultra3000 System C Grounded Neutral us t I t Single Phase AC Input L1 Filter n L2 pi L2 Tt 1 TB1 Terminals Bonded Cabinet Bonded Cabinet ooo Ground Bus 00000000000 Ground Bus Ground Grid or Ground Grid or Power Distribution Ground Power Distribution Ground 1 AC line filter is optional but is required for CE compliance 2 Contactors MI M2 and M3 may be optional For more information refer to Understanding the Machinery Directive publication SHB 900 Note Feeder short circuit protection is not illustrated Figure 3 6 Single Phase Amplifiers on Three Phase Power Delta 2 mane l etae Mi Ioa 1 Li ACLine i IL T m1 Ultra3000 System A i L2 Filter T Single Phase AC Input 2 2 Ik TB1 Terminals q LE _ 9 9 M22 1 Input Fusing TB1 d L2 ih Acin d IL Tl r Ultra3000 System B l L3 Filter zn Single Phase AC Input i L2 2 IL 1 E TB1 Terminals L3 E Input Fusing M3 ER 1 3 ju acting L CHI a Uir
17. 10 RS 485 Standard Differential 2 Wires 1 Signal Pair 1 to 32 Transmitters 1 to 32 Receivers Note Not applicable to Ultra3000 drives 32 Publication 2098 INOO3E EN P April 2004 2 54 Ultra3000 Connector Data Publication 2098 INOO3E EN P April 2004 Restoring Drive Communications The Ultra3000 includes a mechanism for restoring serial communications in case the drive has unknown serial interface settings or communications cannot be established For the first 3 seconds after reset or power up the drive listens for messages with the following serial interface settings Parameter Default Setting Baud Rate 9 600 Frame Format 8 Data No Parity One Stop Drive Address 254 If a message is received during this time the drive will respond and these settings will be retained until the next reset or power down allowing the normal serial interface settings to be determined If no messages are received during this time the normal serial interface settings are used IMPORTANT Only one drive should be connected if this mechanism is used since multiple drives would all respond and the response would be garbled Chapter Objectives Understanding Basic Wiring Requirements Chapter 3 Connecting Your Ultra3000 This chapter provides procedures for wiring your Ultra3000 and
18. Receive Ultra3000 SE hal Ultra3000 SE Receive x Transmit SERCOS fiber optic ring a Receive Transmit Transmit E o H Ultra3000 SE Receive lt x Transmit Note You can mount the two 1756 MxxSE SERCOS interface modules in two separate ControlLogix chassis as shown above or you can mount them in the same chassis Publication 2098 INOO3E EN P April 2004 3 28 Connecting Your Ultra3000 Cable lengths of 32 m 105 ft for plastic cable and 200 m 656 7 ft for glass cable are possible for each transmission section point A to B In Figure 3 24 the second Ultra3000 SE system is located in a separate cabinet and connected with bulkhead adapters To avoid signal loss do not mix glass and plastic IMPORTANT IMPORTANT cables when connecting to a bulkhead adapter Use glass to glass or plastic to plastic cable on both sides of the ad
19. Ultra3000 SE Receive Receive Transmit Transmit Connecting Your Ultra3000 3 27 Refer to figures 3 22 3 23 and 3 24 for examples of fiber optic ring connections between the Ultra3000 SE drive s and the ControlLogix SERCOS interface module Fi gure 3 22 Fiber Optic Ring Connection Example 2 i in D Transmit Receive 1756 MxxSE SERCOS terface Module ControlLogix Chassis SERCOS fiber optic ring Ultra3000 SE r Receive a Transmit Figure 3 23 Fiber Optic Ring Connection Example 3 1756 MxxSE SERCOS interface Modules o a ControlLogix Chassis Transmit Receive Transmit Receive Ultra3000 SE SERCOS fiber optic ring
20. AC input voltage 1 100 240V rms single phase AC input frequency 47 63 Hz AC input current 2 3 Nom rms SA 9A 18A l 230V ac 0 pk max inrush 4 100 A Series A or B 100 A Series A or B 100 A Series A or B 20 A Series C 20 A Series C 20 A Series C Continuous output current 0 pk 25A 5A 10A Intermittent output current 0 pk 75A 15A 30A Bus capacitance 1410 uF 1880 pF 1880 uF Internal shunt resistance N A N A N A Shunt on N A N A N A Shunt off N A N A N A Bus overvoltage 400V dc 400V dc 400V dc Energy absorption capability 115V ac input 93 J 125 J 230V ac input 38 J 51J Continuous power output 115V ac input 0 25 kW 0 5 kW 1 0 kW 230V ac input 0 5 kW 1 0 kW 2 0 kW Specification is for nominal voltage The absolute limits are 1096 or 88 265V rms 7 The 2098 DSD 005x xx 010x xx and 020x xx 230V drives are limited to Series A or B one contactor cycle every two minutes Series C one contactor cycle every 10 s for up to two minutes not to exceed 12 cycles in five minutes Power initialization requires a short period of inrush current Dual element time delay slow blow fuses are recommended Inrush current limiting circuitry is enabled within 3 s after removal of ac line power ATTENTION The inrush current limiting circuitry is limited in the number of power cycles it can withstand within a set period of time If you N exceed these limitations the circuitry will
21. Figure 3 28 Wiring the DeviceNet Connector Plug Connector 1 5 4 3 2 mEHENH Black V Blue Can L Bare Shield White Can H Red V 5 Tighten each terminal screw using a 1 8 inch flat blade screwdriver 6 Gently pull on each wire to make sure it does not come out of its terminal Re insert and tighten any loose wires 7 Plug the DeviceNet cable into the DeviceNet interface connector Refer to Ultra3000 with DeviceNet Front Panel Connections beginning on page 2 18 for the connector location 8 Attach the Ultra3000 with DeviceNet to the DeviceNet network Publication 2098 INOO3E EN P April 2004 3 32 Connecting Your Ultra3000 Publication 2098 INOO3E EN P April 2004 Chapter Objectives Chapter 4 Troubleshooting Status Indicators This chapter provides a description of maintenance and troubleshooting activities for the Ultra3000 This chapter includes these sections e Safety Precautions e General Troubleshooting e Troubleshooting for SERCOS Drives e Troubleshooting for DeviceNet Drives For power up procedures and system integration with Ultraware or ControlLogix and SoftLogix modules PCI cards see table below refer to the Ultra3000 Digital Servo Drives Integration Manual publication 2098 INOO5x EN P Manuals are available electronically as a pdf or in hardcopy from www theautomationbookstore com Interface conta ops Motion SoftLogix PCI Card SERC
22. Ground grid or power distribution ground Motor Power Cable Shield Termination Factory supplied motor power cables for MP Series 1326AB and F H N and Y Series motors are shielded and the power cable is designed to be terminated at the drive during installation A small portion of the cable jacket is removed which exposes the shield braid The exposed area must be clamped to the bottom of the drive chassis refer to Figure 3 11 or the front of the drive chassis refer to Figure 3 12 using the clamp provided ATTENTION To avoid hazard of electrical shock ensure shielded power cables are grounded at a minimum of one point for safety Connecting Your Ultra3000 3 11 Connecting Cable Shields at the Drive All motor power cable shields require attachment to the clamp as shown in the figures below Figure 3 11 Motor Power Cable Shield Connection bottom of drive Ultra3000 Motor cable jacket Motor cable jacket B B Clamp screws Figure 3 12 Motor Power Cable Shield Connection front of drive 93 E E ee ILL Motor cable jacket Clamp screws amp 5 Ultra3000 eng E LN SS eae Clamp wwa FES ae 7 shield Ga Motor cable jacket mE Recibe N fi IMPORTANT The MP Series Food Grade motors have shielded brake wires included in the motor power cable 2
23. Breakout Cables Catalog Number Description 2090 UXBC D15xx 15 pin high density D shell for Ultra3000 CN2 interface connector 2090 U3BC D44xx 44 pin high density D shell for Ultra3000 CN1 control interface connector Publication 2098 INOO3E EN P April 2004 Numerics 16 axis SERCOS interface PCI card installation instructions P 3 1756 MxxSE interface module 3 26 1784 PM16SE PCI card 3 26 2090 U3AE D44 cable B 20 interconnect diagram B 21 2090 U3CBB DM12 2 27 2090 U3CBB DM44 2 27 2090 U3CC D44 cable B 20 interconnect diagram B 22 24V to 5V converter 2 26 C 8 3 8 or 16 axis SERCOS interface module installation instructions P 3 A abbreviations P 4 AC line filters C 3 noise reduction 1 15 specifications A 11 AC power 3 13 analog COMMAND input 2 37 analog encoder PCI card installation instructions P 3 analog encoder servo module installation instructions P 3 analog ILIMIT input 2 38 analog output 2 39 auxiliary encoder feedback 2 49 auxiliary feedback specifications A 10 baud rate 2 51 before mounting your system 1 5 bonding EMI ElectroMagnetic Interference 1 10 painted panels 1 11 subpanels 1 12 brake B 19 brake cables MP series C 5 breakout boards with 24V to 5V converter 2 26 C 8 Index breakout components breakout board kits C 8 breakout boards C 8 breakout cables C 8 building your own cables 3 2 C cable combinations 3 24 cable shield clamp 3 18 cables 2090 U3AE D44 B 20 2090
24. z e 13 4 GREEN IM 5 d 14 SSE weren XX IM 10 43 BLK BR Pigtail WHT BLUE S1 12 Control Interface 44 XX BLK BR jl Brake 17 y Bu XX s2 13 44 pin Connector BROWN S3 8 CN1 Mi 4 4 WHT BROWN XX GRAY 5VDC 14 com luv 23 24 war XC Ecow 8 i 24 DRAIN TBI m User Supplied gt Yt U Note 9 24V dc Power Supply aa Be Y 1A max 2090 XXNFY Sxx flying lead 77 or 2090 UXNFBY Sxx with drive end connector Feedback Cable Notes 12 15 16 Publication 2098 INOO3E EN P April 2004 B 16 Interconnect Diagrams Control String Examples 120V ac This section provides information to assist you in using the configurable Drive Ready output in a control string with 120V ac input voltage Refer to Figure 2 26 in the chapter Ultra3000 Connector Data for more information on the digital relay output The 120V ac control string wired to the Ultra3000 2098 DSD 005x xx 010x xx or 020x xx drives is shown in the figure below ATTENTION Figure B 16 120V ac Single Phase Control String Example Implementation of safety circuits and risk assessment 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
25. Auxiliary Encoder Input A CN1 pins 4 and 5 B CN1 pins 6 and 7 STEP CN1 pins 4 and 5 DIRECTION C pins 6 and 7 CW CN1 pins 4 and 5 CCW CN1 pins 6 and 7 Signal Types J drill La T LIT LL L UU LU f T hnnnnn JuuuuuuL Publication 2098 INOO3E EN P April 2004 2 50 Ultra3000 Connector Data Publication 2098 INOO3E EN P April 2004 Figure 2 54 shows the configuration of the AX Auxiliary Encoder Input channel The BX and IX channels have the same configuration Note CW pulses are only counted when the CCW input is low and CCW pulses are only counted when the CW input is low Figure 2 54 Auxiliary Encoder Input Configuration Ultra3000 Drive 5V 56 pF 10k Q i l COMMON COMMON Note For single ended connections the negative terminals CN1 pins 5 and 7 should be left disconnected and the signal connections should be made to CN1 pins 4 and 6 The following table provides a description of the auxiliary encoder interface Parameter Description Minimum Maximum ON State Input voltage difference between the input Input Voltad and the input that is detected as an ON 1 0V 7 0V p g state OFF State Input voltage difference between the input input Voltage and the input that is detected as an OFF 1 0V 7 0V p g state EORR Mode Voltage b input and logic ground 7 0V 120V Input Voltage oltage between an in
26. ae Sate ge Sit X e lt T GO Serial Po rt Connector Seven Segment Status LED Logic Power LED Module Status LED Network Status LED 7 Node Address Switches Data Rate Switch CN3 9 pin O 38 8 H Serial Port o Connector SERCOS interface Receive Rx and Transmit Tx Connectors Ef w LE O CN2 15 pin Elle lt Motor Feedback Elle i Connector DC Bus 9 i Sit CN1 44 pin User 1 0 Connector ser ele 3 ax 6 9 pin CN3 Serial Connector 15 pin CN2 Feedback Connector Pin 10 Pin 5 Pin 1 44 pin CN1 Pin 31 Pin16 1 O Pin 1 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved Ultra3000 Connector Data 2 13 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector
27. ds right angle 2090 UXNFBN Rxx N Series non flex connector at both en ds right angle skewed 2090 UXNFBN Kxx N Series non flex connector at both en ds right angle skewed 2090 UXNFBN23 K xx Series non flex motor connector to flying leads right angle skewed 2090 UXNFDN23 Kxx N Series non flex motor connector to flying leads right angle 2090 UXNFDN Rxx Y Series non flex connector at both ends straight 2090 UXNFBY S xx Y Series non flex motor feedback connector to flying leads straight 2090 XXNFY S xx Drive Feedback Cable non flex CN2 connector to flying leads MP Series Motor Brake Cable Description MP Series motor brake cable 0 75 mm 18 AWG Ultra3000 Interface Cables Description Serial Interface Cable 9 pin D shell CN3 to personal computer 2090 UXNFM S xx Catalog Number 2090 UXNBMP 18Sxx Catalog Number 2090 UXPC D09xx Controller Interface Cable 44 pin D shell CN1 to 1756 M02AE motion module two axis to premolded connector 2090 U3AE D44xx Controller Interface Cable 44 pin D shell CN1 to 1756 M02AE motion module single axis to no connector 2090 U3CC D44xx Publication 2098 INOO3E EN P April 2004 C 6 Catalog Numbers and Accessories Publication 2098 INOO3E EN P April 2004 SERCOS Interface Fiber Optic Cables Use the following table to identify the SERCOS inter
28. AB Allen Bradley Ultra3000 Digital Servo Drives Catalog Numbers 2098 DSD 005 010 and 020 2098 DSD xxxX 2098 DSD xxx SE 2098 DSD xxx DN 2098 DSD xxxX DN 2098 DSD 030 075 and 150 2098 DSD xxxX 2098 DSD xxx SE 2098 DSD xxx DN 2098 DSD xxxX DN 2098 DSD HV030 HV050 HV100 HV150 and HV220 2098 DSD HV xxxX 2098 DSD HVxxx SE 2098 DSD HV xxx DN 2098 DSD HV xxxX DN Installation Manual Rockwell Automation 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 stat
29. CN1 i 43 I lt START STOP l L imme 24V de 44 Mi Refer to Attention statement Notes 10 11 Publication 2098 DU003B EN P September 2006 8 Ultra3000 Digital Servo Drive Installation Manual Replace the interconnect diagram on page B 6 with the one shown below The new diagram changes the recommended wiring of input fusing ac line filter and contactor Page B 6 Figure B 4 Typical Power Wiring of Ultra3000 System 2098 DSD HVxxx xx and HVxxxX xx Ultra3000 Digital Servo Drives 2098 DSD HV xxx xx and HVxxxX xx Note 14 External Passive Shunt Connections Three phase Motor Power Connections Motor Power Connections Note 12 MI Input Fusing Notes 4 and 5 Note 8 Three phase AC Line L 50 60 Hz IL H Three phase AC Line Filter CN1 Ed AC Input Power H Nee Connections N O Relay Output Fused Disconnect or Circuit Breaker i i N O Relay Output Note 20 Note 1 eese ess Note 6 IT i Input Fusing Cable Shield Isolation Neutral Notes 4 and 5 Clamp Transformer RUN Note 9 Note2 ro Rg Chassis 9 Bio Catinet round Bus 7 Oo ee CN1 i t Three phase Input 12 Jl START STOP
30. Commissioning and Communications RSLogix 5000 Input Output ControlLogix 1756 MxxSE SERCOS Controller a Interface Module m SEDE ControlLogix Chassis ll SERCOS Fiber Optic Ring A Ultra3000 SE Ultra3000 SE Ultra3000 SE D 0 8 8 E plos o Encoder Feedback Encoder Feedback Encoder Feedback i d Motor Power C ad Motor Power L Motor Power T 3 i MP Series MP Series MP Series Servo Motor Servo Motor Servo Motor SERCOS Fiber Optic Ring Figure 1 2 Ultra3000 Digital Servo Drive System Overview PC Powered Ultraware Commissioning and Communications Ultra3000 Input Output B A ControlLogix Controller 1756 M02AE Servo Module y Encoder Feedback BA fal 1 0 and Commands FEE ControlLogix Chassis Motor Power MP Series Servo Motor Publication 2098 IN003E EN P April 2004 Before System Installing Your Ultra3000 1 5 Figure 1 3 Ultra3000 DN DeviceNet Digital Servo Drive System Overview Commissioning and Communications PC Powered Ultraware Ultra3000 DN o6 0 Input Output B l ControlLogix Controller DeviceNet Network Card Encoder
31. XX Si 12 S 3 Motor Brake U YELLOW S2 13 BR lt 4 V K WHT VELLOW XX S3 8 gt gt a j t T 2090 XXNFMP Sxx flying lead 7 7 or 2090 UXNFBMP Sxx with drive end connector Feedback Cable Publication 2098 IN003E EN P April 2004 Notes 12 15 16 2090 XXNPMP xxSxx Motor Power Cable Interconnect Diagrams B 11 In the figure below the Ultra3000 230V is shown connected to MP Series low inertia and integrated gear 230V servo motors Figure B 11 Ultra3000 to MP Series 230V Motor Configuration MPL A and MPG A 230V Note 12 SERVO MOTORS WITH HIGH RESOLUTION FEEDBACK Tie Green Yalow 9 otor Feedback tra rive reen Yellow CN2 Connector Note 13 Blue E W GND RERUM Hea I i Black We ee oue OO ee B lt lt Three Phase Bee ee i Brown A U A 5 gt LACK SIN 1 Motor Feedback lt Motor Power B WHT BLACK XY SIN 2 15 pin Connector C gt gt COS 3 is D y WHT RED XX COS 4 Motor Feedback E GREEN DATA 5 2090 UXNBMP 18S xx Brake Cable E E s LL CWHUGREEN XX_DATA 10 Note 12 K GRAY 5VDC 14 Im 43 Black C T BR L WHT GRAY XX ECOM 6 Bk Control Interface 44 Noten A e BR 3 Motor Brake N 5 T ORANGE 9VDC 1 V M pin Connector White R WHT
32. 2090 UXLF 132 E C 20W 2090 UXLF 136 e ds L 36A 50 C 3 9 go mu 10 200 Hz 25 to 85 C 122 F o 18g 13to 185 F 2090 UXLF 336 250V ac B 24 2090 UXLF 350 90 60 Hz ETR C 5 9 23A 50 C 16 2090 UXLF HV323 ur rus 20W 55 520V ac 30A Q 50 C 18 2090 UXLFHV330 grece 122 H 51W n 50A Q 50 C 48 2090 UXLF HV350 oar 25W 10 8 Use the table below to determine which AC line filter is best suited for your Ultra3000 drive based on the length of the motor cables AC Line Filter Catalog Number Ultra3000 Drives Motor Cables 30m Motor Cables gt 30 m 2098 DSD 005x xx 2090 UXLF 106 2090 UXLF 110 2098 DSD 010x xx 2090 UXLF 110 2090 UXLF 110 2098 DSD 020x xx 2090 UXLF 123 2090 UXLF 123 2098 DSD 030x xx 2090 UXLF 136 2090 UXLF 132 2098 DSD 075x xx 2090 UXLF 336 2090 UXLF HV330 2098 DSD 150x xx 2090 UXLF 350 2090 UXLF HV350 2098 DSD HVO030x xx 2038 OSD HOD 2090 UXLF HV323 2090 UXLF HV323 2098 DSD HV150x xx 2098 DSD HV220x xx 2090 UXLF HV330 2090 UXLF HV330 Publication 2098 INOO3E EN P April 2004 A 12 Specifications and Dimensions Ultra Family External Shunt Module Specifications The following external shunt modules are compatible with the Ultra3000 drives with regenerative loads that exceed the capacity of the internal shunt resistor Specif
33. 2098 DSD HV xxx xx or HVXXXX XX HF Bonding Your System Publication 2098 INOO3E EN P April 2004 Fuse Sizing In the United States the National Electric Code NEC specifies that fuses must be selected based on the motor full load amperage FLA The typical fuse size should be 300 of the motor FLA for non time delay fuses and time delay class CC fuses or 175 of motor FLA for time delay fuses If these ratings are not high enough for starting currents the NEC allows non time delay fuses and time delay class CC fuses to be sized up to 400 of the motor FLA and time delay fuses to be sized up to 225 of the motor FLA In most cases fuses selected to match the drive input current rating will meet the NEC requirements and provide the full drive capabilities Dual element time delay slow acting fuses should be used to avoid nuisance trips during the inrush current of power initialization Refer to the section Ultra3000 Power Specifications in Appendix A for input current and inrush current specifications The Ultra3000 utilizes solid state motor short circuit protection rated as shown in the table below Short Circuit Current Rating with No Fuse Short Circuit Current Rating with Fuse Restrictions Restrictions Suitable for use on a circuit capable of delivering Suitable for use on a circuit capable of delivering not more than 200 000 rms symmetrica not more than 5000 rms symmetrical amperes amperes 240V maximum when
34. 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUT4 21 Buffered Motor Encoder Ch l IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2 Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Inputs AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR_5V 7 Reserved 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 2 20 Ultra3000 Connector Data Use the figure below to locate the front panel connections on the Ultra3000 with DeviceNet Interface 230V drives 3 kW
35. A disconnecting device is required for maintenance and safety If a grounded neutral is used instead of L2 only L1 may be switched or fused 2 An isolation transformer is optional If the transformer secondary has a neutral connection neutral must be bonded to ground Multiple drive modules may be powered from one transformer or other AC supply source 3 Do not daisy chain drive module power connections Make separate connections directly to the AC supply 4 For power wiring specifications refer to Power Wiring Requirements in Chapter 3 5 For input fuse sizes refer to Fuse Specifications in Appendix A 6 May be used to maintain power to logic section of drive and status LEDs when main AC input power is removed A separate AC line source may be used if voltage is between 88 265V acpms on 2098 DSD xxx 230V drives or 207 528V acpnys on 2098 DSD HV xxx 460V drives 7 For AC line filter specifications refer to AC Line Filter Specifications in Appendix A 8 Drive Enable input must be opened when main power is removed and auxiliary power is present 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 9 Cable shield clamp must be used in order to meet CE requirements No external connection to chassis ground required 10 Implementation of safety circuits and risk assessment is the respons
36. F 600V copper wire Maximum length 3 05 m 10 ft 105 C 221 F 600V copper wire preferred 90 C 194 F minimum Maximum length 3 05 m 10 ft Note Refer to Figure 3 15 for TB2 terminal positions Publication 2098 INOO3E EN P April 2004 Connecting Your Ultra3000 3 15 Figure 3 15 TB2 Terminal Positions Internal i 2 External Shunt 3 Refer to Shunt Module Interconnect Diagrams in Appendix B for an example with your Ultra3000 drive The Ultra3000 utilizes solid state motor overload protection which operates in accordance with UL 508C Motor overload protection trips At Eventually 100 overload Within 8 minutes 200 overload Within 20 seconds 600 overload TTTIAETNAE DO not connect an external yo power supply to the DC bus The DC and DC terminals connect directly to the power bus of the drive ATTENTION This drive contains ESD Electrostatic Discharge 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 Publication 2098 INOO3E EN P April 2004 3 16 Connectin
37. If the mounting bracket is coated with a non conductive material anodized Star washer painted etc scrape the material around the mounting hole Publication 2098 INOO3E EN P April 2004 1 12 Installing Your Ultra3000 Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet Subpanels that are not bonded together may not share a common low impedance path This difference in impedance may affect networks and other devices that span multiple panels Refer to the figure below for recommended bonding practices Figure 1 6 Multiple Subpanels and Cabinet Recommended Bond the top and bottom of each subpanel to the cabinet using 25 4 mm 1 0 in by 6 35 mm 0 25 in wire braid A XXX Bonded cabinet ground bus to subpanel Qood Scrape the paint around each fastener to maximize metal to metal contact Planning Your Panel Layout This section outlines the practices which minimize the possibility of noise related failures as they apply specifically to Ultra3000 installations For more information on the concept of electrical noise reduction refer to System Design for Control of Electrical Noise publication GMC RM001x EN P Publication 2098 INOO3E EN P April 2004 Installing Your Ultra3000 1 13 Establishing Noise Zones Observe the following guidelines when laying out your
38. Interconnect Diagrams Ultra3000 Apendix Catalog Numbers and Provides catalog numbers and descriptions of the pp Accessories Ultra3000 and related products You the customer are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company 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 Store the product in its shipping container prior to installation If you are not going to use the equipment for a period of time store using the following guidelines e Use a clean dry location e Maintain an ambient temperature range of 40 to 70 C 40 to 158 F e Maintain a relative humidity range of 5 to 95 non condensing e Store it where it cannot be exposed to a corrosive atmosphere e Store it in a non construction area Related Documentation Preface 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 www theautomationbookstore com For Information on co
39. Ultra3000 with SERCOS interface available with 3 5 10 15 and 22 kW continuous output and 460V input power Ultra3000 DN DeviceNet Drives 2098 DSD xxx DN and XXXX DN Ultra3000 with DeviceNet and Ultra3000 with indexing DeviceNet available with 500W 1 2 3 7 5 and 15 kW continuous output with 230V input power 2098 DSD HV xxx DN and HVxxxX DN Ultra3000 with DeviceNet and Ultra3000 with indexing DeviceNet available with 3 5 10 15 and 22 kW continuous output with 460V input power ControlLogix SoftLogix Platforms 1756 MxxSE module 1784 PM16SE PCI card The SERCOS interface module PCI card serves as a link between the ControlLogix SoftLogix platform and Ultra3000 system The communication link uses the IEC 61491 SErial Real time COmmunication System SERCOS protocol over a fiber optic cable RSLogix 5000 software 9324 RLD300ENE RSLogix 5000 provides support for programming commissioning and maintaining the Logix family of controllers Ultraware Software 2098 UWCPRG The Ultra3000 Analog and DeviceNet drives are configured using Ultraware software Servo Motors MP Series 1326AB F H N and Y Series The MP Series Low Inertia Integrated Gear and Food Grade 230 and 460V 1326AB M2L S2L 460V and F H N and Y Series 230V motors are available for use with the Ultra3000 drives Cables Motor Power Feedback and Brake cables Motor power fe
40. and 020x xx Single Phase Input 100 240V ac RMS Terminal Blocks Note 3 BL dd Note 13 TB1 DC DC Bus Connections MI for Active Shunt Module Note 8 DC refer to Figure B 5 IL T L1 Single Phase aps AC Input Power I us CUM L2 N Connections Input Fusing Note 4 5 U CN1 Bonded Cabinet Three Phase Ground Bus e Motor Power V Motor Power m N O Relay Output i onnections Note 20 CT as ee lt Ww N O Relay Output From CN1 Breakout Oo 44 Board with 24V to 5V Aux Logic Power In 5V Aux Power Converter Aux 5V Common Note ak 2030 U3CBB DM0 Cable Shield 2 Clamp To additional Ultra3000 drive INDICATES USER SUPPLIED COMPONENT CN1 Note 9 43 START l 44 E l peg CR1 STOP Refer to Attention statement Notes 10 11 24V de Note Refer to Figure 2 26 in the chapter Ultra3000 Connector Data for more information on the relay output Publication 2098 INOO3E EN P April 2004 B 4 Interconnect Diagrams The Ultra3000 2098 DSD 030x xx power wiring with 24V dc control string non SERCOS drives only is shown in the figure below For the control string diagram with 120V ac input refer to Figure B 17 For SERCOS drives input line contactor is part of the PLC program
41. i 1 AE IRA GND a XX AM i 2 AN VV BN ee v i 3 35 RED BM 3 CL Three Phase 4 wuyuD XX BN 4 A U p Matar Paw r 5 i GREEN IM 5 6 3 waeren XX IM 10 Motor Feednack 11 5 ORANGE 9VDC 7 13 WHT ORANGE XX TS4 11 AY Thermostat amp 14 s yl G 4 BR Motor 12 F ATE Brake i g 1 PT yj E OSEE PPS ONE RORIS T 2090 XXNFMF Sxx Feedback Cable Note 12 16 MPF A5xxx motors are not compatible with Ultra3000 2098 DSD 005 010 020 drives IMPORTANT Interconnect Diagrams B 13 2090 XXNPH HF xxS xx or UXNPBH HF xxS xx Motor Power Cable Note 12 In the figure below the Ultra3000 230V is shown connected to H and F Series 230V servo motors Figure B 13 Ultra3000 to H and F Series 230V Motor Configuration H or F Series 230V SERVO MOTORS WITH INCREMENTAL FEEDBACK BRN gk BLU GN YL AM Motor Power TB1 Ultra3000 230V Drive Green Yellow D lt Motor Feedback Note 13 Blue C W L GND o s M Black V Jace cesse mee B lt lt Three Phase A et ete EOE i ae Motor Feedback su A lt U Motor Power A ss BLACK AM 15 pin Connector BSS WHT BLACK XX AM 2 CN2 C sH RED BM 3 WHT RED E 4 D AR BM Moto
42. motors High Resolution Feedback Signals for i Motor Drive CN2 m Mer Siors MAPAS s g nn MPF A45xx M S Motors 1 Sine Sine 1 2 Sine Sine 2 3 Cos Cos 3 4 Cos Cos 4 5 Data Data 5 6 Data Data 10 9 Reserved EPWR_5V 14 10 Reserved ECOM 6 11 EPWR 9V Reserved 7 12 ECOM Reserved 6 13 TS TS 11 14 TS TS 6 The following tables provide the signal descriptions and pin outs for the motor feedback CN2 15 pin connector to F H and Y Series 230V motors Motor Incremental Encoder Drive Connector Feedback Signals to Connector Pin F and H Series Motors Pin A AM 1 B AM 2 C BM 3 D BM 4 E IM 5 F IM 10 G Reserved H Reserved J EPWR_5V 14 K EPWR_5V 14 L ECOM 6 M ECOM 6 N S2 Hall B 13 P S3 Hall C 8 R TS 11 S TS 6 T 1 Hall A 12 Motor Incremental Encoder Drive CN2 Connector Feedback Signals to Connector Pin Y Series Motors Pin 9 AM 1 0 AM 2 1 BM 3 2 BM 4 3 IM 4 IM 10 5 S1 Hall A 12 7 S2 Hall B 13 19 S3 Hall C 8 22 EPWR 5V 14 23 ECOM 6 24 Drain Td Reserved Reserved 7 Reserved Reserved 9 Reserved Reserved 11 Reserved Reserved 15 Publication 2098 INOO3E EN P April 2004 3 26 Connecting Your Ultra3000 Connecting Your SERCOS Fiber Optic Cables SERCOS interface ControlLogix 1756 MxxSE SERCO
43. shown below when connecting two Ultra3000 drives to the 1756 MO2AE servo module This cable includes the 1756 TBCH pre wired terminal block Refer to Figure B 22 for the interconnect diagram Figure B 20 2090 U3AE D44xx Two Axis Cable AXIS 0 CN1 10 AX RELAY AX0 Connector e AXIS 0 CN1 D sub high 10 PWR AXO AUX PWR AXO J 02AE density 44 pin A view shown with 45 black without cover PVC overmold AXIS1 CN1 AUX PWR AX1 10 PWR AX1 RELAY AX1 AXIS 1 CN1 10 AX1 Use the 2090 U3CC D44xx control interface cable shown below when connecting a single Ultra3000 drive to either the 1756 MO2AE ControlLogix servo module or 1784 PMO2AE SoftLogix PCI card The 1756 TBCH removable terminal block is required when wiring to the ControlLogix module The 1784 PMO2AE TPxx termination panel is required when wiring to the SoftLogix PCI Card Refer to Figure B 23 for the interconnect diagram Figure B 21 Control Interface Cable and Terminations 45 onnector 2090 U3CC D44xx AUX PWR AX0 sub high Control Interface Cable 10 PWR AXO nsity 44 pin RELAY AXO ith 45 black 10 AXD PVC overmold 18 o sS Os 2D 90 w 9 PE 1756 TBCH S 9s 17
44. surfaces need to be paint free or plated Bonding metal surfaces creates a low impedance exit path for high frequency energy TTTIAETUWNAR TO improve the bond between the drive and subpanel construct your subpanel out of zinc plated paint free steel Improper bonding blocks that direct exit path and allows high frequency energy to travel elsewhere in the cabinet Excessive high frequency energy can effect the operation of other microprocessor controlled equipment The illustrations that follow refer to Figure 1 5 show details of recommended bonding practices for painted panels enclosures and mounting brackets Figure 1 5 Recommended Bonding Practices Stud mounting the subpanel Stud mounting a ground bus to the enclosure back wall or chassis to the subpanel Subpanel Back wall of enclosure Mounting bracket or ground bus Subpanel A Welded stud Star washer Flat washer S Scrape paint Flat washer Use a wire brush to remove paint from threads to maximize ground connection If the mounting bracket is coated with a non conductive material anodized painted etc scrape the material Use plated panels or scrape paint on Star washer around the mounting hole front of panel Bolt mounting a ground bus or chassis to the back panel Subpanel Tapped hole Ground bus or mounting bracket s i Ds Star washer Scrape paint on both sides of O N panel and use star washers N Star washer Flat washer
45. transitions of the incoming A and B encoder signals In Figure 2 49 the channel A signal has two transitions as does the channel B signal which results in x4 interpolation 4 transitions line equals 4 counts line So for example typical 2000 line rev encoder output becomes 8000 counts rev in the drive Counts are not directly available at the encoder outputs only the A quad B representation Figure 2 49 Incremental Encoder Counts e OneCycle Channel A 4 D Y Y 1 Channel B Counts The incremental buffered outputs available from the drive CN1 16 through 21 are software selectable as follows e Buffered Outputs are a filtered representation of the original incoming encoder CN2 signals Buffered outputs have the same number of cycles rev as found on CN2 e Interpolated Outputs are the same as buffered outputs when using an incremental encoder The only interpolation performed on an A quad B signal is the drive s internal counting of transitions 4 counts line Because counts are not available outside the drive selecting this in software is the same as selecting buffered as described above e Divided Outputs are the same as buffered outputs except when divided is selected in the software the lines rev are then reduced by the value of the divisor chosen in the software as shown in the figure below Figure 2 50
46. 2090 U3CBB DM12 e 44 pin CN1 connector catalog number 2090 U3ZCBB DM44 If an auxiliary 5V dc logic supply is used the SERCOS ring remains active and motor position can be monitored by the drive even when the AC input power is removed Since the drive is able to monitor the motor position additional homing sequences can be avoided when the AC input power is re applied IMPORTANT Only the 2098 DSD 005 010 and 020 models support an auxiliary 5V logic supply since an auxiliary AC input is not available Refer to Chapter 3 for more information on the auxiliary AC input IMPORTANT Whenever the auxiliary TIV dc logic supply is used and the AC input supply is disconnected the drive must be disabled When the AC input supply is reconnected the drive should not be re enabled for at least 1 0 second to allow the power stage circuitry to fully charge TTTIAETUNAA Once the AC input supply is applied the auxiliary 5V dc logic supply must not be interrupted Removing the 5V dc logic supply with the AC input voltage applied will cause the drive to reboot and loss of control will occur Publication 2098 INOO3E EN P April 2004 2 28 Ultra3000 Connector Data Publication 2098 INOO3E EN P April 2004 Using an External 5V Logic Supply When using an external 5V dc power supply with your Ultra3000 2098 DSD 005 010 and 020 the 5V dc must not be grounded inside the supply since it will be referenced to the drive c
47. 2090 XXNFY Sxx 1 Requires 2090 2090 UXCK D15 mating connector kit Note Refer to Maximum Feedback Cable Lengths on page A 13 to determine the maximum length o feedback cable UXBB DM15 drive mounted breakout board 2090 UXBK D15xx breakout board kit or Motor Feedback Connector Pin outs your motor The following tables provide the signal descriptions and pin outs for the motor feedback CN2 15 pin connector to MP Series Clow inertia and integrated gear 1326AB and N Series motors High Resolution Feedback Signals for Asia dina Motor Drive CN2 Connector MPL Bxxx M S MPL A3xx M S MPL Axxx H Connector Pin MPL A5xx M S and MPL A4xx M S MPL Bxxx H and Pin 1326AB B xxx M2L S2L MPL A45xx M S N Series Motors Motors MPG A Bxxx M S Motors A Sine Sine AM 1 B Sine Sine AM 2 C Cos Cos BM 3 D Cos Cos BM 4 E Data Data IM 5 F Data Data IM 10 K Reserved EPWR_5V EPWR_5V 14 L Reserved ECOM ECOM 6 N EPWR 9V Reserved Reserved 7 P ECOM Reserved Reserved 6 R TS TS TS 11 S TS TS TS 6 T Reserved Reserved S1 Hall A 12 U Reserved Reserved S2 Hall B 13 V Reserved Reserved S3 Hall C 8 Publication 2098 INOO3E EN P April 2004 Connecting Your Ultra3000 3 25 The following tables provide the signal descriptions and pin outs for the motor feedback CN2 15 pin connector to MP Series food grade
48. 57 RS 232 to RS 485 Connection Diagram Common 12V de RS 232 232 to 485 Interface Adapter COM RCV e e e Note Pin outs vary by manufacturer This example uses a B amp B 485 adapter RCV RCV XMT XMT RCV RCV XMT XMT RCV RCV XMT XMT CN1 CN1 CN1 Drive 2 Drive n Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data 2 53 Four Wire RS 485 Connections The Ultra3000 uses a variation of the RS 485 standard known as four wire RS 485 Four wire RS 485 uses one differential signal for host to drive transmissions and another differential signal for drive to host transmissions The RS 485 standard specifies a single differential signal for transmissions in both directions The four wire RS 485 configuration also allows the host to use a RS 422 interface type Because the host is driving multiple receivers and receiving from multiple transmitters RS 422 is limited to multiple axes connections with 10 or less drives The figure below summarizes the four wire RS 485 RS 422 and RS 485 standards Figure 2 58 RS 485 RS 422 Communication Comparison Four Wire RS 485 Differential 4 Wires 2 Signal Pairs 1 to 32 Transmitters 1 to 32 Receivers 32 RS 422 Differential 4 Wires 2 Signal Pairs 1 Transmitter 1 to 10 Receivers
49. AC Line Filters e External Shunt Kits e Motor Power Cables e Motor Feedback Cables e MP Series Motor Brake Cable e Ultra3000 Interface Cables e SERCOS Interface Fiber Optic Cables e Drive End Connector Kits e Motor End Connector Kits e Breakout Boards Cables and Kits Contact your local Allen Bradley sales office for additional information Refer to the Motion Control Selection Guide publication GMC SG001x EN P for details on products Publication 2098 INOO3E EN P April 2004 C 2 Catalog Numbers and Accessories Ultra3000 Drives Software Publication 2098 INOO3E EN P April 2004 Use the following table to identify Ultra3000 240V drives with ratings of 500W 1 kW and 2 kW where xxx equals 005 010 or 020 Description Ultra3000 Digital Servo Drive Catalog Number 2098 DSD xxx Ultra3000i Digital Servo Drive with Indexing 2098 DSD xxxX Ultra3000 Digital Servo Drive with SERCOS 2098 DSD xxx SE Ultra3000 Digital Servo Drive with DeviceNet 2098 DSD xxx DN Ultra3000 Digital Servo Drive with DeviceNet and Indexing 2098 DSD xxxX DN Use the following table to identify Ultra3000 240V drives with ratings of 3 kW 7 5 kW and 15 kW where xxx equals 030 075 or 150 Description Ultra3000 Digital Servo Drive Catalog Number 2098 DSD xxx Ultra3000i Digital Servo Drive with Indexing 2098 DSD xxxX Ultra3000 Digital Servo Drive with SERCOS 2098 DSD xxx S
50. Cable connector kit 9101 0330 Series N Series Cable connector kit 9101 1698 MP Series food grade Included in the power cable 2090 XXNPMF xxS xx power cable the motor does not have a Y Series brake connector 2090 XXNPY 16Sxx power cable To wire your motor brakes refer to Ultra 3000 Motor Interconnect Diagrams in Appendix B for the interconnect diagram showing the brake connections for your Ultra3000 drive and servo motor Publication 2098 INOO3E EN P April 2004 Follow these guidelines when installing and wiring your active or When tightening screws to secure the wires refer to the table on page 3 13 for torque values To ensure system performance run wires and cables in the wireways as established in Chapter 1 Refer to Appendix B for the Ultra3000 interconnect diagrams Then refer to 3 22 Connecting Your Ultra3000 Understanding Shunt Connections passive shunt module resistor IMPORTANT IMPORTANT io HE And you are wiring to requires an External Shunt this Ultra3000 drive 2098 DSD 005x xx 2098 DSD 010x xx or 2098 DSD 020x xx e Planning Your Panel Layout in Chapter 1 e Figure B 5 on page B 7 of Appendix B e The installation instructions provided with your shunt publication 2090 IN002x EN P 2098 DSD 030x xx e Planning Your Panel Layout in Chapter 1 e Figure B 7 on page B 8 of Appendix B e he installation instructions provided with your shunt publication 209
51. Connector Kit 9101 0329 Straight Feedback Connector Kit 9101 0330 Straight Brake Connector Kit H Series 9101 0402 Right Angle Feedback Connector Kit 9101 0403 Right Angle Brake Connector Kit 2090 MPPC S Straight Power Connector Kit MP Series and 2090 MPPC 08S Straight Power Connector Kit 10 mm 8 AWG 1326AB M2L S2L 2090 MPFC S Straight Feedback Connector Kit 2090 MPBC S Straight Brake Connector Kit 9101 1557 Straight Power Connector Kit N Series 9101 1558 Straight Feedback Connector Kit 9101 1698 Brake Connector Kit Y Series 9106 0066 Straight Power and Feedback Connector Kit Publication 2098 INOO3E EN P April 2004 C 8 Catalog Numbers and Accessories Breakout Board Kits Breakout board kits include the 2090 UxBB Dxx DIN rail terminal block 2090 UxBC Dxxxx cable and mounting hardware Catalog Number Description 2090 UXBK D15xx 15 pin high density D shell for Ultra3000 CN2 interface connector 2090 U3BK D44xx 44 pin high density D shell for Ultra3000 CN1 control interface connector Breakout Boards Catalog Number Description 12 pin drive mounted breakout board for Ultra3000 CN1 connector recommended 1 2090 U3BB DM12 for use with SERCOS interface applications 2090 U3BB2 DM44 1 2 44 pin drive mounted breakout board for Ultra3000 CN1 control interface connector 12 pin drive mounted breakout board for Ultra3000 CN1 connector recommended 3 U3CBB DM12 for use with SERCOS interface application
52. Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 45V EPWR 23 Programmable Analog Output AOUT 7 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Auxiliary Logic Power In 5V AUXPWR 25 Command 4 COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common I0COM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUT3 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUT4 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUT5 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUT4 21 Buffered Motor Encoder Ch l IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs
53. EN P September 2006 Ultra3000 Digital Servo Drive Installation Manual 7 Page B 5 Fused Disconnect or Circuit Breaker Note 1 Isolation Transformer Note 2 Three phase AC Line 50 60 Hz Three phase Input 100 240V ac rms Indicates User Supplied Component Neutral Replace the interconnect diagram on page B 5 with the one shown below The new diagram changes the recommended wiring of input fusing ac line filter and contactor Figure B 3 Typical Power Wiring of Ultra3000 System 2098 DSD 075x xx and 150x xx Three Phase Motor Power Connections Ultra3000 Digital Servo Drives 2098 DSD 075x xx and 150x xx Note 13 TB1 Motor Power Connections AC Input Power Connections Note 12 DC4 Input Fusing M1 Note 4 5 Note 8 DC L T l L1 Three phase TI AC Line Filter L2 EET em L3 Vg i L1 AUX LT L2 N AUX Chassis o ze O 8 ED 12 13 Terminal Blocks Note 3 i VV To additional Ultra3000 drive Input Fusing Note 4 5 Bonded Cabinet Ground Bus CN1 Cable Shield el Clamp Note 9 External Passive Shunt Connections N O Relay Output N O Relay Output Note 20
54. Figure 2 35 The input range is 0 to 10V and the drive current is limited inversely proportional to the input voltage A 10V input corresponds to no current limiting and a OV input prevents any drive current Figure 2 35 Analog ILIMIT Input Configuration Ultra3000 Drive ILIMIT The following table provides a description of the analog ILIMIT input specifications Parameter Description Minimum Maximum Number of states that the input signal is divided into Resolution which is zlto the number of bits 10 bits m Input Open circuit impedance measured between the input 10kQ m Impedance and analog common Input Signal Range Voltage applied to the input oV 10V Deviation from the correct value expected from Offset Error analog to digital conversion when OV is applied to the 50 mV input Deviation of the transfer function from unity gain EU Gain Error expressed in a percent of full scale 1 Propagation Delay from the input to the firmware accessible EN 100 uS Delay Publication 2098 INOO3E EN P April 2004 registers Ultra3000 Connector Data 2 39 Analog Output The Ultra3000 includes a single analog output not supported on the SERCOS models that can be configured through software to represent drive variables Figure 2 36 shows the configuration of the analog output Figure 2 36 Analog Output Configuration Ultra3000 Drive AOUT 100 Q IMPORTANT
55. Incremental Encoder Divided Signal A from Incremental Encoder Unbuffered Signal A Output from Drive Divided by two Signal A Buffered Output from Drive Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data High Resolution Encoder Output When the incoming encoder feedback on CN2 is a high resolution SIN COS signal the drive is capable of generating more than just 4 counts cycle as with incremental encoders The Ultra3000 drive is capable of breaking the SIN COS encoder signals into as many as 1024 counts cycle So for example a 1024 cycle rev SIN COS encoder can result in 1024 x 1024 high resolution counts rev Figure 2 51 Absolute High Resolution Encoder Signals CN1 10 SIN AM Unbuffered encoder feedback signal to drive 1024 cycles rev Voltage CN1 12 COS BM Unbuffered encoder feedback signal to drive 1024 cycles rev Voltage CN1 16 SIN AMOUT Buffered output from drive CN1 18 COS BMOUT Buffered output from drive Publication 2098 INOO3E EN P April 2004 The high resolution buffered outputs available from the drive CN1 16 through 21 are software selectable as follows Buffered Outputs are conditioned SIN COS signals resulting in a square wave A quad B signal refer to Figure 2 51 This signal will have the same number of cycles rev as the incoming SIN COS encoder signals found o
56. Installation and Handling Instructions publication 2090 INO103 EN P for more info mation Publication 2098 INOO3E EN P April 2004 4 10 Troubleshooting Status Indicators Troubleshooting for DeviceNet Drives If the Network Status LED is Status is Not powered DeviceNet Module Status LED Use the table below for troubleshooting the DeviceNet Module Status LED on your Ultra3000 2098 DSD xxx DN xxxX DN HVxxx DN or HVxxxX DN Ke aae Status is Potential Cause is Possible Resolution is Off Not powered No power There is no power going to the device Steady Green Operational Normal operation Normal operation no action needed Device is in Processing or waiting Flashing Green stand by or input Normal operation no action needed Flashing Red Recoverable fault ot operational Power cycle or reset the drive Steady Red Unrecoverable ault Drive problem 1 Check drive for power up error 2 Replace drive Flashing Red Green Self testing Self test in progress DeviceNet Network Status LED The device is in self test wait Use the table below for troubleshooting the DeviceNet Network Status LED on your Ultra3000 2098 DSD xxx DN xxxX DN HVxxx DN or HVxxxX DN Potential Cause is e No power going to Possible Resolution is 1 Check the Module Status LED to verify that the drive is powered Off e Noton line h
57. Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 2098 IN003E EN P April 2004 Supersedes Publication 2098 IN003D EN P May 2003 Copyright 2004 Rockwell Automation Inc All rights reserved Printed in the U S A
58. Motor Power B 41 mr W Me l CN2 C yy RED BM H 3 WHT RED BM Motor Feedback D XX IM 4 9101 1698 Brake Cable Connector Kit gt gt t Tach W E E Note 12 gt gt 1 43 Black C BR R S WHT BROWN TS 11 Control Interface 44 Note 19 A BR 3 Motor Brake ws BROWN XX S3 m 8 a V 44 pin Connector White Ks ME GRAY 45VDC 14 E CNI COM 424V NK gt User Supplied ae WHT GRAY ECOM 6 24V de Power Supply gt Had Cable Shield 1A max Us BLUE 52 113 m Clamp T WHT BLUE XY S1 12 Note 9 H VIOLET 0 2 Thermostat H S s WHT VIOLET TS 6 EB j Publication 2098 INOO3E EN P April 2004 Interconnect Diagrams B 15 In the figure below the Ultra3000 230V is shown connected to Y Series 230V servo motors Figure B 15 Ultra3000 to Y Series 230V Motor Configuration Y Series 230V SERVO MOTORS WITH INCREMENTAL FEEDBACK Ultra3000 230V Drive Green Yellow Motor Feedback Note 13 3 Black GND CN2 Connector 2 Black V cA m mre Tom Three Phase N Pame ESD aao us A l Motor Feedback Motor Power 9 5 pack AM 11 15 pin Connector 2090 XXNPY 16Sxx 10 AVE WHT BLACK XX AM 2 CN2 Motor Power Cable gt BM 3 Note 12 11 RED Motor 12 lt 4 WHU RED XX BM IMEE Feedback
59. N TB1 Terminals L2 Neutral E f L 9909 Bonded cabinet ground bus 9 Ground grid or e Power distribution ground Note Reducing transformer output will reduce motor speed Note Feeder and branch short circuit protection is not illustrated Isolation Transformer in Grounded Power Configurations When using an isolation transformer attach a chassis ground wire to the neutral connection This accomplishes the following e Prevents the system from floating and thereby avoids any high voltages that might otherwise occur e g through static e Provides a solid earth path for fault conditions If the supply transformer is an auto transformer not ATTENTION ATTENTION recommended a chassis earth ground should not be added A chassis earth ground should already be included elsewhere in the system and adding another would create a short Publication 2098 INOO3E EN P April 2004 3 6 Connecting Your Ultra3000 Three Phase Power Wired to Single Phase Drives The following examples figures 3 5 and 3 6 illustrate grounded three phase power wired to single phase Ultra3000 drives when phase to phase voltage is within drive specifications Figure 3 5 Single Phase Amplifiers on Three Phase Power WYE i M1 u Input Fusing TBI
60. No Restrictions Publication 2098 INOO3E EN P April 2004 Installing Your Ultra3000 1 15 The table below indicates the zoning requirements of cables connecting to the External Shunt Resistor Kit Zone Method Wire Cable Connector Ve ry z Ferrite Shielded Dirty Dirty Clean Sleeve Cable Shunt Connections shielded option n X X Shunt Connections unshielded option X Fan if present N A X Mounting Guidelines to Reduce Electrical Noise When mounting an AC line EMO filter or external shunt resistor refer to the sections below for guidelines designed to reduce system failures caused by excessive electrical noise ATTENTION High voltage exists in AC line filters The filter must be grounded properly before applying power Filter capacitors retain high voltages after power removal Before handling the equipment voltages should be measured to determine safe levels Failure to observe this precaution could result in personal injury AC Line Filters Observe the following guidelines when mounting your AC line EMC filter refer to Figure 1 7 for an example e Mount the AC line filter and bonded cabinet ground bus on the same panel as the Ultra3000 and as close to the Ultra3000 as possible e Good HF bonding to the panel is critical For painted panels refer to Figure 1 5 e Segregate input and output wiring as far as possible IMPORTANT CE test certification applies
61. Output values can vary during power up until the specified power supply voltage is reached The following table provides a description of the analog output specifications Parameter Description Minimum Maximum Number of states that the output signal is divided Resolution into which is zlto the number of bits 8 Bits ums Output Current Current capability of the output 2 mA 2 MA Output Signal Range Range of the output voltage 10V 10V Offset Error Deviation when the output should be at OV 500 mv Deviation of the transfer function from unity gain _ 1 Gain Error expressed in a percent of full scale 10 Bandwidth Frequency response of the analog output 50 Hz The offset and gain errors of the analog output can be corrected for an application using Ultraware scale and offset settings Publication 2098 INOO3E EN P April 2004 2 40 Ultra3000 Connector Data Understanding Motor Encoder Feedback Specifications 1kQ Publication 2098 INOO3E EN P April 2004 The Ultra3000 can accept motor encoder signals from the following types of encoders Incremental encoders with TTL outputs with or without Hall signals Sine Cosine encoders with or without Hall signals Intelligent absolute encoders Intelligent high resolution encoders Intelligent incremental encoders Note The intelligent absolute high resolution and incremental encoders are available only in Al
62. RS 232 RS 422 and RS 485 communication standards Standard baud rates include 1 200 2 400 4 800 9 600 19 200 and 38 400 baud Data lengths of 7 and 8 bits are supported Parity settings include odd even and none The connector pinout dedicates separate pins for the RS 232 and RS 422 RS 485 signals so that the communication standard can be changed by just using a different cable Refer to Figure 2 55 for the serial interface configuration Figure 2 55 Serial Interface Configuration DL XMT RECEIVE E I E RCV XMT XMT RCV RCV TRANSMIT gt Publication 2098 INOO3E EN P April 2004 2 52 Ultra3000 Connector Data Default Serial Interface Settings The default setting of the Ultra3000 serial interface is as follows Parameter Default Setting Baud Rate 38 400 Frame Format 8 Data No Parity One Stop Drive Address 0 Figure 2 56 RS 232 Connection Diagram USER PC 9 Pin j 9 Pin 9 Pin Ultra3000 Drive RS 232 Female Male i CN1 Connector RCV 2 A 2 2 XMT 3 3 3 COM 5 5 5 Drive Chassis Note PC pin outs vary by manufacturer l Multiple Axes RS 232 Communications You can control multiple axes systems with a computer equipped with an RS 232 serial port An RS 232 serial communication port may be converted to four wire RS 485 communication by attaching an RS 232 to four wire RS 485 converter The figure below depicts the use of such a device Figure 2
63. UXNPAN 16Rxx Y Series 230V non flex 16 AWG straight 2090 XXNPY 16S xx Publication 2098 INOO3E EN P April 2004 Catalog Numbers and Accessories C 5 Motor Feedback Cables Description H Series non flex connector at both ends right angle Catalog Number 2090 UXNFBH R xx H Series non flex motor connector to flying leads right angle 2090 UXNFDH Rxx H and F Seri es non flex connector at both ends straigh 2090 UXNFBHF S xx H and F Ser ies non flex motor connector to flying leads straight 2090 XXNFHF Sxx H and F Seri es non flex connector at both ends right ang e 2090 UXNFBHF R xx H and F Seri es non flex connector at both ends right angle skewed 2090 UXNFBHF K xx MP Series MPL MPG non flex connector at both ends straight 1326AB Series M2L S2L non flex con nector at both en ds straight 2090 UXNFBMP Sxx MP Series MPL MPG non flex motor connector to flying leads straight 1326AB Series M2L S2L non flex mo or connector to flying leads straight 2090 XXNFMP Sxx MP Series MPF non flex motor conne ctor to flying leads straight 2090 XXNFMF S xx N Series non flex connector at both en ds straight 2090 UXNFBN S xx N Series non flex motor feedback connector to flying leads straight 2090 XXNFN S xx Series non flex connector at both en
64. and output control Figure B 2 Typical Power Wiring of Ultra3000 System 2098 DSD 030x xx Ultra3000 Digital Servo Drives 2098 DSD 030x xx Note 13 TB1 TB2 1 External Passive Three Phase Shunt Connections Motor Power V Motor Power 2 refer to figures Connections Connections beginning on B 7 Note 12 W 3 DC M1 Note 8 DC m n n HHEH HH u Single Phase AC Line Filter LLLI L2 N Note 7 T AC Input Power CN1 Single Phase AC Line GO cones N O Relay Output 50 60 Hz connections 43 y Uutp e s ote v Note E L1 AUX m N O Relay Output L2 N AUX Fused Disconnect Input Fusing or Circuit Breaker Note 4 5 Note 1 Cable Shield Bonded Cabinet amp Clamp Isolation Chassis Ground Bus O Note 9 Transformer AAN O Note 2 MAN O Oo d Single Phase Input CN1 100 240V ac RMS 43 li START STOP CR T v Terminal l QOO l Blocks T L m 24 de Note 3 44 M1 l INDICATES USER SUPPLIED COMPONENT cRI l l i nas Refer to Attention statement Notes 10 11 o additional Ultra3000 drive Note Refer to Figure 2 26 in the chapter Ultra3000 Connector Data for more information on the relay output Publication 2098 INOO3E EN P April 2004 Interconnect Diagrams B 5 The Ul
65. attaching the Ultra3000 DN to a network Publication 2098 INOO3E EN P April 2004 3 30 Connecting Your Ultra3000 Connecting Your DeviceNet Cable To wire the DeviceNet connector 1 Strip 65 mm 2 6 in to 75 mm 2 96 in of the outer jacket from the end of the cable leaving no more than 6 4 mm 0 25 in of the braided shield exposed Figure 3 25 Exposing the Braided Shield 6 4 mm Outer Jacket 0 25 in Braided Shield 4 65 mm 2 6 in 2 Wrap the end of the cable with 38 mm 1 5 in of shrink wrap covering part of the exposed wires and part of the outer jacket Figure 3 26 Adding Shrink Wrap 38 mm 1 5 in Outer Jacket x la 3 Strip 8 1 mm 0 32 in of the insulation from the end of each of the insulated wire MESIT Use caution not to nick cut or otherwise damage strands as you remove the insulation I Shrink Wrap Trim the last 6 4 mm 0 25 in of the bare wires so that the outside dimension does not exceed 0 17 mm 0 045 in Figure 3 27 Exposing Wire Strands 8 1 mm 0 32 in Outer Jacket M lt Shrink Wrap Publication 2098 INOO3E EN P April 2004 Connecting Your Ultra3000 3 31 4 Using a screwdriver loosen the screw for each of the terminal locations refer to Figure 3 28 and attach wires as shown in the table below Insert this wire Into this terminal on the Color Designation DeviceNet connector
66. connections on the Ultra3000 460V drives 3W 5 kW 10 kW 15 kW and 22 kW Figure 2 4 Ultra3000 Front Panel Connections for 2098 DSD HV xxx and HV xxxX Ew Q Passive Shunt Resistor Connections Motor Power Connections AC Input Power Connections Motor Power Cable Shield Clamp Allen Bradley su Ultrasoco B Seven Segment Status LED F Logic Power LED CN3 9 pin Serial Port Connector CN2 15 pin lt Motor Feedback Connector CN1 44 pin User l 0 Connector Publication 2098 INOO3E EN P April 2004 Serial Port Connector 9 pin CN3 Serial Connector 15 pin CN2 Feedback Connector Pin 10 Pin 15 d Pin 11 ese Pin 6 44 pin CN1 1 0 Connector Pin 30 Pin 44 1fege Pin 15 Pin 31 Pint6 1 o Pin 1 The following table provides the signal descriptions and pin outs for the CNS serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 O
67. connections on the Ultra3000 with DeviceNet Interface 230V drives 7 5 and 15 kW Figure 2 11 Ultra3000 Front Panel Connections for 2098 DSD 075 DN 075X DN 150 DN and 150X DN Serial Port Connector Seven Segment Status LED Logic Power LED Module Status LED Network Status LED Node Address Switches Data Rate Switch CN3 9 pin Serial Port Connector CN2 15 pin Motor Feedback Connector CN1 44 pin User 1 0 Connector DeviceNet Interface Connector 9 pin CN3 Serial Connector 15 pin CN2 pin CN1 Pin 1 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT g Reserved 1 0 Connector Ultra3000 Connector Data 2 23 The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector
68. 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 RM001 x EN P 20 Relay Output CN1 pins 43 and 44 must be configured as Ready in Ultraware software 21 The preferred method for supplying the auxiliary power is by using the 12 or 44 pin drive mounted breakout board with 24V to 5V auxiliary power converter catalog number 2090 U3CBB DM12 or DM44 Auxiliary 5V power is required to maintain encoder position when the main AC power is disconnected Publication 2098 INO03E EN P April 2004 Interconnect Diagrams Power Interconnect Diagrams Single Phase AC Line Fused Disconnect or Circuit Breaker Note 1 UU 50 60 Hz Y YN Isolation Transformer Note 2 Chassis The Ultra3000 2098 DSD 005x xx 010x xx and 020x xx power wiring with 24V dc control string non SERCOS drives only is shown in the figure below To avoid a separate 5V dc auxiliary logic power supply the 24V to 5V converter breakout board 2090 U3CBB DMxx is used to wire the control interface CN1 connector For the control string diagram with 120V ac input refer to Figure B 16 For SERCOS drives input line contactor is part of the PLC program and output control Figure B 1 Typical Power Wiring of Ultra3000 System 2098 DSD 005x xx 010x xx and 020x xx Ultra3000 Digital Servo Drives 2098 DSD 005x xx 010x xx
69. distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok
70. drivers can drive a 2V differential voltage into a 100 ohm load Use the block diagram below to follow the motor encoder input through CN2 to the buffered and unbuffered outputs on CN1 Figure 2 48 Motor Encoder Outputs TIL x4 Sin Cos x4 to x1024 Interpolation l Filtering Differential Receivers Ultra3000 Drive Motor Se Encoder Position Feedback 4 7 Division TTL or A quad B incremental If A leads B in A leads B out SIN COS high resolution If A leads B in B leads A out Selected Unbuffered Encoder diced ct QU Output uffered Type Y CN1 Interpolated Differential Buffered Frequency mO Drivers Encoder Limit Output Divided 0 5 to 8 MHz gt O Publication 2098 INOO3E EN P April 2004 1 Interpolation and division operations are performed in firmware and the resulting output frequency is updated at 250 us intervals 2 Interpolated and divided output not available on SERCOS drives Unbuffered Encoder Outputs The unbuffered outputs available from the drive CN1 10 through 15 are tied directly to the incoming incremental or high resolution encoder signals CN2 1 through 6 The unbuffered outputs are not filtered or conditioned CN2 1 CN1 10 CN1 16 Ultra3000 Connector Data 2 47 Incremental Encoder Output Incremental encoder counts are generated in the drive by counting the high to low and low to high
71. for the CN2 motor encoder 15 pin connector CN2Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Input AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Input BM 11 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 13 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR 5V 7 Reserved 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data Passive Shunt Resistor Connections Motor Power Connections AC Input Power Connections Motor Power Cable Shield Clamp Publication 2098 INOO3E EN P April 2004 Use the figure below to locate the front panel connections on the Ultra3000 230V drives 3 kW Figure 2 2 Ultra3000 Front Panel Connections for 2098 DSD 030 and 030X a j 69 B E e 5 ES a S E v poor U B Eli CE lt e 5 DC Bus E i a ell B en lt we ele m d amp ux th n n Serial Po
72. models only when using an external 5V auxiliary power supply Hardware Overtravel ET e Check wiring E06 Dedicated overtravel input is inactive SERCOS only p e Verify motion profile E07 RESERVED Call your local Allen Bradley E08 RESERVED representative e Verify voltage level of the incoming AC power E09 Bus Undervoltage Low AC line AC power input d power source for glitches or e Install an uninterruptible power supply UPS on your AC input Publication 2098 INOO3E EN P April 2004 Troubleshooting Status Indicators 4 5 y Problem or Symptom Possible Cause s Action Solution e Change the deceleration or motion Excessive regeneration of power profile When the motor is driven by an external e Use a larger system motor and mechanical power source it may Ultra3000 E10 Bus Overvoltage regenerate too much peak energy through e Use a resistive shunt the Ultra3000 s power supply The system f i M faults to save itself from an overload e Ifa shunt is connected verify the wiring is correct and shunt fuse is not blown Excessive AC input voltage Verify input is within specifications Incorrect phasing Check the Hall phasing E11 IllegalHall State T e Verify the Hall wiring ad connections e Verify 5V power supply to the encoder e Check wiring E12 Home Search Failed Home sensor and or marker is outside the 9 a overtravel limits e Reposition the overtravel lim
73. motor feedback cable catalog number e Motor Feedback Connector Pin outs on page 3 24 e Understanding Motor Encoder Feedback Specifications beginning on page 2 40 CN3 Serial Connector PC serial connector to premolded drive connector 2090 UXPC DM08 9 pin drive mounted breakout board 2090 UXBB DM09 9 pin high density D shell drive connector kit 2090 UXCK D08 Understanding the Serial Interface beginning on page 2 51 This breakout board accepts 1 0 14 mm 16 26 AWG wire For applications that require a 44 pin drive mounted breakout board that accepts 4 0 5 mm 12 22 AWG wire contact your local Allen Bradley representative Publication 2098 INOO3E EN P April 2004 3 24 Connecting Your Ultra3000 Refer to the table below for motor feedback cable catalog numbers available for specific motor feedback combinations i Use this Feedback Cable For this Motor Series ie m Type of Motor eednack Premolded Flying Lead MPL Axxxx or MPG Axxx xxx High resolution encoder MPL Axxxx Incremental encoder 1 2090 UXNFBMP Sxx 2090 XXNFMP Sxx MPL Bxxxx or MPG Bxxx xxx High resolution encoder 1326AB M2L S2L High resolution encoder MPF Axxxx or MPF Bxxxx High resolution encoder N A 2090 XXNFMF Sxx F Series 1 2090 UXNFBHF Sxx 2090 XXNFHF Sxx H Series Incremental encoder i N Series 2090 UXNFBN S xx 2090 XXNFN Sxx Y Series 2090 UXNFBY Sxx
74. motor end C 7 connector specifications A 10 contactor specifications A 7 contents of manual P 2 control string 120V single phase 0 5 1 and 2 kW B 16 120V single phase 3 kW B 17 120V three phase 7 5 and 15 kW B 18 control string examples B 16 controlling a brake B 19 ControlLogix integration P 1 Controllogix motion module programming manual P 3 ControlLogix motion module setup and configuration manual P 3 conventions used in this manual P 4 D data rate 3 29 declarations of conformity DOC 1 2 DeviceNet cable 3 30 connector 3 30 network 3 29 DeviceNet cable system planning and installation manual P 3 3 29 digital inputs 2 28 assigned preselect inputs 2 29 input interface examples 2 30 2 32 digital outputs drive output examples 2 34 hardware configuration 2 33 digital relay output B 2 B 16 dimensions 230V A 14 A 15 460V A 16 drive end connectors C 6 drive ready B 16 E elevation requirements 1 6 EMC cable shield bottom of drive 3 11 cable shield front of drive 3 11 motor ground termination at motor 3 10 EMI ElectroMagnetic Interference HF bonding 1 10 enclosure sizing A 7 error codes and messages 4 3 external shunt kit C 3 external shunt resistor noise reduction 1 16 wiring 3 22 F fiber optic cables C 6 receive and transmit connectors 3 26 Fiber optic cable installation instructions P 3 flyback diodes B 19 front panel connections 2 1 2 4 2 6 2 8 2 10 2 12 2 14 2 16 2
75. motor feedback A 10 physical and environmental A 8 power dissipation A 7 power 230V A 2 A 3 power 460V A 4 shunt modules A 12 status LED 4 3 storage responsibility P 2 support comments regarding this manual P 4 local product P 4 technical product assistance P 4 System Design for Control of Electrical Noise Reference Manual P 3 system mounting requirements Index 1 5 elevation 1 6 fuse sizing 1 10 minimum clearances 1 7 sizing an enclosure 1 8 transformer sizing 1 8 ventilation 1 7 T TB1 terminal positions 3 14 TB2 terminal positions 3 15 terminal block connections 3 13 3 14 terminal positions TB1 3 14 terminal positions TB2 3 15 The Automation Bookstore P 1 transformer sizing 1 8 troubleshooting 4 3 DeviceNet module status LED 4 10 network status LED 4 10 error codes 4 3 module status LED 4 9 SERCOS module status LED 4 9 network status LED 4 9 troubleshooting status indicators 4 1 typical installation 1 3 Ultra3000 1 4 Ultra3000 DeviceNet 1 5 Ultra3000 SERCOS 1 4 U Ultra3000 component overview 1 3 troubleshooting status indicators 4 1 typical installation 1 4 DeviceNet 1 5 SERCOS 1 4 Ultra3000 accessories catalog numbers C 1 Itra3000 DeviceNet reference manual P 3 Itra3000 digital servo drives integration manual P 3 Itra3000 drives C 2 Itraware CD installation instructions P 3 Ultraware software C 2 G G ee Publication 2098 INOO3E EN P April 2004 1 6 Index Publicatio
76. not being driven mechanically causing the motor to behave as a generator The motor physically connected to the drive E42 Motor Keying Error SERCOS drives only differs from the motor specified in the user Select the correct motor in the user program program e Anattempt was made to enable the e Disable the Drive Enable Input fault axis through software while the Drive s Verh that Duve Enable hard inet Drive Enable Input Enable hardware input was inactive RET Mete nee M E43 c i M is active whenever the drive is enabled SERCOS drives only e The Drive Enable input transitioned through software from active to inactive while the axis was enabled E50 Duplicate Node Fault Duplicate node address detected on Verify that each SERCOS drive is assigned rives only ring a unique node address SERCOS dri ly SERCOS ri i de add All others RESERVED Call your local Allen Bradley Publication 2098 IN003E EN P April 2004 representative Troubleshooting for SERCOS Drives Troubleshooting Status Indicators SERCOS Module Status LED Use the table below for troubleshooting the SERCOS Module Status LED on your Ultra3000 2098 DSD xxx SE or HVxxx SE If the SERCOS Module Status Status is Potential Cause is Possible Resolution is LED is Steady Green Normal Drive is enabled Normal operation when drive is enabled Flashing Green Standby Drive is not enabled Normal operation when drive is disabled 7m ashing Red
77. only to AC line filter and single drive Multiple drive loads may perform satisfactorily but the user takes legal responsibility Publication 2098 INOO3E EN P April 2004 1 16 Installing Your Ultra3000 Publication 2098 INOO3E EN P April 2004 External Shunt Resistor Observe the following guidelines when mounting your external shunt resistor refer to Figure 1 9 and for an example e Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI e Mount resistors other than metal clad in a shielded and ventilated enclosure outside the cabinet e Keep unshielded wiring as short as possible Keep shunt wiring as flat to the cabinet as possible Figure 1 9 External Shunt Resistor Outside the Enclosure Customer supplied metal enclosure 150 mm 6 0 in of clearance on all sides of the shunt module pio Metal conduit minimum where required by local code Clean Wireway Dirty Wirewa i i Shunt Wiring Methods Twisted pair in conduit 1st choice Shielded twisted pair 2nd choice Twisted pair 2 twists per foot min 3rd choice Very dirty shunt connections segregated not in wireway Maximum Length 3 05 m 10 ft
78. or above Requires use of drive mounted breakout board 2090 U3BB2 DM44 Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2Pin Description Sigal CN2Pin Description Signal 1 ChannelAsSineDifferenialInput AMe g PostiveOvetravellimt 4IMT 2 Channel A Sine Differential Input AM 10 Channel I Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 2 Commutation Channel S1 S1 5 Channel l Index Pulse IM 13 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR_5V 7 Encoder Power 9V EPWR_9SV 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 3 Publication 2098 INOO3E EN P April 2004 2 14 Ultra3000 Connector Data Use the figure below to locate the front panel connections on the Ultra3000 with SERCOS interface 230V drives 7 5 and 15 kW Figure 2 7 Ultra3000 Front Panel Connections for 2098 DSD 075 SE and 150 SE Passive Shunt Taal 1 Resistor Connections aa LEN Ew pre TB2 lle Motor Power Le Connections elle Elle DC Bus E E
79. or the ControlLogix and SoftLogix modules PCI cards see table below refer to the Ultra3000 Digital Servo Drives Integration Manual publication 2098 IN005x EN P Manuals are available electronically as a pdf or in hardcopy from www theautomationbookstore com Interface eens Motion SoftLogix PCI Card SERCOS interface 1756 MxxSE 1784 PM16SE Analog interface 1756 M02AE 1784 PMO2AE Publication 2098 INOO3E EN P April 2004 P 2 Preface Contents of this Manual Product Receiving and Storage Responsibility Publication 2098 INOO3E EN P April 2004 Refer to the following listing for the descriptive contents of this installation manual Chapter Title Contents Describes the purpose background and scope of Preface this manual Also specifies the audience for whom this manual is intended 1 Installing Your Ultra3000 Provides mounting information for the Ultra3000 Provides 1 0 encoder and serial interface 2 Ultra3000 Connector Data connector locations and signal descriptions 3 Connecting Your Ultra3000 Provides connection and wiring information for the Ultra3000 4 Troubleshooting Status Provides troubleshooting tables that define the Indicators Ultra3000 status LED error codes Provides physical electrical environmental and Appendix A Specifications and Dimensions functional specifications for the Ultra3000 Provides interconnect diagrams for the Appendix B_
80. panel refer to Figure 1 7 for zone locations e The clean zone C is above and beneath the Ultra3000 and includes CN1 CN2 CN3 and the DC filter grey wireways e The dirty zone D is left of the Ultra3000 black wireways and includes the circuit breakers transformer AC line filter contactors 24V dc power supply and motor power cables e The very dirty zone VD is limited to where the AC line EMO filter AC output jumpers over to the Ultra3000 Shielded cable is required only if the very dirty cables enter a wireway e The SERCOS fiber optic cables are immune to electrical noise Figure 1 7 Establishing Noise Zones Dirty Wireway Clean Wireway a 5 Ultra3000 ount AC line zi filter as close CN3 Circuit to the drive as ay Breaker 24V Contactors possible D a Power Supply e e CN2 ae om Line Filter Very dirty EMC filter connections segregated not in wireway Motor Power Cables CN1 1 0 Cable Route Motor Power Route Encoder Analog Registration Shielded Cable Shielded Cable If 0 cable contains dirty relay wires route cable with motor power wires in dirty wireway This is a clean 24V dc available for CN1 1 0 power supply The 24V enters the clean wireway and exit
81. pin outs for the CN3 serial port 9 pin connector CN3Pin Description JSigya 1 RS 422 RS 485 Inputs CRC 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT g Reserved Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data 2 7 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector CN1 Pin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 45V EPWR 23 Programmable Analog Output AOUT 7 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Command COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common IOCOM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUTS 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUT4 13 Unb
82. the table below for the available options Connector Option 44 pin drive mounted breakout board wi power converter h 24V to 5V auxiliary Option Catalog Number 2090 U3CBB DM44 12 pin drive mounted breakout board with 24V to 5V auxiliary power converter for SERCOS interface applications 2090 U3CBB DM12 Reference e CN1 Control Interface Breakout Boards with 24V to 5V Auxiliary Power Converter publication 2090 INO08X EN P e Understanding Ultra3000 1 0 Specifications beginning on page 2 26 44 pin panel mounted breakout board ki 2090 U3BK D44xx 44 pin drive mounted breakout board 2090 U3BB2 DM44 44 pin high density D shell drive connector kit 2090 U3CK D44 Single axis flying lead to 1756 MO2AE module or 1784 PM02AE PCI card 2090 U3CC D44xx Understanding Ultra3000 I O Specifications beginning on page 2 26 Two axis pre wired to 1756 M02AE module 2080 U3AE D44xx e Understanding Ultra3000 I O Specifications on page B 20 e Understanding Ultra3000 1 0 Specifications beginning on page 2 26 CN2 Feedback Connector Premolded cable at drive and motor end 2090 UXNFBxx Sxx 15 pin drive mounted breakout board 2090 UXBB DM15 Flying lead cable at y 15 pin panel mounted breakout board kit drive end 2090 UXBK DM15xx 2090 XXNFxx Sxx 15 pin high density D shell drive connector kit 2090 UXCK D15 e The table below for your
83. thermostat The logic is designed so that an open condition will generate a fault If the motor does not have a thermostat signal the drive can be configured through software to ignore the signal Figure 2 39 Thermostat Input Configuration Ultra3000 Drive 5V TS COMMON COMMON Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data 2 43 Figure 2 40 Typical Thermostat Connection Ultra3000 Drive Motor Encoder Thermostat normally closed Limit and Limit Inputs The Ultra3000 drive includes integral overtravel limit inputs on the motor encoder connector CN2 The logic is designed so that an open condition will halt motion in the corresponding direction The integral limits are configured by the actual motor file and not software programmable Although typically not for use on standard servo motors they may be activated for linear motors or other unique applications Figure 2 41 shows the configuration of the Limit and Limit inputs Figure 2 42 shows a typical connection to a motor with integral limit switches Figure 2 41 Limit and Limit Input Configuration Ultra3000 Drive aS 5V 5V LIMIT or LIMIT COMMON COMMON Figure 2 42 Typical Limit and Limit Connection Motor Encoder Ultra3000 Drive LIMIT POSITIVE OVERTRAVEL Yd LIMIT NEGATIVE OVERTRAVEL L 1 Publication 2098 INOO3E EN P April 2004 2 44 Ultra3000 C
84. to systems with absolute feedback pgraee rmware i e Operate within not above the A R continuous torque rating for the and or ambient temperature 40 C maximum e Lower ambient temperature increase E04 Motor Overtemperature e Excessive current motor cooling Motor wiring error Check motor wiring Incorrect motor selection Verify the proper motor has been selected Verify continuity of motor power cable and Motor cables shorted onneton Disconnect motor power cables from the Motor winding shorted internally motor If the motor is difficult to turn by hand it may need to be replaced e Check for clogged vents or defective fan Ultra3000 temperature too high C e Ensure cooling is not restricted by insufficient space around the unit e Verify ambient temperature is not too high Operation above continuous power rating e Operate within the continuous power E05 IPMFault rating e Reduce acceleration rates Remove all power and motor connections and preform a continuity check from the DC Ultra3000 has a bad IPM output short bus to the U V and W motor outputs If a circuit or overcurrent continuity exists check for wire fibers between terminals or send drive in for repair An attempt was made to enable the drive without waiting at least 1 0 second after applying the main AC power Note This Wait at least 1 0 second after the main AC applies to 2098 DSD 005 010 and 020 is applied before enabling the drive Ultra3000
85. x4540 dd Y 3023 0 37 A MPG A004 0 33 A TL A110P H A120P H and A130P H 0 208 A MPG 4010 TL A220P H and A230P H 0 375 A MPG x025 on TL A2530P H and A2540P H 0 396 A MPG x050 0 50 A TL A410P H 0 746 A MPG x110 10A 1 Applies to 230V and 460V motors Replace Figure B 19 with the one shown below The new figure correctly identifies the relay output pins as CN1 43 and CN1 44 Figure B 19 Example Configuration Controlling a Motor Brake O O Power Supply 3A 24V d H Ultra3000 Drive i 0 Bo Te n Teire m s Te m TT z L LE ph dd e e e 43 N O Relay Output bea Motor Power ME CNA N O Relay Output wt Q TER 44 N O Relay Outp ere Tm 1 Flyback diode 1N4004 rated 1 0 A 400V dc or MOV suppresses the collapsing field of the brake coil For non SERCOS drive the relay output CN1 43 and 44 must be configured as a brake IMPORTANT Electrical arcing may occur at the relay contacts until the brake power dissipates A customer supplied diode or metal oxide varistor MOV is recommended to prevent arcing Use of an MOV can also reduce the time to mechanically engage the brake Allen Bradley Rockwell Automation and Ultra3000 a
86. 0 IN003x EN P 2098 DSD 075x xx or 2098 DSD 150x xx e Planning Your Panel Layout in Chapter 1 e Figures B 7 and B 8 on page B 8 of Appendix B e The installation instructions provided with your shunt publication 2090 INO01 x EN P 2098 DSD HV030 xx HV050 xx or HV100 xx e Planning Your Panel Layout in Chapter 1 e Figure B 7 on page B 8 of Appendix B e The installation instructions provided with your shunt publication 2090 IN004 x EN P 2098 DSD HV150 xx or HV220 xx e Planning Your Panel Layout in Chapter 1 e Figure B 9 on page B 9 of Appendix B e The installation instructions provided with your shunt Internal Shunt 2098 DSD 030x xx 2098 DSD 075x xx 2098 DSD 150x xx 2098 DSD HV xxx xx or 2098 DSD HVxxxX xx Figure 3 19 Connecting Your Shunt Resistor Verify the TB2 internal shunt jumper is in place between TB2 1 and TB2 2 as shown in Figure 3 19 below Connecting the Internal Shunt Resistor cc fel TB2 This is the factory default jumper setting for TB2 Publication 2098 INOO3E EN P April 2004 Understanding Feedback and I 0 Cable Connections Drive Connector CN1 1 0 Connector Connecting Your Ultra3000 3 23 Factory made cables with premolded connectors are designed to minimize EMI and are recommended over hand built cables to improve system performance However other options are available for building your own feedback and I O cables Refer to
87. 000000008 A 10 AC Line Filter Specifications issus 4 ee ea m Rd A 11 Ultra Family External Shunt Module Specifications A 12 Maximum Feedback Cable Lengths A 13 Dimensions RTI s A 14 Ultra3000 230V Dimensions gat e RR RR Scc A 14 Ultra3000 460V Dimensions 005 A 16 Appendix B Chapter Objectives iusso dear oe eo e orc e deed B 1 Ultra3000 Interconnect Diagram Notes B 2 Power Interconnect Diagrams llle B 3 Shunt Module Interconnect Diagrams cs o mn B 7 Active Shunt Module Diagrams ccs rs B 7 Passive Shunt Module Diagrams B 7 Ultra3000 Motor Interconnect Diagrams B 10 Control String Examples 120V ac isses ek En era B 16 Publication 2098 INOO3E EN P April 2004 iv Table of Contents Catalog Numbers and Accessories Publication 2098 INOO3E EN P April 2004 Controlling a Brake Example 000 B 19 Ultra3000 to Logix Cable and Interconnect Diagrams B 20 Ultra3000 to IMC S Compact Cable and Interconnect Diagram llle B 23 Appendix C Chapter Objectives ia gas Ps ded dede ido Pe od oo dee C 1 Ultra3000 Drives eere C 2 Software co oqa iura OR ENG date wee y qe E C 2 AC Line Filters es C 3 External Shunt Kits aaa C 3 d 0n ADD C 4 Motor Power Cables a 2a dg rode RO HE dq Reo d C 4 Motor Feedback Cables i osse eas pe aww Rs C 5 MP Series Motor Brake Cable v s cs cr
88. 003B EN P includes important information about changes and updates to this Ultra3000 Digital Servo Drive Installation Manual The document update used to be provided as a separate document but is now incorporated into this installation manual in the section immediately following this Summary of Changes section and before the Table of Contents Before using this installation manual read and understand the changes and updates identified in the document update section No engineering or editorial changes have been made to either the document update or the installation manual therefore the publication dates and revisions of each respective manual did not change The publication date of this Summary of Changes section indicates the date that the combined manuals were released Rockwell Automation Publication 2098 INO03E EN P March 2012 I Summary of Changes Notes Il Rockwell Automation Publication 2098 INO03E EN P March 2012 About This Publication Document Update Ultra3000 Digital Servo Drive Installation Manual Catalog Numbers 2098 DSD 005 010 and 020 2098 DSD xxxX 2098 DSD xxxSE 2098 DSD xxx DN 2098 DSD xxxX DN 2098 DSD 030 075 and 150 2098 DSD xxxX 2098 DSD xxxSE 2098 DSD xxx DN 2098 DSD xxxX DN 2098 DSD HV030 HV050 HV100 HV150 and HV220 2098 DSD xxxX 2098 DSD xxxSE 2098 DSD xxx DN 2098 DSD xxxX DN This document updates information about the Ultra3000 digital servo drive products U
89. 090 XXNPMF xxSxx Fold the brake wire shields back under the drive clamp before making connections to the brake circuit Publication 2098 INOO3E EN P April 2004 3 12 Connecting Your Ultra3000 Connecting the Y Series Cable Shield at the Motor Y Series motors have a short pigtail cable which connects to the motor but is not shielded The preferred method for grounding the Y Series motor power cable on the motor side is to expose a section of the cable shield and clamp it directly to the machine frame The motor power cable also has a 150 mm 6 0 in shield termination wire with a ring lug that connects to the closest earth ground Use this method in addition to the cable clamp The termination wire may be extended to the full length of the motor pigtail if necessary but it is best to connect the supplied wire directly to ground without lengthening Refer to Figure 3 13 for an illustration and Figure B 15 in Appendix B for the interconnect diagram Figure 3 13 Y Series Motor Power Cable Connection Cable Braid Clamped C i Wee onnectors Motor Power Cable t0 Machine Prag B Pigtail Cable Y Series mu Motor Machine Fr ie r 150 mm 6 0 Termination Publication 2098 INOO3E EN P April 2004 Remove paint from machine frame to ensure proper HF bond between machine frame and motor case shield clamp ground stud etc Power Wiring Requirements Connecting Your Ultra3000 3 13
90. 1 3 1 through CN1 38 Po Q2 2 222 2c Ultra3000 Connector Data 2 33 Figure 2 24 Drive Input Connected to PNP Transistor Ultra3000 Drive cnt 29 IOPWR IOPWR CN1 31 through CN1 38 M Digital Outputs There are four opto isolated transistor outputs that can be configured for a variety of functions through software Additionally the drive has a relay output with normally open contacts On SERCOS drives the relay output is dedicated as a Brake output where closed contacts release a motor brake The configuration of the transistor outputs is shown in Figure 2 25 and the configuration of the relay output is shown in Figure 2 26 IMPORTANT There is no overload protection on the transistor outputs Figure 2 25 Transistor Output Hardware Configuration Ultra3000 Drive 200 Q IOPWR VN TLP127 i OUTPUT Publication 2098 INOO3E EN P April 2004 2 34 Ultra3000 Connector Data Publication 2098 INOO3E EN P April 2004 The following table provides a description of the digital output specifications Parameter Description Minimum Maximum poe Current flow when the output transistor is ON 50 mA nud Current flow when the output transistor is OFF 0 1 mA a Voltage across the output transistor when ON 1 5V Ta Voltage across the output transistor when OFF lt 50V Figure 2 26 Relay Output Hardware Configuration Ultra3000 Drive l CN
91. 1 43 Normally Relay Open i Relay i CN1 44 Relay The following table provides a description of the relay output specifications Parameter Description Minimum Maximum oe Current flow when the relay is closed 1A m Contact resistance when the relay is closed 10 DT Voltage across the contacts when the relay is open 30V Drive Output Interface Examples Figure 2 27 Drive Output Connected to an Opto Isolator Ultra3000 Drive Ultra3000 Connector Data 2 35 Figure 2 28 Drive Output Connected to an LED Indicator Ultra3000 Drive IOPWR ie AY a Figure 2 29 Drive Output Connected to a Resistive Load Ultra3000 Drive IOPWR xa AY Figure 2 30 Drive Output Connected to a Switch Relay Ultra3000 Drive i IOPWR Aw Publication 2098 INOO3E EN P April 2004 2 36 Ultra3000 Connector Data Publication 2098 INOO3E EN P April 2004 Figure 2 31 Drive Output Connected to an Active Low Input using a Switch Relay Ultra3000 Drive Output IOPWR Figure 2 32 Drive Output Connected to an Active Low Input using an Opto Isolator Ultra3000 Drive Output E IOPWR 33k Q Drive Output Connected to an Active High sinking Input IOPWR NAN OCOM i Figure 2 33 Ultra3000 Drive Output IOPWR 10C0M CN1 27 or 28 I0C0M 10COM Ultra3000 Drive Input Ultra3000 Connector Data Analog COMM
92. 11J 381 J 669 J 230V ac inpu 117 J 211 J 370 J Continuous power output 115V ac inpu 1 5 kW 3 75 kW 7 5 kW 230V ac inpu 3 kW 7 5 kW 15 kW n Specification is for nominal voltage The absolute limits are 10 or 88 265V rms 400 us half wave sine ATTENTION A Publication 2098 DU003B EN P September 2006 The 2098 DSD 030x xx 075x xx and 150x xx 230V drives are limited to one contactor cycles per two minutes Power initialization requires a short period of inrush current Dual element time delay slow blow fuses are recommended The inrush current limiting circuitry is limited in the number of power cycles it can withstand within a set period of time If you exceed these limitations the circuitry will be damaged Ultra3000 Digital Servo Drive Installation Manual 5 Page A 4 Specification Add the attention statement below to the Ultra3000 460V Power Specifications table on page A 4 The table didn t change however the warning applies to all Ultra3000 drives Ultra3000 Drive 460V Power Specifications 2098 DSD HV030x xx HV050x xx HV100x xx HV150x xx and HV220x xx Description 2098 DSD HV030 2098 DSD HV050 2098 DSD HV100 2098 DSD HV150 2098 DSD HV220 230 480V rms Three phase AC Input Voltage 2 AC Input Frequency 47 63 Hz Main AC Input Current 3 4 460V ac rms Nom 4A 7A
93. 14A 20A 28 A 460V ac rms Max inrush 6A 6A 6A 6A 6A Auxiliary AC Input Current 230V ac rms Nom 0 55A 360V ac rms Nom 0 35A 480V ac rms Nom 0 25A 230V ac 0 pk Max inrush 5 47A 480V ac 0 pk Max inrush 5 68 A Continuous Output Current 0 pk 7A 11A 23A 34A 47 A Intermittent Output Current 0 pk 14A 22A 46A 68 A 94 A Bus Capacitance 470 uF 705 pF 940 pF 1880 uF Internal Shunt Resistance 120 Q 40 Q 25 20 Shunt On 800V dc Shunt Off 750V dc Bus Overvoltage 810V dc nternal Shunt Continuous power 100 W 200 W 200 W 400 W Peak power 5 3 kW 6 kW 25 6 kW 32 kW External Shunt Resistance 0 5 120 Q 40 Q 250 200 Continuous power 3kW 0 kW 15kW 22 kW Peak power 5 3 kW 16 kW 25 6 kW 32 kW Energy Absorption Capability 230V ac input with 230V motor 15J 22 J 29 J 59 J 230V ac input with 460V motor 129 J 94 J 259 J 517 J 460V ac input 55 J 82 J 109 J 219 J Continuous Power Output 230V ac input 1 5 kW 2 5 kW 5 0 kW 7 5 kW 11 kW 460V ac input 3 0 kW 5 0 kW 10 kW 15kW 22 kW 400 us half wave sine Specification is for nominal voltage The absolute limits are 10 or 207 528V rms The 2098 DSD HVxxx xx drives can be powered with 230 240 V rms in order to be used in conjunction with motors designed for 230V operation In such cases the voltage levels used for shunting and DC bus overvoltage limits are adjusted to be compatible with the voltage limit of the motor The 2098 DSD HV xxx xx 460V drives are limited to three c
94. 18 2 20 2 22 2 24 Ultra3000 2 2 with DeviceNet 2 18 with SERCOS 2 10 fuse sizing 1 10 fuse specifications A 5 G grounded power configuration 3 3 grounding cable shield bottom of drive 3 11 cable shield front of drive 3 11 multiple subpanels 3 10 system to subpanel 3 9 H heat losses for sizing enclosures A 7 HF bonding bonding practices 1 11 high frequency energy 1 12 I O connections 3 23 input power 3 16 input power wiring 3 phase Delta 3 4 3 phase WYE 3 3 determining input power 3 3 grounded power configuration 3 3 single phase 3 5 single phase amplifiers on 3 phase power 3 6 3 7 3 8 installing your Ultra3000 1 1 integration P 1 integration manual P 3 interconnect diagrams controlling a brake example B 19 power B 3 B 4 B 5 B 6 shunt module B 7 B 8 B 9 Ultra3000 to 1326AB motors B 10 Ultra3000 to H and F series motor B 13 Index l 3 ltra3000 to IMC S B 23 ltra3000 to Logix B 20 ltra3000 to MP series motor B 10 B 11 B 12 ltra3000 to N series motor B 14 ltra3000 to servo module B 21 ltra3000 to SoftLogix B 22 ltra3000 to Y series motor B 15 interface cables C 5 introduction P 1 C GEG c ae LED module status DeviceNet 4 10 module status SERCOS 4 9 network status DeviceNet 4 10 network status SERCOS 4 9 LED indicator 4 3 logic power LED 4 3 Logix controller motion instruction set reference manual P 3 Low Voltage Directive 1 3 maintenance troubleshooting
95. 3 16 for your motor power cable configuration Refer to Appendix B for the motor drive interconnect diagrams Figure 3 16 Motor Power Cable MPL A B MPG A B 1326AB and F H or N Series Motors U or W Brown or Blue y Black W or U Blue or Brown Green Yellow 2090 UXNPA PBxx xxSxx O Exposed Braid o gt i 4mm 12 AWG conductors or larger Exposed Braid US 2090 XXNPXx xxSxx 1 5 or 2 5 mm 16 or 14 AWG conductors only Green Yellow 1 Motor cable leads shortest to longest are labeled differently depending on the drive input voltage 230V 460V When using MP Series food grade motors the brake wires are included in the motor power cable 2090 XXNPMF xxSxx as shown in Figure 3 17 Refer to Appendix B for the motor drive interconnect diagram Figure 3 17 Motor Power Cable MPF A B Food Grade Motors Brown Black 2090 XXNPMExxS xx Cable Shield overall Blue Green Yellow BR BR Cable Shield 7 V for brake wires When using Y Series motors the brake wires are included in the motor power cable 2090 XXNPY 16Sxx as shown in Figure 3 18 Refer to Appendix B for the motor drive interconnect diagram Figure 3 18 Motor Power Cable Y Series Motors Exposed Braid 2090 XXNPY 16Sxx a Black 3 Black 7
96. 4 3 manuals on line P 4 maximum feedback cable length specifications A 13 module status LED 4 9 4 10 Motion Book P 3 motion control problem report form P 4 Motion Control Selection Guide P 3 motor encoder specifications AM BM and IM inputs 2 40 auxiliary encoder 2 49 connections 2 45 encoder phasing 2 44 Hall inputs 2 42 limit inputs 2 43 thermostat input 2 42 motor feedback cables 3 24 C 5 Publication 2098 INOO3E EN P April 2004 1 4 Index Publication 2098 INOO3E EN P April 2004 motor feedback specifications A 10 motor power and brakes 3 18 motor power cables 3 19 3 20 C 4 motors 3 24 3 25 connector kits C 7 power wiring Y Series 3 11 3 12 motors brake wiring 3 21 mounting before mounting 1 5 external shunt resistor 1 16 1 17 guidelines to reduce noise 1 15 HF bonding 1 10 procedure 1 18 system requirements 1 6 network cable system 3 29 data rate 3 29 network status LED DeviceNet 4 10 network status LED SERCOS 4 9 noise P 3 see HF bonding 1 10 noise zones 1 13 1 14 notes B 2 0 overload protection 3 15 P panel cable categories 1 14 layout 1 12 noise zones ControlLogix 1 14 Ultra3000 1 13 pin outs motor encoder connector 2 3 2 5 2 7 2 9 2 11 2 13 2 15 2 17 2 19 2 21 2 23 2 25 motor feedback connector 3 24 3 25 serial connector 2 2 2 4 2 6 2 8 2 10 2 12 2 14 2 16 2 18 2 20 2 22 2 24 Ultra3000 I O connector 2 3 2 5 2 7 2 9 w
97. 6 kW 32 kW External Shunt Resistance 0 5 120 Ohms 120 Ohms 40 Ohms 25 Ohms 20 Ohms Continuous power 3 kW 5 kW 0 kW 15 kW 22 kW Peak power 53kW 5 3 kW 6 kW 25 6 kW 32 kW Energy Absorption Capability 230V ac input with 230V motor 15 Joules 15 Joules 22 Joules 29 Joules 59 Joules 230V ac input with 460V motor 129 Joules 129 Joules 94 Joules 259 Joules 517 Joules 460V ac input 55 Joules 55 Joules 82 Joules 109 Joules 219 Joules Continuous Power Output 230V ac input 1 5 kW 25kW 5 0 kW 7 5 kW 11 kW 460V ac input 3 0 kW 5 0 kW 10 kW 15 kW 22 kW 1 Specification is for nominal voltage The absolute limits are 10 or 207 528V ms The 2098 DSD HVxxx xx drives can be powered with 230 240V ms in order to be used in conjunction with motors designed for 230V operation In such cases the voltage levels used for shunting and DC bus overvoltage limits are adjusted to be compatible with the voltage limit of the motor 3 The 2098 DSD HVxxx xx 460V drives are limited to three contactor cycles per minute 4 400 us half wave sine 5 Power initialization requires a short period of inrush current processor controlled via soft start circuitry Dual element time delay slow blow fuses are recommended refer to Fuse Specifications on page A 5 Publication 2098 INOO3E EN P April 2004 Fuse Specifications Specifications and Dimensions A 5 Use class CC G J L R or T class fuses with current ratings as indicated in the table
98. 800 www ab com support Please have the catalog numbers of your products available when you call 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 Objectives Chapter 1 Installing Your Ultra3000 This chapter provides system installation guidelines and procedures for mounting your Ultra3000 This chapter covers the following topics Complying with European Union Directives Ultra3000 System Component Overview Before Mounting Your System HF Bonding Your System Planning Your Panel Layout Mounting Your Ultra3000 Drive ATTENTION The following information is a guideline for proper installation The National Electrical Code and any other governing regional or local codes overrule this information The Allen Bradley Company cannot assume responsibility for the compliance or the noncompliance with any code national local or otherwise for the proper installation of this system or associated equipment If you ignore codes during installation hazard of personal injury and or equipment damage exists Publication 2098 INOO3E EN P April 2004 1 2 Installing Your Ultra3000 Complying with European Union Directives Publication 2098 INOO3E EN P April 2004 If this product is installed within the European Union or EEC regi
99. 84 PMO2AE TPxx Removable Terminal Block a2 On Termination Panel use with 1756 M02AE ControlLogix Servo Module 2S On use with 1784 PMO2AE SoftLogix PCI Card E 322 Ox ue 33 xS Sy Publication 2098 INOO3E EN P April 2004 RELAY Figure B 22 Interconnec t Diagrams B 21 Ultra3000 to ControlLogix Servo Module Interconnect Diagram WHT ORG 22GA WHT YEL 22GA RELAY WHT ORG 22GA WHT YEL 22GA RELAY RELAY RELAY RELAY DRAIN user configured user configured DRAIN 10 PWR WHT RED 22GA WHT RED 226A 10 PWR 10 COM f warrevack 26h A Vom ER WHT BLACK 26h A I0 COM DRAIN DRAIN Dl AUX PWR 45 RED 226A RED 14GA AUX PWR 5 AUXCOM ECOM BLACK 22GA AUX PWR AUX PWR BLACK 14GA AUXCOM ECOM DRAIN optional optional DRAIN Qu gp EE AXIS 0 AXIS 1 ANALOG COMMAND WHT GRN 226A ouT 0 5 2o o 4 Lsours WHT GRN 226A ANALOG COMMAND A
100. 9 pin standard D shell TB DC bus Motor and 9 position screw style barrier terminal strip AC power 2098 DSD 005x xx 010x xx and 020x xx TBI M e 11 or 12 position screw style barrier terminal strip AC p Wer y 2098 DSD 030x xx 075x xx 150x xx HVxxx xx and HVxxxX xx TB2 Shunt 3 position screw style barrier terminal strip 2098 DSD 030x xx 075x xx 150x xx HVxxx xx and HVoooX xx All signal connections on the Ultra3000 use commonly available D shell type connectors For connector pin outs and the location of connectors switches and status LEDs on 2098 DSD xxx and HVxxx Ultra3000 drives Refer to Figures 2 1 2 4 and the tables that follow on pages 2 2 through 2 9 2098 DSD xxx and HVxxx Ultra3000 drives with SERCOS interface Figures 2 5 2 8 and the tables that follow on pages 2 10 through 2 17 2098 DSD xxx and HVxxx Ultra3000 drives with DeviceNet interface Figures 2 9 2 12 and the tables that follow on pages 2 18 through 2 25 Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data Seven Segment Ultra3000 Front Panel Connections Use the figure below to locate the front panel connections on the Ultra3000 230V drives SOOW 1 kW and 2 kW Figure 2 1 Ultra3000 Front Panel Connections for 2098 DSD 005 005X 010 010X 020 and 020X D Status LED DC Bus Connections for Active Shunt Resistor Kit AC Input Power Connections Mot
101. AC Input LH Ultra3000 System A Single Phase AC Input TB1 Terminals ul PEEL 12 AC Line Filter 13 Fe TB1 Terminals TB1 L1 L2 N Ultra3000 System C Single Phase AC Input TB1 Terminals Grounded Neutral 9 Feee Bonded Cabinet ______ gt 60 Ground Bus Ground Grid or Ground Grid or Power Distribution Ground Power Distribution Ground Publication 2098 INOO3E EN P April 2004 Note Feeder and branch short circuit protection is not illustrated Voiding of CE Compliance The three phase and neutral in line filter applications described above may not be adequate from an EMC aspect for CE compliance Therefore EMC validity and CE marking by Rockwell Automation is voided when three phase and neutral in line filters are used ATTENTION The three phase isolation transformer and neutral in line filter applications described in this document have not been tested for EMC by Rockwell Automation and products used in such installations are not considered CE marked by Rockwell Automation If this three phase isolation transformer and neutral in line filter application is used the responsibility for EMC validation lies with the user and CE marking of the system becomes the user s responsibility If CE compliance is a customer requirement single phase
102. AND Input 2 37 The COMMAND input to the drive can provide a position velocity or current command signal A 14 bit A D converter digitizes the signal The configuration of the input is shown in Figure 2 34 Figure 2 34 Analog COMMAND Input Configuration Ultra3000 Drive 1000 pF COMMAND COMMAND 1000 pF 20k Q iod The following table provides a description of the analog COMMAND input specifications Parameter Description Minimum Maximum Number of states that the input signal is divided into Resolution which is zlto the number of bits 14 bits m Input Open circuit impedance measured between the and 20kQ m Impedance inputs Input Signal p Range Voltage applied to the input 10V 10V Deviation from the correct value expected from Offset Error analog to digital conversion when OV is applied to the 50 mV input Deviation of the transfer function from unity gain o Gain Error expressed in a percent of full scale 1 Propagation Delay from the input to the firmware accessible en 100 uS Delay registers Publication 2098 INOO3E EN P April 2004 2 38 Ultra3000 Connector Data Analog ILIMIT Input The ILIMIT input specifies to the drive if the drive output current should be limited If the ILIMIT input is not connected current is not limited A 10 bit A D converter digitizes the signal The configuration of the ILIMIT input is shown in
103. B Dir CCW BX 28 1 0 Common IOCOM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUTS 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUT4 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUT5 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUT4 21 Buffered Motor Encoder Ch l IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2 Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Inputs AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Inpute BM 1 Thermostat TS 4 Channel B Cosi
104. B Bxxxx M2L S2L single turn or multi turn motors with absolute high resolution feedback 2 Refers to F H N or Y Series motors with incremental optical encoder feedback Publication 2098 INOO3E EN P April 2004 A 14 Specifications and Dimensions Dimensions The following diagrams show the dimensions and mounting hole locations for the Ultra3000 drives Ultra3000 230V Dimensions In the figure below xxx is replaced by 005 010 or 020 to represent the Ultra3000 500W 1 kW and 2 kW drives respectively Figure A 2 Ultra3000 230V Dimensions 2098 DSD xxx xxxX xxx SE xxx DN xxxX DN 129 03 c le 5 08 i e A Dimensions are in millimeters inches 186 18 e 165 1 FS 198 12 Unit shown is the 2098 DSD 005 SE 7 33 65 bY 7 8 9 i i i Vv l at Y EE 9l 144 27 a 5 68 je F gt Ultra3000 Drive 2098 DSD A C E F 72 64 005 005X 65 02 13 26 32 77 2 86 010 010X 020 2 56 0 52 1 29 98 1 020X 3 89 005 SE 005 DN 95 5 and 005X DN 3 76 ie 87 88 24 64 43 94 UIU oE UTU
105. B l aie i Refer to Attention statement above Motor d Sfl a use 2 d Block M1 ES N O Relay Output u 3 5 43 lt Three Phase T elle Note 20 AC Line gt 14 2 Ef j 50 60 Hz gt f h 4 LT TU w wur belo L1 Aux u dj N O Relay Output a TP UIN Aux ails ai O th n Publication 2098 INOO3E EN P April 2004 Controlling a Brake Example Interconnect Diagrams B 19 The relay output of the Ultra3000 is suitable for directly controlling a motor brake subject to the relay voltage limit of 30V dc and the relay current limit of 1A dc For brake requirements outside of these limits an external relay must be used If a transistor output is used a control relay is also required The following table lists Allen Bradley motors that are compatible with the internal relay output CN1 pins 43 and 44 when used for controlling a brake All other motors require an external control relay Compatible Brake Motors Brake Current Compatible Brake Motors Brake Current F 4030 4050 and 4075 0 88A MPL MPF x310 x320 x330 0 50A H 3007 and 3016 0 60A MPL x420 x430 x4520 x4530 x4540 die H 4030 4050
106. C Input Power Connections Motor Power Connections Bas 0 MSD C Ip L E Te TAL 1 DC Bus n idm lof s a 8 e 1 c 808 lt lt amp 3 ogo Data Rate u A 1 125kB sers L9 Jy N 50 60 Hz F sed Sr 8 a d Ifc 088 DeviceNet amp 9 E 9 O 9 999 c 080 N a jjv E uu ER I can j 980 Shield sy w 6 209 Can H 1 080 Ve 9 aal jJ QO Motor Power Cable Shield Clamp Publication 2098 INOO3E EN P April 2004 MM as D Serial Port Connector Logic Power LED Module Status LED Network Status LED CN3 9 pin Serial Port Connector Node Address Switches CN2 15 pin Motor Feedback Connector Data Rate Switch DeviceNet Interface Connector CN1 44 pin User 1 0 Connector 9 pin CN3 Serial Connector Pin 9 Pin 6 1 Pin 5 oo ooo I Pin 1 15 pin CN2 Feedback Connector Pin 31 Pin 16 t lt Pin 10 Pin 5 44 pin C S Pin 1 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3 Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output
107. D HV050x xx 175 dissipative shunt 2098 DSD HV100x xx 350 dissipative shunt 2098 DSD HV150x xx 350 dissipative shunt 2098 DSD HV220x xx 600 dissipative shunt Publication 2098 INOO3E EN P April 2004 A 8 Specifications and Dimensions Ultra3000 General Specifications The following sections provide physical environmental control I O communication feedback connector and AC line filter specifications for the Ultra3000 drives Physical and Environmental Specifications Specification Weight 2098 DSD 005x xx 2098 DSD 010x xx 2098 DSD 020x xx 2098 DSD 030x xx 2098 DSD 075x xx 2098 DSD 150x xx Ambient Temperature Description Specification Description Weight 1 8 kg 4 1 Ibs 2098 DSD HV030x x 8 55 kg 18 8 Ibs 2 1 kg 4 6 Ibs 2098 DSD HVO50x xx 8 55 kg 18 8 Ibs 2 1 kg 4 6 Ibs 2098 DSD HV100x xx 10 44kg 22 96 Ibs 6 2 kg 13 6 Ibs 2098 DSD HV150x xx 10 44kg 22 96 Ibs 9 3 kg 20 6 Ibs 2098 DSD HV220x xx 14 1 kg 31 0 Ibs 14 1 kg 31 0 Ibs Storage 40 C to 70 C 40 F to 158 F Operation 0 C to 55 C 32 F to 131 F Relative Humidity 5 95 non condensing Publication 2098 INOO3E EN P April 2004 Altitude 1500 m 4921 5 ft Derate 3 per 300 m 984 3 ft above 1500 m 4 921 5 ft Vibration 5 2000 Hz 2 5g peak 0 0006 mm 0 015 in maximum displacement Shock 15g 11 ms half sine Control Specifications S
108. E Ultra3000 Digital Servo Drive with DeviceNet 2098 DSD xxx DN Ultra3000 Digital Servo Drive with DeviceNet and Indexing 2098 DSD xxxX DN Use the following table to identify Ultra3000 460V drives with ratings of 3 kW 5 kW 10 kW 15 kW and 22 kW where xxx equals 030 050 100 150 or 220 Description Ultra3000 Digital Servo Drive Catalog Number 2098 DSD HV xxx Ultra3000i Digital Servo Drive with Indexing 2098 DSD HVxxxX Ultra3000 Digital Servo Drive with SERCOS 2098 DSD HVxxx SE Ultra3000 Digital Servo Drive with DeviceNet 2098 DSD HVxxx DN Ultra3000 Digital Servo Drive with DeviceNet and Indexing 2098 DSD HVxxxX DN The Ultra3000 SE drives are configured using RSLogix 5000 Ultra3000 Ultra3000 with indexing Ultra3000 DN and Ultra3000 DN with indexing drives are configured using Ultraware Both are Windows based applications that allow drive configuration to be done off line and saved to disk Description RSLogix 5000 Software version 11 0 or above Catalog Number 9324 RLD300ENE Ultraware Software 2098 UWCPRG AC Line Filters External Shunt Kits Catalog Numbers and Accessories C 3 Use the following table to identify the AC Line Filter for your application AC Line Filter Description Boa Filter Fuse Catalog Number 6 Amp 2090 UXLF 106 10 Amp 2090 UXLF 110 AC Line Filter single phase 240V m S
109. ED 28GA NPUT6 INPUTG WHT BLK RED 28GA RED BLK 28GA NPUT7 INPUT7 RED BLK 28GA Uitrag000 WHT BLK ORG 286A INPUTS Ur aa ee CN1 Connector D CN1 Connector l ORG BLK 28GA OUTPUT 2 OUTPUT 2 ORG BLK 28GA Axis 1 Axis 0 WHT BLK YEL 28GA OUTPUT 3 OUTPUT 3 WHT BLK YEL 28GA YEL BLK 28GA OUTPUT 4 OUTPUT 4 YEL BLK 28GA DRAIN DRAIN yo power pins 28 and 30 must be connected to user supplied 12 24V dc 2 Input 1 pin 31 must configured as Drive Enable using 3 Output 1 pin 39 must be configured as Ready using U 4 This cable does not carry the unbuffered motor encoder signals CN1 pins 10 15 Contact your Allen Bradley sales representative if these signals are required for your application Ultraware software traware software Publication 2098 IN003E EN P April 2004 B 22 Interconnect Diagrams Figure B 23 Ultra3000 to SoftLogix PCI Card Interconnect Diagram RELAY WHT ORG 22GA WHT ORG 22GA RELAY 43 RELAY WHT YEL 22GA y RELAY RELAY WHT YEL 22GA RELAY 44 DRAIN user configured user configured DRAIN 10 PWR WHT RED 22GA WHT RED 22GA 10 PWR 39 10 COM f waens z6A A io pwat Nun WHT BLACK 26h I I0 COM 28 DRAIN DRAIN AUX PWR 5 RED 22GA RED 14GA AUX P
110. Encoder Ch l IMOUT 42 Digital Output 4 OUTPUT4 21 Buffered Motor Encoder Ch l IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Inputt AMe 9 PostiveOvetravellimt 4IMT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Inpute BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR 5V 7 Encoder Power 49V EPWR 9V 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 2 22 Ultra3000 Connector Data m d i rara 81 8 Passive Shunt Fes A Resistor Connections T li c elle pas 5 uu C O lt B gl lt A Motor Power SIT Connections gt El amp e DC Bus 2T amp emit efle AC Input Power c Connections ser ree ax Ela TB1 Motor Power Cable Shield Clamp gt m N Publication 2098 INOO3E EN P April 2004 Use the figure below to locate the front panel
111. Feedback rea ei s 1 i q ControlLogix Chassis 1 0 and Commands DeviceNet Network Motor Power MP Series Servo Motor Mounting Your Before you mount your Ultra3000 system make sure you understand the following e how to unpack the system e the minimum mounting requirements Unpacking Modules Each Ultra3000 ships with the following e One Ultra3000 drive e One installation manual publication 2098 IN003x EN P Remove all packing material wedges and braces from within and around the components After unpacking check the item s name plate catalog number against the purchase order Publication 2098 INOO3E EN P April 2004 1 6 Installing Your Ultra3000 Publication 2098 INOO3E EN P April 2004 System Mounting Requirements There are several things that you need to take into account when preparing to mount the Ultra3000 e The Ultra3000 must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 IEC 529 to IP22 such that they are not accessible to an operator or unskilled person in order to comply with UL and CE requirements A NEMA 4X enclosure exceeds these requirements providing protection to IP66 e The ambient temperature of the location in which yo
112. Green DC Bus Undervoltage The DC bus voltage is low e Normal operation when using auxiliary power main AC power is not applied e When using main AC power refer to the section Error Codes to continue troubleshooting Refer to the section Error Codes to continue Flashing Red Minor fault Drive is faulted but the fault can be cleared troubleshooting Drive is faulted and the fault cannot be Contact your local Allen Bradley Steady Red Unrecoverable fault cl srod representative SERCOS Network Status LED Use the table below for troubleshooting the SERCOS Network Status LED on your Ultra3000 2098 DSD xxx SE or HVxxx SE If the SERCOS Network Status LED Status is Potential Cause is Possible Resolution is is Steady Green Communication ready No faults or failures N A Flashing Green Establishing communication System is still in the process of establishing SERCOS communication Wait for steady green LED status Node address setting on the drive module does not match SERCOS controller configuration Verify proper node switch setting Flashing Red No communication Loose fiber optic connection Verify proper fiber optic cable connections Broken fiber optic cable Replace fiber optic cable Receive fiber optic cable connected to SERCOS transmit connector and vice versa Check proper SERCOS fiber optic cable connections 1 Refer to Fiber Optic Cable
113. Green Yellow Brake Wires Black 9 Publication 2098 INOO3E EN P April 2004 Black 1 Iv Black 2 3 20 Connecting Your Ultra3000 Refer to the table below for the catalog number of the motor power cable for your Ultra3000 drive Use this Motor Power Cable when For this motor This Universal Cable is available Universal Gables aro not available MP Series 2090 XXNPMP 16S xx Low Inertia and Integrated 2090 XXNPMP 14S xx Gear 230V or 460V systems 2090 XXNPMP 10Sxx 1326AB Series M2L S2L 2090 XXNPMP 8S xx N A 2090 XXNPMF 16S xx ae 2090 XXNPMIF 14S xx PREIS DS 2090 XXNPMF 10Sxx ESeries 2090 XXNPHF 16Sxx 090 UXNPAHF 10Sxx 2090 XXNPHF 14Sxx 090 UXNPAHF 8S xx 2 2 DS DON PEE 2090 UXNPAHF 1 OSxx 2 H Series 090 UXNPAHF 8S xx 2090 XXNPHF 14Sxx 090 UXNPAH 6Sxx N Series 2090 XXNPN 16Sxx N A Y Series 2090 XXNPY 16Sxx N A To wire your motor power 1 Route the motor power cable to your Ultra3000 drive To ensure system performance run wires an IMPORTANT O ensure system performance ru es and cables in the wireways as established in Chapter 1 2 Using a screw driver loosen the screw for each of the terminal locations and attach wires as shown in the table below Insert the motor power wires from this servo motor 1326AB M2L S2L F H N and MP Series U Brown 1 Black V Black 2 Black W Blue 3 Blac
114. Grounding Technique for Feedback Cable Shield Exposed shield secured under clamp Motor Feedback Breakout Board 2090 UXBB DM15 BR 3 w enp Incremental Feedback Three Phase U Motor Power Motor Feedback Motor Brake Pigtail otor Feedback CN2 Connector i Ace sumen ee 04 Da hn ek tee Sia E nee ee m 9 5 BLACK AM 1 10 3 WHT BLACK XX AM me 11 RED BM 3 12 d warren XX BM 4 13 GREEN IM 5 14 wurenN XX IM 10 15 gt WHT BLUE S1 12 TEC au XX g 13 BROWN S3 8 x WHT BROWN Y gt GRAY 5VDC 14 WHT GRAY XX ECOM 6 2 SSA DRAIN LE Refer to illustration lower left 1 _ _ _1 for proper grounding technique 2090 XXNFY Sxx flying lead or 2090 UXNFBY Sxx with drive end connector Feedback Cable Notes 12 15 16 Publication 2098 DU003B EN P September 2006 Page B 19 Replace the table on page B 19 with the one shown below The new table includes the MPL x15xx MPL x2xx and TL Series motors Compatible Brake Motors J Coil Current Compatible Brake Motors Coil Current Meas o Tosa 1325AB B4xxx 0 88 A MPL x2xx 0 51 A F 4030 4050 and 4075 0 69 A MPL MPF MPS x310 x320 x330 0 50 A Y 1002 and 1003 0 26 A MPL x420 x430 x4520 x4530 x4540 Y 2006 and 2012 0 31 A MPF x430 x4530
115. H Unit shown is the 2098 DSD HV030 EIT j a ae __ 9 54 Ultra3000 Drive 2098 DSD HV i c B D H l 030x 030 xx 050x 138 7 18 5 050 xx 5 46 0 73 50 8 349 3 331 5 360 7 100x 100 xx 150x 151 6 25 2 0 13 75 13 05 14 2 150 xx 5 97 0 99 203 2 25 4 76 2 380 4 362 6 391 8 220x 220 xx 8 0 1 0 3 0 14 98 14 26 15 43 1 The x represents the indexing X option The xx represents the SERCOS interface SE or DeviceNet DN option SERCOS interface is not available with the DeviceNet option Publication 2098 INOO3E EN P April 2004 Chapter Objectives Appendix B Interconnect Diagrams This appendix contains the following interconnect diagrams e Power Interconnect Diagrams e Shunt Module Interconnect Diagrams e Ultra3000 Motor Interconnect Diagrams e Control String Examples 120V ac e Controlling a Brake Example e Ultra3000 to Logix Cable and Interconnect Diagrams e Ultra3000 to IMC S Compact Cable and Interconnect Diagram Publication 2098 INOO3E EN P April 2004 Interconnect Diagrams Ultra3000 Interconnect The notes in the table below apply to the power drive motor shunt Diagram Notes Note and 120V ac control string interconnect diagrams ATTENTION The Nation meanma Code and loal ec codes take precedence over the values and methods provided Implementation of these codes are the responsibility of the machine builder Information
116. NALOG COMMAND A WHT BLU 226A 0070 1D o 3 OUT WHT BLU 226A ANALOG COMMAND DRAIN CHASSIS i o D 1 Chassis DRAIN o Q 10 POWER BROWN 28GA ENABLE O amp n2 o 5 SENABLE 1 BROWN 28GA 10 POWER INPUT 1 ENABLE RED 286A ENABLEO g 25 6 CENABLE 1 RED 286A ZINPUT 1 ENABLE OUTPUT 1 READY 3 ORANGE 286A DRVFLT 0 i MS Ss a DRVELT ORANGE 286A 3 QUTPUT 1 READY 10 COM Ix YELLOW 28GA i IN COM 14 PO O i LINCOM i YELLOW 28GA 10 COM DRAIN aO Vo DRAIN 29 O5 AOUT GREEN 286A CHA 0 op 149 95 95 CHA GREEN 28GA AQUT BLUE 28GA CHAD 3g aS Oz a BLUE 28GA VIOLET 28GA CHB O 39 O VIOLET 28GA GRAY 286A 2 o Oa B GRAY 286A WHITE 28GA CHZ 0 a e e 3g tCHZ 1 WHITE 286A hl BLACK 286A CHZO 35 o Ox a5 CHZ4 BLACK 286A DRAIN CHASSIS 5 4 O Ox 03 CHASSIS DRAIN Q o 1756 M02AE SERVO MODULE BLACK286A _ ACOM ANALOG GRD ACOM ANALOG GRD BLACK28GA r4 WHT BLK 28GA ANALOG OUT PROG ANALOG OUT PROG WHT BLK 28GA BROWN 28GA ILIMIT ILIMIT BROWN 28GA WHT BRN 286A EPWR 5 OUT EPWR 5 OUT WHT BRN 286A 2090 U3AE D44xx Tea AX AX RED 286A 2090 U3AE D44xx Controller Interface JRED 28 AX WHT RED 286A Controller Interface Cable ORANGE 286A BX BX ORANGE 286A Cable WHT ORG 28GA BX WHT ORG 28GA YELLOW 28GA Xe Xt YELLOW 286A WHT YEL 28GA X X WHT YEL 28GA GRAY 286A NPUT 2 INPUT 2 GRAY 28GA WHT GRY 28GA NPUT3 INPUT3 WHT GRY 28GA PINK 28GA NPUT 4 INPUT4 PINK 28GA WHT PNK 28GA NPUT 5 INPUTS WHT PNK 28GA WHT BLK R
117. OFF of commanded motion e Increase time permitted for motion e Use larger Ultra3000 and motor e Check tuning E24 Excess Velocity Error Velocity error limit was exceeded e Increase time or size of allowable error e Reduce acceleration e Check tuning E25 Sensor Not Assigned Homing or registration motion was attempted without a sensor assigned Assign a sensor to a digital input E26 User Specified Velocity Fault User specified velocity level was exceeded Increase to a less restrictive setting E27 Axis Not Homed Publication 2098 INOO3E EN P April 2004 Absolute positioning was attempted without homing Verify homing sequence Troubleshooting Status Indicators 4 7 ae Problem or Symptom Possible Cause s Action Solution Parameter loaded from smart encoder or Selecta different motor through the E28 Motor Parameter Error received from SERCOS controller is SERCOS controller incompatible with the drive e Select a different motor e Increase the encoder output maximum Encoder output frequency exceeds the frequency parameter maximum user specified value This only e Decrease the encoder interpolation E29 Encoder Output Frequency Exceeded applies when the encoder output is parameter synthesized by the drive e Increase the encoder output divider parameter e Verify motor selection at Commun
118. OPWR IOPWR curat through CN1 38 a I0C0M I0C0M DGND Figure 2 15 Drive Input Connected to Opto Isolator pi Ultra3000 Drive CN1 29 IOPWR IOPWR CN1 31 i through CN1 38 1 27K Q I0C0M I0C0M DGND Figure 2 16 Drive Input Connected to NPN Transistor Ultra3000 Drive Nea i IOPWR IOPWR Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data 2 31 Figure 2 17 Drive Input Connected to NPN Transistor using Switch Relay Ultra3000 Drive a es es mud Figure 2 18 Drive Input Connected to NPN Transistor using Opto Isolator Ultra3000 Drive Output Ultra3000 Drive Input zl I0COM Figure 2 19 Drive Input Connected to another Ultra3000 Output Ultra3000 Drive Output i CN1 39 CNI 31 through CN1 42 through CN1 38 Figure 2 20 Drive Input Connected to PNP Transistor IUPWH CN1 31 through CN1 38 10C0M Publication 2098 INOO3E EN P April 2004 2 32 Ultra3000 Connector Data Publication 2098 INOO3E EN P April 2004 Input Interface Examples for Active Low Inputs Figure 2 21 Drive Input Connected to Normally Closed Switch j Ultra3000 Drive CN1 29 IOPWR IOPWR CN1 31 through CN1 38 Figure 2 22 Drive Input Connected to Opto Isolator j Ultra3000 Drive 22 I0COM Figure 2 23 Drive Input Connected to NPN Transistor Ultra3000 Drive CN1 29 IOPWR IOPWR CN
119. ORANGE C TS 11 LI gu Cnt 9 rT GN YL W COM 24V Thermostat HY S GE User Supplied Oo M 24V dc Power Supply ibus Cable Shield 1A max 5 ower Ne a ne a ye ne hs E TB1 Clamp p S yo Note 9 1 i 1 AL eat 2090 XXNFMP Sxx flying lead ae So or 2090 UXNFBMP Sxx with drive end connector Feedback Cable Notes 12 15 16 18 Motor Feedback MPL A 230V SERVO MOTORS CN2 Connector WITH INCREMENTAL FEEDBACK k PROPERE RENE usq 1 m GR CDM I D A BLACK AM 1 C e W l SiD B WHT BLACK XX AM 2 E C RED BM 3 A a Three Phase D WHT RED XX BM 4 U J lt Mt r Powar E GREEN IM 5 F WHT GREEN XX IM 0 Motor Feedback K SS GRAY 45VDC 4 L S se weyemv XX ECOM 6 N ORANGE R 221 Weonawcr XX TS ri 1 Thermostat ub S ssi ie Ts C BR T K WHT BLUE XX SI 2 A BR i Motor Brake U YELLOW S2 lt q V warvewow XX S3 i poy i PAE So E e I l oes 2090 XXNFMP Sxx flying lead sou or 2090 UXNFBMP S xx with drive end connector Feedback Cable Notes 12 15 16 IMPORTANT MPL A5xxx motors are not compatible with Ultra3000 2098 DSD 005 010 020 drives Publication 2098 INOO3E EN P April 2004 B 12 Interconnect Diagrams In the figure below the Ultra3000 230V is shown connected to MP Series food grade servo motors Figure B 12 Ultra3000 to MP Series F
120. OS interface 1756 MxxSE 1784 PM16SE Analog interface 1756 M02AE 1784 PMO2AE Publication 2098 INOO3E EN P April 2004 4 2 Troubleshooting Status Indicators Safety Precautions Publication 2098 INOO3E EN P April 2004 Observe the following safety precautions when troubleshooting your Ultra3000 drive ATTENTION DC bus capacitors may retain hazardous voltages after input power has been removed 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 drive warning label 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 the equipment as a result of uncontrolled machine system operation Test equipment such as an oscilloscope or chart recorder must be properly grounded Failure to include an earth ground connection could result in a potentially fatal voltage on the oscilloscope chassis Troubleshooting Status Indicators 4 3 General Troubleshooting If the Logic Power LED is ON and the Status LED display on your 2098 DSD xxx xxxX HV xxx or HVXxxX drive Refer to the Error Codes section below to identify problem
121. Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2 Pin Description Signal CN2 Pin Description Signal 1 Channel A Sine Differential Input AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR_5V 7 Encoder Power 9V EPWR 9V 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 3 Publication 2098 INOO3E EN P April 2004 2 26 Ultra3000 Connector Data Understanding Ultra3000 1 0 Specifications Publication 2098 INOO3E EN P April 2004 A description of the Ultra3000 digital I O power requirements and I O signal specifications is provided on the following pages Also included are I O circuitry examples Digital 1 0 Power Supply All Ultra3000 drives require an isolated external 12 24V power supply for proper operation of the digital I O IMPORTANT The following table provides a description of the digital I O power supply CN1 29 and 30 Do not tie the 24V digital I O common CN1 27 and 28 to the auxiliary encoder 5V common CN1 2 Parameter Description Minimum Maximum 1 0 Power Supply Voltag
122. P April 2004 3 14 Connecting Your Ultra3000 TB1 Terminal Positions 2098 DSD 005x xx 010x xx 020x xx DC Bus Active Shunt DC Bus Connections L1 Input Power EUN Connections U M Motor Power W Connections Figure 3 14 TB1 Terminal Positions TB1 Terminal Positions 2098 DSD 030x xx Motor Power Connections AC Input Power Connections TB1 Terminal Positions 2098 DSD HVxxx xx and HVxxxX xx TB1 Terminal Positions 2098 DSD 075x xx and 150x xx Y DC Bus v Motor Power DC Bus Ww Connections m Motor Power V DC Bus Connections U DC Bus L1 p AC Input AC Input L2 or Power Power L1 L1 AUX Connections Connections HAU L2 N AUX LIN AUX Shunt Module Power Wiring Requirements Recommended Terminal Block Ultra3000 Drives reat ade ag TOET to Wire Size Torque Values mm AWG Nm Ib in TB1 DC Bus 2098 DSD 005x xx 010 d To DSD 005x xx 010x xx an TB1 L1 1 2090 UCSR A300 Q20x x CS TB12 N 4 0 12 2098 DSD 030x xx 9101 1183 25 1 4 2098 DSD 075x xx and 1 2098 DSD 150x xx ee 1018 con 2098 DSD HV030 xx HV030X xx l DSD HV050 xx and HVO50X xx 2090 SR120 09 2098 DSD HV100 xx and 2090 SR040 09 or 18 4 HV100X xx 2090 SR040 18 j 6 10 2098 DSD HV150 xx and 2090 SR025 09 or A HV150X xx 2090 SR025 18 2098 DSD HV220 xx and ARCA 2090 SR020 36 1 75 C 167
123. Power wiring requirements are given in the tables below Wire should be copper with 75 C 167 F minimum rating unless otherwise noted Phasing of main AC power is arbitrary and earth ground connection is required for safe and proper operation IMPORTANT The National Electrical Code and local electrical codes take precedence over the values and methods provided Ultra3000 Power Wiring Requirements Connects to Recommended Terminal Block Ultra3000 Drives Description Terminals Wire Size Torque Values TB1 mm AWG Nm Ib in 2098 DSD 005x xx i 1 5 16 Input Power 2098 DSD 010x xx 100 240V ac L1 L2 N and 2 5 14 2098 DSD 020x xx nape 3 12 L1 L2 N 1 25 11 Inpu Power 2098 DSD 030x xx 100 240V ac single phase L1 AUX 6 10 and L2 N AUX 2098 DSD 075x xx l L1 L2 L3 Input Power 100 240V ac o 2098 DSD 1 50x xx th ree phase L1 AUX 10 8 4 0 35 and L2 N AUX 2098 DSD HV030x xx 2504 2098 DSD HVO50x xx Input Power 13 12 11 2098 DSD HV100x xx 230 480V ac L1 AUX 4 12 2098 DSD HV150x xx mee pase and L2 N AUX 6 10 1 25 11 2098 DSD HV220x xx 10 8 Motor power cable All Ultra3000 drives Motor Power U V W and depends on motor 230V and 460V D drive combination 1 The input power may be optionally isolated through a transformer Note Refer to Figure 3 14 for TB1 terminal positions Publication 2098 INOO3E EN
124. RT y y YELLOW 39 DIGITAL OUT 1 L GUB 32 DIGITALINPUT2 Fault Reset P B 2 gt 43 RELAY OUT 3 44 RELAY OUT 3 STOP START 2NACDO cp EST dn O al gt 120V AC wao N Omu Ge CRI Refer to Attention statement below 1 The preferred method for supplying the auxiliary 45V is by using the 12 or 44 pin drive mounted breakout board with 24V to 5V auxiliary power converter catalog number 2090 U3CBB DM12 or DM44 Auxiliary 5V power is required to maintain encoder position with an external position controller during a controlled stop condition Drive Enable and Fault Reset are configured in Ultraware software 3 Relay Output CN1 pins 43 and 44 must be configured as Ready in Ultraware software Implementation of safety circuits and risk assessment Did HIE Plo 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 Publication 2098 INOO3E EN P April 2004 B 24 Interconnect Diagrams Publication 2098 INOO3E EN P April 2004 Chapter Objectives Appendix C Catalog Numbers and Accessories This appendix lists the Ultra3000 drives and accessory items in tables by catalog number providing detailed descriptions of each component This appendix describes catalog numbers for e Ultra3000 Drives e Software e
125. Reserved 21 Buffered Motor Encoder Ch l IMOUT 43 Brake Relay Output BRAKE 22 Common ACOM 44 Brake Relay Output BRAKE READY signal only available with firmware version 1 29 or above Requires use of drive mounted breakout board 2090 U3CBB DM44 Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Inputs AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 10 Channel Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 2 Commutation Channel S1 S1 5 Channel l Index Pulse IM 13 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 45V EPWR 5V 7 Reserved 5 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 2 12 Ultra3000 Connector Data Passive Shunt Resistor Connections Motor Power Connections AC Input Power Connections Motor Power Cable Shield Clamp Publication 2098 INOO3E EN P April 2004 Use the figure below to locate the front panel connections on the Ultra3000 with SERCOS interface 230V drive 3 kW Figure 2 6 Ultra3000 Front Panel Connections for 2098 DSD 030 SE Status m Internal External Shunt a
126. S BOK interface Module Tx ear Vi Front View x ont AZ Bottom View O SERCOS Receive Connector Rx front Transmit Receive Ultra3000 SE Publication 2098 INOO3E EN P April 2004 This procedure assumes you have your ControlLogix chassis with 1756 MxxSE interface module or personal computer with 1784 PM16SE PCI card and Ultra3000 SERCOS interface system s mounted and are ready to connect the fiber optic cables The SERCOS fiber optic ring is connected using the SERCOS Receive and Transmit connectors Refer to Chapter 2 for the location of the connectors on your Ultra3000 SE drive s and Figure 3 20 to locate the connectors on your SERCOS interface module or PCI card 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 3 20 ControlLogix and SoftLogix SERCOS Connector Locations RSLogix 5000 SoftLogix 1756 PM16SE SERCOS interface PCI Card as viewed from the back of your PC SERCOS Receive Connector Rx ox c TX O SERCOS Transmit Connector Tx RX O SERCOS Transmit Connector Tx rear Refer to Figure 3 21 for an example of fiber optic ring connections between the Ultra3000 SE drive s and the SoftLogix PCI card Figure 3 21 Fiber Optic Ring Connection Example 1 SoftLogix 1784 PM16SE SERCOS interface PCI Card SERCOS fiber optic ring
127. T 230 480V ac rms 24V de CR1 44 Mi HH CRI Terminal Blocks Note 3 Refer to Attention statement Notes 10 11 Y Indi H To additional ndicates User Supplied Component Ultre3000 drive Publication 2098 DU003B EN P September 2006 Ultra3000 Digital Servo Drive Installation Manual 9 Page B 12 Replace Figure B 12 on page B 12 with the one shown below The new figure includes MP Series food grade MPF stainless steel MPS and low inertia MPL A B15xx and MPL A B2xx motors Also included is an illustration of grounding the feedback cable shield Figure B 12 Ultra3000 Drive to MP Series MPL A B MPF A B and MPS A B Motors MPL A B15xx and A B2xx MPF A B xxx and MPS A B xxx Servo Motors with High Resolution Feedback Motor Feedback Green Yell Ultra3000 Drive AL A l CN2 Connector Notes 13 14 Blue CAN lt lt W GND ieee T Black i Wimiei gis a cigtae aintaiat BA lt lt X Three Phase rs f Ah eNe Ser Brown A U U Motor Power 1 5 gt LACK SIN 1 Motor Feedback II lt lt 3 2 WHT BLACK XX SIN 2 15 pin Connector 2090 XXNPMEF xxS xx gt gt CN Motor Power Cable 3 s gt RED COS 3 No
128. U3CC D44 B 20 building your own cables 3 2 categories 1 14 fiber optic cable length 3 26 fiber optic cables C 6 interface cables C 5 motor feedback cables C 5 motor power C 4 MP series brake cables C 5 Ultra3000 to 1326AB motors B 10 Ultra3000 to H and F series motor B 13 Itra3000 to IMC S B 23 Itra3000 to Logix B 20 Itra3000 to MP series motor B 10 B 11 B 12 Itra3000 to N series motor B 14 Ultra3000 to Y series motor B 15 catalog numbers AC line filters C 3 drive end connector kits C 6 external shunt kit C 3 fiber optic cables C 6 interface cables C 5 motor feedback cables C 5 motor power cables C 4 MP series brake cables C 5 RSLogix 5000 software C 2 Ultra3000 accessories C 1 Ultra3000 drives C 2 Ultraware software C 2 CE determining product compliance 1 2 invalidating compliance 3 8 Low Voltage Directive 1 3 Cees Publication 2098 INOO3E EN P April 2004 1 2 Index Publication 2098 INOO3E EN P April 2004 meeting requirements 1 2 certifications A 1 Rockwell Automation Product Certification P 3 circuit breaker specifications A 6 clearances 1 7 communications specifications A 9 complying with CE 1 2 EMC directive 1 2 product compliance 1 2 connecting DeviceNet 3 29 external shunt resistor 3 22 feedback 3 23 fiber optic cables 3 26 I O 3 23 input power 3 16 motor brake 3 21 motor power 3 20 connecting your Ultra3000 3 1 connector front panel connectors 2 1 connector kits drive end C 6
129. UE S2 13 Power e amp UE Shield 1 0 A max T SS WHT BLUE X S1 12 amp TB1 Note 9 H 5 gt VIOLET Thermostat AY S T sa TS 6 peers eere ETE a Deer y ZT l NEEE EA Grounding Technique for RECS Refer to illustration lower left b i Feedback Cable Shield Exposed shield secured under clamp Motor Feedback Breakout Board 2090 UXBB DM15 Publication 2098 DU003B EN P September 2006 for proper grounding technique 2090 XXNFHF Sxx flying lead or 2090 UXNFBHF Sxx with drive end connector Feedback Cable Notes 12 15 16 Ultra3000 Digital Servo Drive Installation Manual 11 Page B 15 Replace Figure B 15 on page B 15 with the one shown below The new figure correctly identifies the motor power cable pins as 1 2 3 and 5 Also included is an illustration of grounding the feedback cable shield Figure B 15 Ultra3000 Drive to Y Series 230V Motors Y Series 230V Servo Motors with V Pigtail BR Ultra3000 230V Drive Green Yellow lt lt Note 13 3 Black 2 Black e 1 Black Motor Feedback lt 15 pin Connector 2090 XXNPY 16Sxx CN2 Motor Power Cable Note 12 BIK 43 BLK 9 e Bd U Control Interface 44 XX BLK 7 2 BLK V 44 pin Connector V lt lt 38K Ty CNI Note 19 GN YL Motor COM 24V Power e Shield User Supplied TB Note T 24V dc Power Supply 1 0 A max
130. UN 3 46 0 97 1 73 010X DN 020 SE VE 020 DN 020X DN Publication 2098 INOO3E EN P April 2004 m 349 25 13 75 o e je LJ E e ke Specifications and Dimensions A 15 In the figure below xxx is replaced by 030 075 or 150 to represent the Ultra3000 3 7 5 and 15 kW drives respectively Figure A 3 Ultra3000 230V Dimensions 2098 DSD xxx xxxX xxx SE xxx DN xxxX DN 221 08 8 94 jaz Ey 1 Dimensions are in millimeters inches 360 68 os T ius Unit shown is the 2098 DSD 030 13 05 Hi S i Y J gt Ultra3000 Drive 2098 DSD A B C J AR SE iN 21 44 50 8 20 32 243 84 030X DN 3 6 2 0 0 8 9 6 eee epu eee 88 9 24 89 247 14 Q75X DN 5 41 3 5 0 96 9 73 SE 50 DN 188 97 139 7 24 6 241 05 150X DN 7 44 5 5 0 97 9 49 Publication 2098 INOO3E EN P April 2004 A 16 Specifications and Dimensions Ultra3000 460V Dimensions In the figure below xxx is replaced by 030 050 100 150 or 220 to represent the Ultra3000 3 5 10 15 and 22 kW drives respectively Figure A 4 Ultra3000 460V Dimensions 2098 DSD HV xxx HVxxxX HVxxx SE HVxxx DN HVxxxX DN A gt 225 8 x C 8 89 Xx T 0 TIAM Dimensions are in millimeters inches
131. V drives 2098 DSD HV030x xx HV050x xx HV100x xx HV150x xx and HV220x xx Description Specification 2098 DSD HV030 2098 DSD HV050 2098 DSD HV100 2098 DSD HV150 2098 DSD HV220 F 1 2 230 480Vims AC Input and Auxiliary Input Voltage Three Page AC Input Frequency 47 63 Hz Main AC Input Current 9 Nominal 460V ac input Ans 7Ams 14Ams 20A ms 28 ms Maximum inrush 460V ac input 6Arms GA rms 6Acns 6Arms 6Arms Auxiliary AC Input Current Nominal 230V ac input 0 55A ms 0 55A ims 0 55A ims 0 55A ms 0 55A ms Nominal 360V ac input 0 35A ms 0 35A ms 0 35A ms 0 35A ms 0 35A ms Nominal 480V ac input 0 25A ms 0 25A ims 0 25A ms 0 25A ms 0 25A ms Maximum inrush 230V ac input 4 47A 0 peak 47A 0 peak 47A 0 peak 47A 0 peak 47A 0 peak Maximum inrush 480V ac input 4 68A 0 peak 68A 0 peak 68A 0 peak 68A 0 peak 68A 0 peak Continuous Output Current 7A 0 peak 11A 0 peak 23A 0 peak 34A 0 peak 47A 0 peak Intermittent Output Current 14A 0 peak 22A 0 peak 46A 0 peak 68A 0 peak 94A 0 peak Bus Capacitance 470 pF 470 uF 705 pF 940 uF 1880 uF Internal Shunt Resistance 120 Ohms 120 Ohms 40 Ohms 25 Ohms 20 Ohms Shunt On 800V dc 800V dc 800V dc 800V dc 800V dc Shunt Off 750V dc 750V dc 750V dc 750V dc 750V dc Bus Overvoltage 810V dc 810V dc 810V dc 810V dc 810V dc Internal Shunt Continuous power 100W 100W 200W 200W 400W Peak power 5 3 kW 5 3 kW 6 kW 25
132. WR 5 AUXCOM ECOM BLACK 22GA AUX PWR AUX PWR BLACK 14GA AUXCOM ECOM DRAIN optional optional DRAIN pu e 2 T AXIS 0 AXIS 1 ANALOG COMMAND WHT GRN 22GA OUT 0 p3 B 7 P4 B _ OUT 1 WHT GRN 22GA ANALOG COMMAND ANALOG COMMAND A WHT BLU 22GA OUT 0 P3 B 8 P4 B 8 OUT 1 WHT BLU 22GA ANALOG COMMAND DRAIN e CHASSIS P3 B 6 P4 B 6 CHASSIS e DRAIN 10 POWER BROWN 28GA ENABLE 0 P3 A 6 P4 A 6 ENABLE 1 BROWN 28GA 10 POWER 26 INPUT 1 ENABLE RED 286A ENABLE 0 p3 A 7 P4 A 7 ENABLE 1 RED 28GA 2 INPUT 1 ENABLE a OUTPUT 1 READY 3 ORANGE 28GA DRVFLT 0 P3 A 0 P4 A 0 DRVFLT 1 ORANGE 28GA 3 OUTPUT 1 READY 10 COM i YELLOW 28GA i IN COM P3 A 5 P4 A 5 IN COM hi YELLOW 28GA 10 COM DRAIN DRAIN SS AQUT GREEN 28GA CHA 0 P3 B 0 P4 B 0 CHA 1 GREEN 28GA AOUT AOUT BLUE 28GA CHA 0 p3 B 1 P4 B 1 CHA 1 BLUE 28GA X AOUT BOUT VIOLET 28GA CHB 0 P3 B 2 P4 B 2 CHB 1 VIOLET 28GA BouT BOUT 8 GRAY 28GA CHB 0 P3 B 3 P4 B 3 CHB 1 X GRAY 28GA X BOUT WHITE 28GA P3 B 4 P4 B 4 CHZ 1 WHITE 28GA IOUT BLACK 28GA CHZ 0 P3 B 5 P4 B 5 CHZ 1 BLACK 28GA lout DRAIN CHASSIS p3 B 6 P4 B 6 CHASSIS DRAIN P2 P3 P4 BIQ B ooog DDDDDO OOOO B A 22 000000 2002 eoooooo09QQ A 0 0 1 9 0 9 1784 PM02AE TP xx Termination Panel Connector Pin out
133. XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT g Reserved Ultra3000 Connector Data 2 19 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector CN1 Pin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 45V EPWR 23 Programmable Analog Output AOUT 7 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Auxiliary Logic Power In 5V AUXPWR 25 Command 4 COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common I0COM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUT3 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUT4 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUT5 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT
134. and 4075 0 69A MPF x430 x4530 x4540 N 2302 and 2304 0 28A MPG x004 0 33A N 3406 3412 4214 and 4220 0 36A MPG x010 na N 5630 5637 and 5647 0 71A MPG x025 Y 1002 and 1003 0 26A MPG x050 0 50A Y 2006 and 2012 0 31A MPG x110 1 0A Y 3023 0 37A 1326AB B4xxx 0 88A i Applies to 230V and 460V motors Figure B 19 shows an example configuration using Digital Output 1 and an external control relay to control a motor brake which exceeds internal relay ratings Figure B 19 Example Configuration Controlling a Motor Brake O Power Supply 3A 24V dc Ultra3000 o oa 29 1 0 Power ALO 2 1 0 Common Ee CR1 1 ur ZN S Brake Servo uie CN1 3g _Digital Output 1 23 Feedback Motor 5 cat L Power 28 1 0 Common Flyback diode 1N4004 rated 1 0A 400V dc suppresses collapsing field of brake coil Digital Output IMPORTANT pin 39 configured as Brake in Ultraware software 3 For Digital Output 1 specifications refer to Figure 2 25 in Chapter 2 Flyback diodes must be used when controlling a brake coil with the relay or digital output Publication 2098 INOO3E EN P April 2004 B 20 Interconnect Diagrams Ultra3000 to Logix Cable This section provides information to assist you in wiring the Ultra3000 CN1 44 pin cable connector with either the ControlLogix and Interconnect Diagrams 1756 MO2AE servo module or SoftLogix 1784 PMO2AE motion card Use the 2090 U3AE D44xx control interface cable
135. anel layout recommendations Mounting hole dimensions for the Ultra3000 are shown in Appendix A 2 Attach the Ultra3000 to the cabinet first using the upper mounting slots of the drive and then the lower The recommended mounting hardware is M5 metric 1 4 20 or 10 MS bolts Observe bonding techniques as described in HF Bonding Your System Tirta TO improve the bond between the Ultra3000 and subpanel construct your subpanel out of zinc plated paint free steel 3 Tighten all mounting fasteners Chapter 2 Ultra3000 Connector Data Chapter Objectives This chapter provides I O encoder and serial interface connector locations and signal descriptions for your Ultra3000 This chapter includes nderstanding Ultra3000 Connectors nderstanding Ultra3000 I O Specifications U U e Understanding Motor Encoder Feedback Specifications Understanding Auxiliary Encoder Feedback Specifications U nderstanding the Serial Interface Switch and LED locations are shown however for switch and LED configuration refer to the Ultra3000 Digital Servo Drives Integration Manual publication 2098 IN005x EN P Understanding Ultra3000 The following table provides a brief description of the Ultra3000 front panel connectors and describes the connector type Connectors Designator Description Connector CN1 User Input Output 44 pin high density D shell CN2 Motor Feedback 15 pin high density D shell CN3 Serial Port
136. apter IMPORTANT Clean the fiber optic cable connectors prior to installation Dust in the connectors can reduce signal strength For more information refer to Fiber Optic Cable Installation and Handling Instructions publication 2090 INO10x EN P Figure 3 24 Fiber Optic Ring Connection Example 4 1756 MxxSE SERCOS Interface Module ControlLogix Chassis SERCOS Fiber Optic Bulkhead Adapter AB seus Fiber Optic Ring e stis Ring x Bol SERCOS Fiber Optic B lox Bulkhead Adapter fk oz Ultra3000 SE Ultra3000 SE Publication 2098 INOO3E EN P April 2004 To connect the SERCOS fiber optic cables 1 Insert one end of a fiber optic cable into the Receive SERCOS connector on the Ultra3000 SE and thread the connector on finger tight 2 Insert the other end of the cable from step 1 into the Transmit SERCOS connector on the ControlLogix module SoftLogix PCI Card and thread the connector on finger tight 3 Insert one end of another fiber optic cable into the Transmit SERCOS connector on the last Ultra3000 SE dri
137. asoon System C L1 Filter ingle Phase npu L2 L IL T TB1 Terminals Grounded Neutral Bonded Cabinet OO Ground Bus O N Ground Grid or Ground Grid or Power Distribution Ground Power Distribution Ground AC line filter is optional but is required for CE compliance Contactors MI M2 and M3 may be optional For more information refer to Understanding the Machinery Directive publication SHB 900 Note Feeder short circuit protection is not illustrated Bonded Cabinet 00000000 Ground Bus Publication 2098 INOO3E EN P April 2004 Connecting Your Ultra3000 3 7 The following examples figures 3 7 and 3 8 illustrate grounded three phase power wired to single phase Ultra3000 drives when phase to phase voltage exceeds drive specifications A neutral must be connected when single phase drives are attached to a three phase isolating transformer secondary It is not necessary that all three phases be loaded with drives but each drive must have its power return via the neutral connection Failure to connect the neutral can result in ATTENTION supply voltage swings at the individual loads i e drives This occurs when the neutral point moves vectorially as a result of load variations normally experienced by the individual drives The supply voltage swing may cause undervoltage and overvoltage trips on the drives and the drive can be damaged if th
138. ature difference between inside air and outside ambient C Q is heat generated in enclosure Watts and A is enclosure surface area m3 The exterior surface of all six sides of an enclosure is calculated as Where T is temperature difference between inside air and outside ambient F Q is heat generated in enclosure Watts and A is enclosure surface area ft The exterior surface of all six sides of an enclosure is calculated as A 2dw 2dh 2wh A 2dw 2dh 2wh 144 Where d depth w width and h height are in meters Transformer Sizing Where d depth w width and h height are in inches The Ultra3000 does not require isolation transformers However a transformer may be required to match the voltage requirements of the controller to the available service To size a transformer for the main AC power inputs the power output KVA of each axis must be known This can be derived by calculating the horsepower for each axis and converting that horsepower into units of watts If you are supplying power to more than one motor and an Ultra3000 simply add the kW ratings together from each calculation to get a system kW total IMPORTANT If using an autotransformer ensure that the phase to neutral ground voltages do not exceed the input voltage ratings of the drive Definitions kW power or real power KVA apparent power Transformer KVA rating Sum of average output power of eac
139. be damaged Publication 2098 DU003B EN P September 2006 4 Ultra3000 Digital Servo Drive Installation Manual Replace the Ultra3000 230V Power Specifications table on page A 3 with the one shown below The new table includes an updated value in the bus capacitance field for 2098 DSD 030 drives Page A 3 Ultra3000 Drive 230V Power Specifications 2098 DSD 030x xx 2098 DSD 075x xx and 2098 DSD 150x xx Description Specification 2098 DSD 030 2098 DSD 075 2098 DSD 150 ACi 1 100 240V rms 100 240V rms Input voltage Single phase Three phase AC input frequency 47 63 Hz Main ac input current 2 3 Nom rms 28 A 30A 46 A 230V ac 0 pk Max inrush 50A 50A 68A Auxiliary ac Input current 115V ac rms Nom 1 0A 1 0A 1 0A 230V ac rms Nom 0 5A 0 5A 05A 115V ac 0 pk Max inrush 4 47 A 47A 47A 230V ac 0 pk Max inrush 95 A 95 A 95 A Continuous output current 0 pk 15A 35A 65A Intermittent output current 0 pk 30A 75A 150A Bus capacitance 2820 pF 4290 pF 7520 pF Internal shunt resistance 35 Q 16 5 Q 91 Q Shunt on 420V dc 420V de 420V dc Shunt off 402V dc 402V de 402V dc Bus overvoltage 452V dc 452V de 452V dc Internal shunt Continuous power 50 W 50 W 180 W Peak power 4 5 kW 10 kW 18 kW External shunt Resistance 30 Q 0 5 16 5 Q 0 5 9 Q 0 5 Continuous power 2 4 kW 4 kW 8 kW Peak power 6 kW 10 kW 19 kW Energy absorption capability 115V ac inpu 2
140. below The table below lists fuse examples recommended for use with the Ultra3000 230V and 460V drives Refer to Power Wiring Requirements in Chapter 3 for input wire size Catalog Number put Voltage Type iioi ad oltage Class CC Class J 2098 DSD 005x xx FNQ R 6 LPJ 6SP 2098 DSD 010x xx FNQ R 10 LPJ 10SP 2098 DSD 020x xx FNQ R 20 LPJ 20SP 2098 DSD 030x xx 230V UM FNQ R 30 LPJ 30SP 2098 DSD 075x xx FNQ R 30 LPJ 30SP 2098 DSD 150x xx A LPJ 60SP 2098 DSD xxxx xx Auxiliary Input Power FNQ R 10 LPJ 10SP 2098 DSD HV030x xx TK R 5 LPJ 5SP 2098 DSD HVO50x xx TK R 8 LPJ 8SP 2098 DSD HV100x xx mr Input Power TK R 20 LPJ 17 1 2SP 2098 DSD HV150x xx TK R 30 LPJ 30SP 2098 DSD HV220x xx A LPJ 35SP 2098 DSD HV xxxx xx Auxiliary Input Power FNO R 10 LPJ 10SP Bussmann Fuse IMPORTANT Follow the wire size information as shown in the Power Wiring Requirements table on page 3 13 and select the fuse for the appropriate temperature rating of the wire Auxiliary input fuses must not exceed 13A Publication 2098 INOO3E EN P April 2004 Specifications and Dimensions Circuit Breaker Specifications While circuit breakers offer some convenience there are limitations for their use Circuit breakers do not handle high current inrush as well as fuses The Ultra3000 needs to be protected by a device having a short circuit interrupt cur
141. built cables to ensure system performance When building your own cables follow the guidelines listed below e Connect the cable shield to the connector shells on both ends of the cable for a complete 360 connection e Use a twisted pair cable whenever possible twisting differential signals with each other and single ended signals with the appropriate ground return Refer to Appendix C for drive connector kit catalog numbers Routing Power and Signal Wiring Be aware that when you route power and signal wiring on a machine or system radiated noise from nearby relays transformers and other electronic drives can be induced into motor or encoder feedback communications or other sensitive low voltage signals This can cause system faults and communication problems Refer to Chapter 1 for examples of routing high and low voltage cables in wireways Refer to System Design for Control of Electrical Noise publication GMC RMO01x EN P for more information Determining Your Type of Input Power Connecting Your Ultra3000 3 3 On the following pages are examples of typical single phase and three phase facility input power wired to single phase and three phase Ultra3000 drives designed to operate from grounded or ungrounded power configurations For systems requiring CE or for Ultra3000 2098 DSD xxx 230V drives the supply must be grounded The grounded power configuration allows you to ground your single phase or
142. coder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUT4 21 Buffered Motor Encoder Ch l IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2 Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Inputs AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Inpute BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR 5V 7 Encoder Power 49V EPWR 9V 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 2 10 Ultra3000 Connector Data Ultra3000 with SERCOS Front Panel Connections Use the figure below to locate the front panel connections on the Ultra3000 with SERCOS interface 230V drives 500W 1 kW and 2 kW Figure 2 5 Ultra3000 Front Panel Connections for 2098 DSD 005 SE 010 SE and 020 SE D O
143. d not be used on the output of an ac drive as an isolating disconnect switch or motor overload device These devices are designed to operate on sine wave voltage and the drive s PWM waveform does not allow it to operate properly As a result damage to the device will occur Catalog Number Contactor Ratings Specifications and Dimensions The table below lists contactor examples recommended for use with the Ultra3000 460V drives Input Catalog Number Voltage 2098 DSD HV030x xx 2098 DSD HV050x xx 2098 DSD HV100x xx 460V 2098 DSD HV150x xx 2098 DSD HV220x xx Contactor 0 C23x10 AC Coil 0 C23Zx10 D 0 C30x10 AC Coil 0 C30Zx10 D 0 C37x10 AC Coil 0 C43x10 AC Coil 0 C437x10 D 0 0 0 0 0 00 C37Zx10 0 0 0 0 0 C60x10 AC Coil 0 C60Zx10 D Power Dissipation Specifications Use the following table to size an enclosure and calculate required ventilation for the Ultra3000 Typical heat losses run approximately one half maximum power losses The maximum power losses are shown below Maximum Loss Watts 2098 DSD 005x xx 48 2098 DSD 010x xx 48 2098 DSD 020x xx 50 2098 DSD 030x xx 150 dissipative shunt 2098 DSD 075x xx 300 dissipative shunt 2098 DSD 150x xx 500 dissipative shunt Catalog Number 2098 DSD HV030x xx Maximum Loss Watts 175 dissipative shunt 2098 DS
144. dback away from potential noise sources e Check the system grounds e Verify that the unbuffered encoder signals are not subjected to EMI in the CN1 cable Remove these signals from he CN1 cable if they are not being used e Verify that the motor has a high frequency bond to the drive s enclosure panel e Verify that any stage connected to the motor shaft for example using a ball screw has a high frequency bond to the machine frame and the drive s enclosure panel Bad encoder Replace motor encoder E21 Auxiliary Encoder state error The auxiliary encoder encountered an illegal transition e Use shielded cables with twisted pair wires e Route the encoder cable away from potential noise sources e Bad encoder replace encoder e Check the ground connections Setup time violation for Step Direction or CW CCW input Check timing of Step Direction or CW CCW inputs to determine if setup time requirements are being met E22 Motor Thermal Protection Fault The internal filter protecting the motor from overheating has tripped e Reduce acceleration rates e Reduce duty cycle ON OFF of commanded motion e Increase time permitted for motion e Use larger Ultra3000 and motor e Check tuning E23 IPM Thermal Protection Fault The internal filter protecting the drive from over heating has tripped e Reduce acceleration rates e Reduce duty cycle ON
145. e AC Input Power E i Connections 9 mzoue amp 3 amp e 9 ux amp 8 ur TB Motor Power Cable Shield Clamp 2 Data ate 2 E 8 Publication 2098 INOO3E EN P April 2004 Serial Port Connector P f Status LED ba Logic Power LED m Module Status LED se Network Status LED J bo Node Address Switches ID uo 9 pin CN3 Serial Connector Seven Segment 15 pin CN2 oW lt Data Rate Switch 2 CN3 9 pin E i lt Serial Port o Connector S CN2 15 pin a Motor Feedback g Connector ree O f CN1 44 pin Lapin d 8 lt User 1 0 i ps Pin 44 1 Pin 15 SERCOS interface Receive Rx and i i Transmit Tx Pin 31 eg Pin 1 Connectors Pin 16 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3 Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved Ultra3000 Connector Data 2 15 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector
146. e device 2 Check that one or more nodes are communicating on the network e Failed Duplicate 3 Check that at least one other node on the network is operational and the data MAC ID check rate is the same as the drive e On line e Passed Duplicate No action is needed The LED is flashing to signify that there are no open Flach inasaraan e Notconnected MAC ID check communication connections between the drive and any other device Any connection 99 e Noconnection I O or explicit message made to the drive over DeviceNet will cause the LED to stop established flashing and remain Steady ON for the duration of any open connection e On line One or more Steady green eC ted connections No action needed This condition is normal DUREE established e On line ded 1 Re initiate I O messaging by the master controller cachingered 1 0 connection timed PIE asning Te e Time out out 2 Reduce traffic or errors on the network so that messages can get through within the necessary time frame e Failed Duplicate 1 Ensure that all nodes have unique addresses Steady red Network Failure MAC ID check 2 If all node addresses are unique examine network for correct media installation e Bus off Publication 2098 INOO3E EN P April 2004 3 Ensure that all nodes have the same Data Rate Chapter Objectives Certifications Appendix A Specifications and Dimensions This appendix covers the following topics e Certifications e Ultra3000 P
147. e 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 ATTENTION Identifies information about practices oro circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard e avoid a hazard e recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley A B ControlLogix and Rockwell Automation are registered trademarks of Rockwell Automation RSLogix RSLogix 5000 SoftLogix and Ultra3000 are trademarks of Rockwell Automation DeviceNet is a trademark of the Open DeviceNet Vendor Association SERCOS interface is a trademark of the Interests Group SERCOS interface e V IGS Windows is a registered trademark of Microsoft Corporation UL is a registered trademark of Underwriters Laboratories Inc Bussmann is a registered trademark of Cooper Industries Inc LittelFuse is a registered trademark of LittelFuse Summary of Changes The Ultra3000 Digital Servo Drive Installation Manual Document Update publication 2098 DU
148. e overvoltage limit is exceeded Figure 3 7 Single Phase Amplifiers One EMC Filter Drive Transformer WYE Secondary Ultra3000 System A Single Phase AC Input TB1 Terminals Ultra3000 System B Single Phase AC Input TB1 Terminals L Ultra3000 System C Single Phase AC Input TB1 Terminals Grounded Neutral Grounded Neutral ooo Bonded Cabinet Ground B Ground Grid or ML Ground Grid or Power Distribution Ground NV v 4 Power Distribution Ground Note Feeder and branch short circuit protection is not illustrated IMPORTANT Providing an EMC line filter for each drive is the preferred configuration and required for CE compliance Publication 2098 INOO3E EN P April 2004 3 8 Connecting Your Ultra3000 Grounded Neutral Transformer WYE Secondary L If a three phase line filter is used to feed multiple single phase drives not recommended it is important that the filter include a neutral connection as shown in Figure 3 8 This applies if three phase is brought directly into the filter i e no isolating transformer present Figure 3 8 Single Phase Amplifiers One EMC Filter Multiple Drives TB1 L1 L2 N 18 m Ultra3000 System B LIN Single Phase
149. e range of the external power supply for 10 8V 264V Voltage proper operation of the digital 1 0 i j Current draw from the external power supply for ME Supply the digital I O not including the relay output 300 mA usage Auxiliary 5V Logic Supply The Ultra3000 drives 2098 DSD 005 010 and 020 require an external 5V power supply in applications in which it is necessary to maintain logic power when the AC line voltage is removed The 24V I O supply IOPWR allows use of the drive mounted breakout boards with 24V to 5V dc converter 2090 U3CBB DM12 and DM44 The following table provides a description of the 24V IOPWR power supply requirements when used to maintain logic power Parameter Description Minimum Maximum Input voltage range of the external power Men d supply for drive mounted breakout boards with 18V 30V 24V to 5V converter Input current draw from the external power supply for the drive mounted breakout boards with 24V to 5V converter Input Current 400 mA A single 24V power supply can be used to power the digital I O and supply 24V to the drive mounted breakout boards 2090 U3CBB DMxx provided the cumulative minimum current requirements are met IMPORTANT Ultra3000 Connector Data 2 27 Two versions of the drive mounted breakout board with 24V to 5V auxiliary power converter exist e 12 pin CN1 connector designed for use with SERCOS interface applications catalog number
150. edback and brake cables include integral molded bayonet style quick connect quick release connectors at the motor Power and brake cables have flying leads on the drive end and straight connectors that connect to servo motors Standard feedback cables have angled connectors 45 on the drive end and straight connectors that connect to servo motors SERCOS fiber optic cables are available in enclosure only PVC nylon and glass with connectors at Fiber Optic cables path ends AC UNER 2090 UXLF xxx AC line filters with 6 10 23 32 36 and 50A are available for Ultra3000 230V drive systems ine Filters 2090 UXLF HVxxx AC line filters with 23 30 and 50A are available for Ultra3000 460V drive systems 2090 UCSR xxxx ee 9101 1183 and External shunt modules are available when the Ultra3000 internal shunt capability is exceeded 2090 SRxxx xx Note Refer to Appendix C for a complete list of catalog numbers for the Ultra3000 system components listed above Publication 2098 INOO3E EN P April 2004 1 4 Installing Your Ultra3000 The typical Ultra3000 system installation includes the following as shown in the figures below Figure 1 1 Ultra3000 SE SERCOS Digital Servo Drive System Overview
151. en Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2 Pin Description Signal CN2 Pin Description Signal 1 Channel A Sine Differential Input AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR_5V 7 Encoder Power 9V EPWR 9V 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 3 Publication 2098 INOO3E EN P April 2004 2 24 Ultra3000 Connector Data Use the figure below to locate the front panel connections on the Ultra3000 with DeviceNet Interface 460V drives 3 kW 5 kW 10 kW 15 kW and 22 kW Figure 2 12 Ultra3000 Front Panel Connections for 2098 DSD HVxxx DN and HVxxxX DN me Passive Shunt Resistor Connections 1 Motor Power MES Connections AC Input Power i ne Connections Motor Power Cable Shield Clamp gt d Ultrasooo Allen Bradley suus External Shunt Internal lhe LT Ace vu NS
152. en any loose wires 7 Re attach the plastic cover to the terminal block Publication 2098 INOO3E EN P April 2004 3 18 Connecting Your Ultra3000 Connecting Motor Power and Brakes Publication 2098 INOO3E EN P April 2004 This procedure assumes you have wired your input power and are ready to wire the motor power and brake connections IMPORTANT When tightening screws to secure the wires refer to the table on page 3 13 for torque values IMPORTANT To ensure system performance run wires and cables in the wireways as established in Chapter 1 Refer to Appendix B for the power wiring diagram for your Ultra3000 Applying the Motor Cable Shield Clamp To apply the motor power cable shield clamp 1 Loosen the two screws securing the cable clamp on the Ultra3000 drive refer to figures 3 11 or 3 12 for the cable clamp location on your Ultra3000 drive Feed the cable into the clamp and position the exposed portion of the cable braid directly in line with the clamp Extend the cable along side the drive leaving an appropriate length of cable for terminating the motor power wires Check that the exposed cable braid is still in line with the clamp adjust alignment if necessary Tighten the screws with a torque of 0 9 1 1 Nm 8 0 10 0 Ib in Connecting Your Ultra3000 3 19 Wiring Motor Power When using MP Series low inertia and integrated gear 1326AB and F H or N Series motors refer to Figure
153. ents Regarding this Manual P 4 Chapter 1 Chapter Objectives cy cca quidc E X4 d RAE RIZ ERR US 1 1 Complying with European Union Directives 1 2 EMG Directive goin bokeh Bae bees ee ey eo ib eM 1 2 Meeting CE Requirements llle 1 2 Low Voltage Directive 4 4 qox o oca esos a 1 3 Ultra3000 System Component Overview 1 3 Before Mounting Your System l l leen 1 5 Unpacking Modules s uus aute ia mh eR bee Res 1 5 System Mounting Requirements 1 6 Ventilation Requirements 4 0 aee Cae ee ee wD 1 7 Sizing an ETICIOSIESC ou ib wu e dose 9d Ro o dor E dE edo ad 1 8 Transformer DIEI qe orc SKE ced ae ee OO 1 8 FUS SIZ Oe okies Qu desc us Pete Ae Beane RE aD 1 10 HF Bonding Your System uius sc soc sober eoe E Rode ees 1 10 Bonding Modes Leo qoas do EEA oe ae OR Rc 1 11 Bonding Multiple Subpanels cvs v e eges 1 12 Planning Your Panel Layout 42452024634 d CORRER RR 4 1 12 Establishing Noise Zones 2 2 05 64 xag x Raa BOSS d 1 13 Cable Categories for the Ultra3000 1 14 Mounting Guidelines to Reduce Electrical Noise 1 15 Mounting Your Ultra3000 Dive 664444 itadb 4e4sa44 1 18 Chapter 2 Chapter Objectives corsi PHD AeA RERAREREH OR EK OD 2 1 Understanding Ultra3000 Connectors 2 1 Ultra3000 Front Panel Connections 2 2 Ultra3000 with SERCOS Front Panel Connections 2 10 Ultra3000 with DeviceNet Front Pane
154. eo Y ER C 5 Ultra3000 Interface Cables oa donee RO Ry RS C 5 SERCOS Interface Fiber Optic Cables C 6 Drive End Connector Kits 5 0 detache ddr re EE C 6 Motor End Connector RIS uu duos een eek wen eee C 7 Breakout Board Kits 4 0 6 405 604 e e Ree v d C 8 Breakout Dosftds iius kc edo o acie ie Ro Red C 8 Breakout Cres au voces prece ae LEER ROSA aed C 8 Introduction Who Should Use this Manual Purpose of this Manual Preface Read this preface to familiarize yourself with the rest of the manual This preface contains the following topics e Who Should Use this Manual e Purpose of this Manual e Contents of this Manual e Product Receiving and Storage Responsibility e Related Documentation e Conventions Used in this Manual e Allen Bradley Support Use this manual for designing installing and wiring your Ultra 3000 Digital Servo Drive DSD The manual is intended for engineers or technicians directly involved in the installation and wiring of the Ultra3000 If you do not have a basic understanding of the Ultra3000 contact your local Allen Bradley representative for information on available training courses before using this product This manual provides the mounting wiring and connecting procedures for the Ultra3000 and standard Rockwell Automation Allen Bradley motors recommended for use with the Ultra3000 For power up procedures troubleshooting tables and system integration with Ultraware
155. face fiber optic plastic cables for your Ultra3000 connectors at both ends Description Catalog Number SERCOS fiber optic plastic cable for use inside enclosure only 2090 SCEPx x SERCOS fiber optic plastic PVC cable for use outside enclosure 2090 SCVPx x ommend plastic nylon cable for use outside enclosure in harsh 2090 SCNPx x SERCOS fiber optic glass PVC cable 2090 SCVGx x Note Cable length x x is in meters 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 Drive End Connector Kits Use the following table to identify the drive end connector kit for your serial feedback and I O cable Refer to the chapter Ultra3000 Connector Data for pin signal and wiring information Description Drive Connector Kit 9 pin D shell serial cable to drive CN3 Catalog Number 2090 UXCK D09 Drive Connector Kit 15 pin high density D shell feedback cable to drive CN2 2090 UXCK D15 Drive Connector Kit 44 pin high density D shell I O cable to drive CN1 2090 U3CK D44 The following table lists Amp drive cable connectors that are not available from Rockwell Automation Please contact Amp at 1 800 522 6752 or a distributor for additional information CN1 Controller CN2 Motor Feedback CN3 Serial Connector 44 Pin 15 Pin 9 Pin Components High Density High Density Standard Density D Shell D Shell D Shell Drive Connecto
156. flex 16 AWG straight 2090 XXNPH 16S xx H Series 230V non flex 16 AWG right angle 2090 UXNPAH 16Rxx H Series 230V non flex 6 AWG straight 2090 UXNPAH 6S xx H Series 230V non flex 6 AWG right angle 2090 UXNPAH 6Rxx H and F Series 230V non flex 14 AWG straight 2090 XXNPHF 14S xx H and F Series 230V non flex 14 AWG right angle 2090 UXNPAHF 14Rxx H and F Series 230V non flex 10 AWG straight 2090 UXNPAHF 10Sxx H and F Series 230V non flex 10 AWG right angle 2090 UXNPAHF 10Rxx H and F Series 230V non flex 8 AWG straight 2090 UXNPAHF 8S xx H and F Series 230V non flex 8 AWG right angle 2090 UXNPAHF 8Rxx MP Series MPL MPG 23 0 460V non flex 16 AWG straight 1326AB M2L S2L 460V n 2090 XXNPMP 16Sxx on flex 16 AWG straight MP Ser ies MPL MPG 230 460V non flex 14 AWG straight 2090 XXNPMP 14S xx MP Ser ies MPL MPG 230 460V non flex 10 AWG straight 1326AB M2L S2L 460V n 2090 XXNPMP 10Sxx on flex 10 AWG straight MP Series MPL MPG 230 460V non flex 8 AWG straight 2090 XXNPMP 8S xx MP Series MPF 230 460V non flex 16 AWG straight 2090 XXNPMF 16S xx MP Series MPF 230 460V non flex 14 AWG straight 2090 XXNPMF 148 xx MP Series MPF 230 460V non flex 10 AWG straight 2090 XXNPMF 10S xx Series 230V non flex 16 AWG straight 2090 XXNPN 16S xx N Series 230V non flex 16 AWG right angle 2090
157. g Your Ultra3000 Connecting Input Power Publication 2098 INOO3E EN P April 2004 ATTENTION To avoid personal injury and or equipment damage ensure installation complies with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices The National Electrical Code NEC and local codes outline provisions for safely installing electrical equipment To avoid personal injury and or equipment damage ensure motor power connectors are used for connection purposes only Do not use them to turn the unit on and off To avoid personal injury and or equipment damage ensure shielded power cables are grounded to prevent potentially high voltages on the shield This procedure assumes you have mounted your Ultra3000 drive and are ready to wire your AC input power IMPORTANT When tightening screws to secure the wires refer to the table on page 3 13 for torque values IMPORTANT To ensure system performance run wires and cables in the wireways as established in Chapter 1 Refer to Appendix B for the power wiring diagram for your Ultra3000 To wire your input power 1 Prepare your wires by stripping approximately 12 mm 0 50 in of insulation from the end Tinie Use caution not to nick cut or otherwise damage strands as you remove the insulation 2 Route the power cable to your Ultra3000 drive Connecting Your Ultra3000 3 17 3 Locate the TB1 terminal block and
158. h axis x 2 0 Installing Your Ultra3000 1 9 IMPORTANT If you are using the Rockwell Automation Allen Bradley system sizing program the average speed and average torque data has already been calculated and can be used in the above equation If you are not sure of the exact speed and torque in your application another approach is to look at the speed torque curve for your Ultra3000 motor combination and use the values for the worst case continuous speed and torque IMPORTANT Calculations are multiplied by a factor to compensate for the power and loss elements within a power system A factor of 2 0 is used with a single phase system and a factor of 1 5 is used with a three phase system This factor should minimize the effects of the secondary line voltage sagging in the transformer during peak current periods Example sizing a transformer to the voltage requirements of an 2098 DSD 020 and MPL A320P motor KVA Speed RPM xTorque Ib in 746Watts KVA 63 025 HP 1000Watts va amp DO RPM XT7 CI in 42 250 K Transformer Size 2 1 KVA The speed torque curve information for 230V motors is based upon an Ultra3000 input voltage of 230V ac For a 115V ac input voltage the maximum speed can be reduced up to one half Publication 2098 INOO3E EN P April 2004 1 10 Installing Your Ultra3000 Drive Models Input Power Type 2098 DSD xxx xx or XXXX Xx Input Power and Auxiliary Input Power
159. hase Control String Example ssl ER External E d Ultra3000 c TB2 1 lt l START srOP T l E l CR1 i MES 120VAC 50 60Hz CRI Mi A CRI ec Q Refer to Attention statement above ma LE cm E E E IE E p Elle ig ib was LELU N O Relay Outputs Block M1 E lt n L1 Note 20 Single Phase x CH Ee AC Line 50 60 Hz j ZMN lll 24V DC xw Tg CR2 L1 Aux mie N O Relay Output L2 N Aux Ella e N N Publication 2098 INOO3E EN P April 2004 B 18 Interconnect Diagrams The 120V ac control string wired to the Ultra3000 2098 DSD 075x xx 150x xx HVxxx xx and HVxxxX xx drives is shown in the figure below Implementation of safety circuits and risk assessment Did HIE Pis 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 Figure B 18 120V ac Three Phase Control String Example mm iE B Ultra3000 LE d m ii START STOP T l CR1 ng geom 120VAC 50 60 Hz CR1 Mi CRI
160. hasing is IMPORTANT IMPORTANT different than the phasing of the TTL encoders Figure 2 46 Phasing of Sine Cosine Encoder Signals Motor Encoder Connection Diagram Figure 2 47 shows a typical wiring diagram of a motor feedback cable If the thermostat limit or Hall signals are not available no connections are required but the drive must be configured through software to ignore these signals Refer to Appendix B for specific Ultra3000 drive motor interconnect diagrams Figure 2 47 Drive Motor Wiring Diagram i S EEN e 1 moase A A amfi Drive A or SIN f T AM 2 B or COS j j BM 3 B or COS 1 1 BM 4 l or Data i IM 5 l or Data i it IM 10 POWER 5V j EPWR SV 14 GROUND 1 1 ECOM 6 TS i TS 11 TS 1 S1 H2 S2 S2 13 Denotes twisted pair 3 3 8 Connector backshell shielded 360 both ends Total resistance of the wiring for 5V encoder power IMPORTANT and ground connections between the drive and motor must be less than 1 4 ohms Publication 2098 INOO3E EN P April 2004 2 46 Ultra3000 Connector Data Understanding Motor Feedback Signals and Outputs The Ultra3000 is compatible with motors equipped with both incremental A quad B or high resolution Stegmann Hiperface SIN COS encoders The buffered motor encoder outputs use RS 485 differential drivers and have a maximum signal frequency of 2 5 MHz The
161. hnique 2080 XXNFMF Sxx Feedback Cable Note 12 16 Publication 2098 DU003B EN P September 2006 10 Ultra3000 Digital Servo Drive Installation Manual Page B 13 2090 XXNPH HF xxS xx or UXNPBH HF xxS xx Motor Power Cable Note 12 Replace Figure B 13 on page B 13 with the one shown below The new figure correctly identifies the motor brake connector pins as A and B Also included is an illustration of grounding the feedback cable shield Figure B 13 Ultra3000 Drive to H and F Series 230V Motors H or F Series 230V Servo Motors with Incremental Feedback Ultra3000 230V Drive Green Yellow Motor Feedback Note 13 Blue CN2 Connector Black Mn CPC et RON h aaa Three Phase ERS RUE on pS UE 1 pean Motor Feedback Motor Power A sy BLACK AM 1 15 pin Connector BS WHT BLACK XX AM 2 CN2 MEN RED BM 3 D WHT RED XX BM 4 9101 0330 Brake Cable C Ki a gt GREEN Mc 2 rake Cable Connector Kit F WHT GREEN IM 10 Note 12 43 Black B BR R s gt WHT BROWN TS 1 P SS BROWN S3 8 Control Interface 44 Now IA lt lt Bn 3 Motor Brake 7 44 pin Connector White CI Te GRAY 5VDC 14 CNI COM 24V i gt User Supplied M 3 WHT GRAY ECOM 6 Motor 2AV de ipid Supply N 5 BL
162. ibility of the machine builder Please reference international standards EN1050 and EN954 estimation and safety performance categories For more information refer to Understanding tbe Machinery Directive publication SHB 900 11 The recommended minimum wire size for wiring the safety circuit to the contactor enable connector is 1 5 mm 16 AWG 12 For motor cable specifications and drive motor cable combinations refer to the Motion Control Selection Guide publication GMC SG001 x EN P 13 The Ultra3000 referenced is either a 2098 DSD xxx or xxxX Ultra3000 with indexing xxx SE SERCOS interface xxx DN DeviceNet interface xxxX DN DeviceNet with indexing 230V drive 14 The Ultra3000 referenced is either a 2098 DSD HV xxx or HVxxxX Ultra3000 with indexing HVxxx SE SERCOS interface HV xxx DN DeviceNet interface HVxxxX DN DeviceNet with indexing 460V drive 15 Wire colors are for flying lead cable 2090 XXNFxx Sxx and may vary from the premolded connector cable 2090 UXNFB xx Sxx Wires without terminations at the drive are not shown for clarity 16 If flying lead feedback cable has a drain wire it must be folded back and clamped with the cable shield CN2 breakout board 2090 UXBB DM15 17 Only the MPG Bxxx encoder uses the 5V dc supply MPL Bxxx and 1326AB M2L S2L encoders use the 49V dc supply 18 Only the MPL A5xx and MPF A5xx encoders use the 9V dc supply MPG Axxx encoders use the 5V dc supply 19 Use a flyback
163. ication was not established with e Verify the motor supports automatic E30 Encoder Communication Fautt an intelligent encoder identification e Verify motor encoder wiring E31 Encoder Data Encoder data is corrupted Replace the motor encoder i AS i e Decrease velocity E32 Sine Cosine Encoder Frequency Limit Maximum frequency of the sine cosine Exceeded circuitry has been exceeded e Use encoder with lower resolution before interpolation Motion is commanded to a position outside the position rollover range e An absolute index is initiated that specifies a position outside the position rollover range e A homing cycle is initiated with the E33 Absolute Position Exceeds Position home position outside the position Set motion command to a position within Rollover rollover range the position rollover range e A define home is initiated with the home position outside the position rollover range e A preset position is initiated that specifies a position outside the position rollover range Wiring error Check motor power wiring Motor internal ground short Replace motor E34 Ground Fault Disconnect motor power cable from drive and enable drive with current limit set to 0 Internal malfunction If fault remains call your A B representative If fault clears then a wiring error or motor internal problem exists Low AC input voltage Check input AC voltage on all phases E35 Precharge Fault Internal malfunction Call your A B rep
164. ications Shunt Module inni Ultra3000 Drives Drive Peak Peak Continuous Shipping Fuse Replacement Catalog Number Voltage dee DNE Power Current Power Weight r VAC kW Amps Watts kg Ibs 2098 DSD 005 010 and 020 2090 UCSR A300 36 4 0 10 5 300 1 51 3 3 2098 DSD 030 9101 1183 230 30 5 9 14 0 200 CCMR 4 142 2098 DSD 075 and 2090 UCSR P900 18 10 233 408 9 0 FWP 10A14F 2098 DSD HV030 900 1 and HV050 2090 SR120 09 120 5 3 6 7 FWP 2 5A14F 3 63 8 0 2090 SR040 09 40 20 0 FWP 5A14F 2098 DSD HV100 16 2090 SR040 18 460 40 20 0 1800 8 6 19 0 FWP 10A14F M3575R H27B0 C 900 N A 2098 xxx HV150 25 31 25 6 31 0 11 3 25 0 M3575R H27BE C 1800 N A 2098 xxx HV220 M3575R H33BF C 2 20 25 32 0 36 0 3600 12 7 28 0 N A Publication 2098 INOO3E EN P April 2004 Bussmann part number 2 LittelFuse part number 3 Bonitron part number For more information contact Bonitron Inc 521 Fairground Court Nashville TN 37211 Tel 615 244 2825 www BONITRON com Drive Family Ultra3000 Specifications and Dimensions A 13 Maximum Feedback Cable Lengths Although motor feedback cables are available in standard lengths up to 90 m 295 3 ft the drive motor feedback combination may limit the maximum cable length as shown in the tables below These tables assume the use of cables recommended in the Motion Control Selection Guide publication GMC SGO01x EN P The maxim
165. ion on the relay output Publication 2098 INOO3E EN P April 2004 B 6 Interconnect Diagrams The Ultra3000 2098 DSD HVxxx xx and HV xxxX xx power wiring with 24V dc control string is shown in the figure below For the control string diagram with 120V ac input refer to Figure B 18 Figure B 4 Typical Power Wiring of Ultra3000 System 2098 DSD HV xxx xx and HV xxxX xx Ultra3000 Digital Servo Drives 2098 DSD HV xxx xx and HVxxxX xx Note 14 TB1 TB2 DC 1 External Passive 1 Shunt Connections DC 2 refer to figures beginning on B 7 3 Three Phase Motor Power V Motor Power Connections Connections Note 12 Three Phase AC Line L L3 50 60 Hz Three Phase IL TI Lis H L2 AC Line Filter il AC Input Power CN1 Note 7 IL T IHH oH Connections N O Relay Output Fused Disconnect 43 or Circuit Breaker m L1 AUX M N O Relay Output Note 20 Note 1 bte L2 N AUX ml Input Fusing Notes 4 and 5 Cable Shield Isolation Clamp Transformer Neutral Note 9 Note 2 ro Chassis O Bonded Cabinet ji Ground Bus O 13 CN1 43 T lt Three Phase Input L2 START STOP cri 230 480V ac RMS a L 5 24V dc CRI ul 44 ut CR1 Terminal Blocks Note 3 Refer to Attent
166. ion statement Notes 10 11 VV To additional INDICATES USER SUPPLIED COMPONENT Ultra3000 drive Publication 2098 INOO3E EN P April 2004 Note Refer to Figure 2 26 in the chapter Ultra3000 Connector Data for more information on the relay output Interconnect Diagrams B 7 Shunt Module Interconnect This section contains the interconnect diagrams connecting the Diagrams Ultra3000 drives with active and passive shunt modules Refer to External Shunt Kits in Appendix C for Ultra3000 shunt combinations Active Shunt Module Diagrams In the figure below the Ultra3000 2098 DSD 005x xx 010x xx or 020x xx is shown wired with the 2090 UCSR A300 active shunt module Figure B 5 External Active Shunt Module Interconnect Diagram Ultra3000 Digital Servo Drives 2098 DSD 005x xx 010x xx and 020x xx External Active Shunt Module 2090 UCSR A300 DC Bus Connections DC for Active Shunt Module AC Input Power L2 N Connections Passive Shunt Module Diagrams In the Figure B 6 the Ultra3000 is shown wired for internal shunt operation This is the factory default jumper setting IMPORTANT Internal shunt operation is only present on the drives listed in the figure below Figure B 6 Internal Shunt Interconnect Diagram Ultra3000 Digital Servo Drives 2098 DSD 030x xx 075x xx 150x xx HV xxx xx and HVxxxX xx Internal Passive Shunt Res
167. ion terms and abbreviations Allen Bradley Industrial Automation Glossary AG 7 1 Publication 2098 INOO3E EN P April 2004 P 4 Preface Conventions Used in this Manual Allen Bradley Support Publication 2098 INOO3E EN P April 2004 The following conventions are used throughout this manual e Bulleted lists such as this one provide information not procedural steps e Numbered lists provide sequential steps or hierarchical information e Words that you type or select appear in bold e When we refer you to another location the section or chapter name appears in italics e Abbreviations for the Ultra3000 drives shown in the table below are used throughout this manual Ultra3000 Drive Abbreviation Ultra3000 with SERCOS interface Ultra3000 SE Ultra3000 with DeviceNet interface Ultra3000 DN 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 e Sales and order support e Product technical training e Warranty support e Support service agreements Technical Product Assistance If you need technical assistance contact your local Allen Bradley representative or Rockwell Automation Technical Support at 440 646 5
168. is clamp provided refer to Chapter 3 for wiring instructions e When installing the Ultra3000 system inside an enclosure run input power wiring grounded to the enclosure in conduit outside of the enclosure e Separate signal and power cables as shown in Planning Your Panel Layout of this chapter Ultra3000 System Component Overview a Catalog Numbers 2098 DSD xxx and xxxX Ultra3000 Drives Installing Your Ultra3000 Low Voltage Directive These units are tested to meet Council Directive 73 23 EEC Low Voltage Directive The EN 60204 1 Safety of Machinery Electrical Equipment of Machines Part 1 Specification for General Requirements standard applies in whole or in part Additionally the standard EN 50178 Electronic Equipment for use in Power Installations applies in whole or in part Refer to Appendix B for interconnect information This section provides an overview of the Ultra3000 system components and a typical installation Description Ultra3000 and Ultra3000 with indexing available with 500W 1 2 3 7 5 and 15 kW continuous output and 230V input power 2098 DSD HV xxx and HVxxxX Ultra3000 and Ultra3000 with indexing available with 3 5 10 15 and 22 kW continuous output and 460V input power Ultra3000 SE SERCOS interface Drives 2098 DSD xxx SE Ultra3000 with SERCOS interface available with 500W 1 2 3 7 5 and 15 kW continuous output and 230V input power 2098 DSD HV xxx SE
169. istor Connections Publication 2098 INOO3E EN P April 2004 B 8 Interconnect Diagrams Publication 2098 INOO3E EN P April 2004 In the figure below the Ultra3000 is shown wired with an external passive shunt resistor Refer to External Shunt Kits in Appendix C for Ultra3000 shunt combinations Figure B 7 External Passive Shunt Module Interconnect Diagram Ultra3000 Digital Servo Drives 2098 DSD 030x xx 075x xx 150x xx HVxxx xx and HVxxxX xx External Passive Shunt Module External Passive Shunt Resistor Connections In the figure below the Ultra3000 2098 DSD 150x xx is shown wired with two external passive shunt resistors When two 900W shunt modules are connected in parallel the shunt capacity is doubled for a total of 1800W of continuous power dissipation Figure B 8 External Passive Shunt Module Interconnect Diagram Ultra3000 Digital Servo Drives 2098 DSD 150x xx External Passive Shunt Module 2090 UCSR P900 External Passive Shunt Resistor Connections External Passive Shunt Module 2090 UCSR P900 Bonitron Shunt Module M3575R H xxxx TEMP Alarm Interconnect Diagrams B 9 In the figure below the Ultra3000 2098 DSD HV150x xx or HV220x xx is shown wired to a Bonitron shunt module Figure B 9 External Passive Shunt Module Interconnect Diagram Ultra3000 Digital Servo Drive
170. ith DeviceNet I O connector 2 19 2 21 2 23 2 25 with SERCOS I O connector 2 11 2 13 2 15 2 17 power losses A 7 power diagrams 2098 DSD 005 010 020 B 3 2098 DSD 030 B 4 2098 DSD 075 150 B 5 2098 DSD HVxxx B 6 power dissipation A 7 power specifications A 2 A 3 A 4 preselect inputs 2 29 problem report form P 4 purpose of this manual P 1 R ready B 2 related documentation P 3 relay output B 2 B 3 B 4 B 5 B 6 B 16 B 19 routing power and signal wiring 2 2 RS 232 2 51 2 52 RS 422 2 51 2 53 RS 485 2 51 2 52 2 53 RSLogix 5000 software C 2 S serial interface specifications 2 51 default serial interface settings 2 52 four wire RS 485 connection 2 53 multiple axes RS 232 communications 2 52 restoring drive communications 2 54 serial port 2 51 shunt module catalog numbers C 3 interconnect diagram B 7 B 8 B 9 specifications A 12 sizing an enclosure 1 8 SoftLogix integration P 1 SoftLogix motion card setup and configuration manual P 3 specifications ac line filters A 11 auxiliary 5V power supply 2 26 auxiliary encoder power supply 2 51 auxiliary feedback A 10 certifications A 1 circuit breakers A 6 communications A 9 connectors A 10 contactor ratings A 7 control A 8 digital I O power supply 2 26 external 5V logic power supply 2 28 fuses A 5 I O 2 26 I O digital inputs 2 28 I O digital outputs 2 34 inputs and outputs A 9 maximum feedback cable lengths A 13 motor encoder feedback 2 40
171. its or sensor Home sensor marker or final home e Reposition the overtravel limits or home E13 Home Position In Limit position exceeds a hardware overtravel Sensor limit e Adjust the final home position SERCOS Hardware Fault A fault was detected with the operation of Contact your local Allen Bradley SERCOS drives only the drive s internal SERCOS hardware representative E14 SAT Dee MM communications network is Troubleshoot DeviceNet communications E15 Excessive Electrical Cycle Length E MISTER Replace the linear motor encoder 2 e Verify motion profile E16 Software Overtravel Programmed overtravel limit has been i E SERCOS only exceeded e Verify overtravel settings are appropriate E T User Specified average current level has pres E17 User Specified Current Fault beancexteadad Increase to a less restrictive setting E18 RH Faul Motor speed has exceeded 12596 of e Check cables for noise q p maximum rated speed e Check tuning e Increase the feedforward gain E19 Excess Position Error Position error limit was exceeded e Increase following error limit or time e Check position loop tuning Publication 2098 INOO3E EN P April 2004 4 6 Troubleshooting Status Indicators Code Problem or Symptom Possible Cause s Action Solution E20 Motor Encoder State Error The motor encoder encountered an illegal transition e Replace the motor encoder e Use shielded cables with twisted pair wires e Route the fee
172. k Green Yellow Q Green Yellow Into this terminal on Y Series TB1 TTTTAFYREE Ensure motor power is wired with proper phasing relative to the motor terminals On some motors the motor leads may be labeled R S and T which correspond to U V and W respectively 3 Tighten each terminal screw Refer to the table on page 3 13 for torque values Publication 2098 INOO3E EN P April 2004 Connecting Your Ultra3000 3 21 4 Gently pull on each wire to make sure it does not come out of its terminal Re insert and tighten any loose wires If your motor is 1 Connect the 152 4 mm 6 0 in termination wire at the motor end of the cable to the closest earth ground refer Y Series to Figure 3 13 for an illustration 2 Go to Understanding Motor Brake Connections Go to Understanding Motor Brake Not Y Series t Connections Understanding Motor Brake Connections The procedure for wiring your motor brake varies slightly depending on the motor series you are using Refer to the table below to determine where the brake wires for your servo motor are located and for the appropriate brake cable or connector kit catalog number For this Motor Series The Brake Wires are Cable Catalog Number MP Series low inertia and integrated gear 2090 UXNBMP 18S xx brake cable 1326AB Series M2L S2L In a separate brake cable the Gans motor has a brake connector H Sei
173. k Maximum inrush 230V ac input 95A 0 peak 95A 0 peak 95A 0 peak Continuous Output Current 15A 0 peak 35A 0 peak 65A 0 peak Intermittent Output Current 30A 0 peak 75A 0 peak 150A 0 peak Bus Capacitance 2370 pF 4290 pF 7520 pF Internal Shunt Resistance 35 Ohms 16 5 Ohms 9 1 Ohms Shunt On 420V de 420V de 420V de Shunt Off 402V de 402V de 402V dc Bus Overvoltage 452N dc 452N dc 452V dc Internal Shunt Continuous power 50W 50W 180W Peak power 4 5 kW 10 kW 18 kW External Shunt Resistance 30 Ohms 0 5 16 5 Ohms 0 5 9 Ohms 0 5 Continuous power 2 4 kW 4kW 8 kW Peak power 6 kW 10 kW 19 kW Energy Absorption Capability 115V ac input 211 Joules 381 Joules 669 Joules 230V ac input 117 Joules 211 Joules 370 Joules Continuous Power Output 115V ac input 1 5 kW 3 75 kW 7 5 kW 230V ac input 3 kW 7 5 kW 15 kW 1 Specification is for nominal voltage The absolute limits are 10 or 88 265V ms The 2098 DSD 030x xx 0 3 400 us half wave sine 75x xx and 150x xx 230V drives are limited to one contactor cycles per two minutes Power initialization requires a short period of inrush current Dual element time delay slow blow fuses are recommended refer to Fuse Specifications on page A 5 Publication 2098 INOO3E EN P April 2004 A 4 Specifications and Dimensions Ultra3000 460V Power Specifications The table below lists general power specifications and requirements for the Ultra3000 460
174. l Connections 2 18 Understanding Ultra3000 I O Specifications 2 26 Digital I O Power Supply 4 4 05 cae 444420845 2 26 Auxiliary 5V Logic Supply 656s we eka WBA ARES 2 26 Digital Inputs 4 05 665 ERD SRE TAOS Pope Roi CR 2 28 Digital Outputs xia ose bad me do ood 2 33 Analog COMMAND Input ee ok i rre o eee 2 37 Publication 2098 INOO3E EN P April 2004 ii Table of Contents Connecting Your Ultra3000 Publication 2098 INOO3E EN P April 2004 Analog ILIMIT Input iussus ay deed pe es heh ees 2 38 Analog Output 5 x ouk d URS bote ol AS edd Ow SS 2 39 Understanding Motor Encoder Feedback Specifications 2 40 AM BM and IM Inputs aoaaa oe e e oe ee 2 40 Hall TESDOES snes hw bbe OE a8 he RO ew a 2 42 Thermostat IHDUE 4 44 sco Kak o d ei Sa d 2 42 Limit and Limit Inputs avs ad os eo ea RR xs 2 43 Encoder Phasltig cessare ped ahd RUPEE RIVER Ped 0 2 44 Motor Encoder Connection Diagram 2 45 Understanding Motor Feedback Signals and Outputs 2 46 Unbuffered Encoder Outputs dre ERR 2 46 Incremental Encoder Output ia sie ew ERE CER 2 47 High Resolution Encoder Output 25 22 azar 2 48 Understanding Auxiliary Encoder Feedback Specifications 2 49 5V Auxiliary Encoder Power Supply 2 31 Understanding the Serial Interface aeree res 2 51 Default Serial Interface Settings sius a 2 52 Multiple Axes RS 232 Communications 2 52 Four Wire RS 485 Connecti
175. l descriptions and pin outs for the CN1 I O 44 pin connector CN1 Pin Description Signal CN1 Pin Description Signal Auxiliary Encoder Power Out 5V EPWR 23 Reserved 2 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Auxiliary Logic Power In 5V AUXPWR 25 Reserved 4 Auxiliary Encoder Ch A AX 26 Reserved 5 Auxiliary Encoder Ch A AX 27 1 0 Common IOCOM 6 Auxiliary Encoder Ch B BX 28 1 0 Common IOCOM 7 Auxiliary Encoder Ch B BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Drive Enable Input ENABLE 10 Unbuffered Motor Encoder Ch A AM 32 Home Sensor Input HOME 11 Unbuffered Motor Encoder Ch A AM 33 Registration Sensor 1 Input REG1 12 Unbuffered Motor Encoder Ch B BM 34 Registration Sensor 2 Input REG2 13 Unbuffered Motor Encoder Ch B BM 35 Reserved 14 Unbuffered Motor Encoder Ch l IM 36 Reserved 15 Unbuffered Motor Encoder Ch l IM 37 Positive Overtravel Input OT_POS 16 Buffered Motor Encoder Ch A AMOUT 38 Negative Overtravel Input OT_NEG 17 Buffered Motor Encoder Ch A AMOUT 39 Drive Ready READY 18 Buffered Motor Encoder Ch B BMOUT 40 Reserved 19 Buffered Motor Encoder Ch B BMOUT 41 Reserved 20 Buffered Motor Encoder Ch l IMOUT 42
176. len Bradley motors AM BM and IM Inputs AM BM and IM Input encoder signals are filtered using analog and digital filtering The inputs also include illegal state change detection Refer to Figure 2 37 for a schematic of the AM BM and IM inputs Figure 2 37 Schematic of the Motor Encoder Inputs Hp AM and BM Channel Inputs IM Channel Input Ultra3000 Drive Ultra3000 Drive Ultra3000 Connector Data 2 41 The Ultra3000 supports both TTL and Sine Cosine encoders The following table provides a description of the AM BM and IM inputs for TTL encoders Parameter Description Minimum Maximum AM BM and IM Input voltage difference between the input ON State and the input that is detected as an ON 1 0V 7 0V nput Voltage state AM BM and IM Input voltage difference between the input OFF State and the input that is detected as an OFF 1 0V 7 0V nput Voltage state Common Mode Potential difference between any encoder nput Voltage signal and logic ground 7 0V 12 0V DC Current Draw Current draw into the or input 30 mA 30 mA Frequency of the AM or BM signal inputs AM BM Input The count frequency is 4 times this EE 25 MHz Signal Frequency frequency since the circuitry counts all four i transitions Pulse width of the index input signal Since s the index is active for a percentage of a _ IM Pulse Width revolution the speed will determine the 125 nS pulse wid
177. line filters which have been tested by Rockwell and specified for the product should be used Refer to AC Line Filters on page C 3 for catalog numbers Connecting Your Ultra3000 3 9 Grounding Your Ultra3000 All equipment and components of a machine or process system should have a common earth ground point connected to their chassis A grounded system provides a safety ground path for short circuit protection Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short circuits transient overvoltages and accidental connection of energized conductors to the equipment chassis For CE grounding requirements refer to Meeting CE Requirements in Chapter 1 IMPORTANT To improve the bond between the Ultra3000 and subpanel construct your subpanel out of zinc plated paint free steel Grounding Your System to the Subpanel ATTENTION The National Electrical Code contains grounding requirements conventions and definitions Follow all applicable local codes and regulations to safely ground your system Refer to the illustration below for details on grounding your Ultra3000 Refer to Appendix B for the power wiring diagram for your Ultra3000 drive Figure 3 9 Chassis Ground Configuration Multiple Ultra3000 Systems on One Panel
178. lter Specifications in Appendix A Page B 4 Replace the interconnect diagram on page B 4 with the one shown below The new diagram changes the recommended wiring of input fusing ac line filter and contactor Figure B 2 Typical Power Wiring of Ultra3000 System 2098 DSD 030x xx Ultra3000 Digital Servo Drive 2098 DSD 030x xx Note 13 eA U Three phase External Passive Motor Power V Motor Power Shunt Connections Connections Connections Note 12 lt W H DC Input Fusing MI Note 4 5 Note 8 DC HET edes et L1 AC Line Filter H L2 N Note 7 AC Input Power CN1 Single phase AC Line Connections N O Relay Output 50 60 Hz lod eT 43 L1 AUX N O Relay Output Note 20 Y y Note 6 y LM _ L2 N AUX Fused Disconnect Input Fusing or Circuit Breaker Note 4 5 m Cable Shield able Shiel Bonded Cabinet amp Clamp Isolation Chassis Ground Bus O Note 9 Transformer ILL Note 2 vvY Oo u o CN1 Single phase Input 43 lt 100 240V ac rms T START STOP L2 N p CRI 24V de Terminal CRI Blocks VV 44 LS M1 Note 3 To additional CRI Ultra3000 drive Indicates User Supplied Component Refer to Attention statement Notes 10 11 Publication 2098 DU003B
179. making cable connections This chapter includes e Understanding Basic Wiring Requirements e Determining Your Type of Input Power e Grounding Your Ultra3000 e Power Wiring Requirements e Connecting Input Power e Connecting Motor Power and Brakes e Understanding Shunt Connections e Understanding Feedback and I O Cable Connections e Connecting Your SERCOS Fiber Optic Cables e Connecting to a DeviceNet Network This section contains basic wiring information for the Ultra3000 ATTENTION Plan the installation of your system so that you can perform all cutting drilling tapping and welding with the system removed from the enclosure Because the system is of the open type construction be careful to keep any metal debris from falling into it Metal debris or other foreign matter can become lodged in the circuitry which can result in damage to components IMPORTANT This section contains common PWM servo system wiring configurations size and practices that can be used in a majority of applications National Electrical Code local electrical codes special operating temperatures duty cycles or system configurations take precedence over the values and methods provided Publication 2098 INOO3E EN P April 2004 3 2 Connecting Your Ultra3000 Publication 2098 INOO3E EN P April 2004 Building Your Own Cables TTTIAETUEBR Factory made cables are designed to minimize EMI and are recommended over hand
180. n Call your Allen Bradley representative p pply y y rep Power PWR indicator is ON but seven T segment Status LED display is OFF Externally applied 5V auxiliary power M ue A NU KE Note This applies to 2098 DSD 005 010 supply voltage is too low A DEUS UR 5 10V and 5 25V and 020 Ultra3000 models only Ur Motor wiring error Check motor wiring Motor jumps when first enabled Incorrect motor chosen Verify the proper motor is selected Digital 1 0 not working correctl 1 0 power supply disconnected Verify connections and I O power source g g y p pply y p Range of motion and number of home i position definitions during the product life This is an unrecoverable fault the drive E01 Non Volatile Memory Endurance Exceeded exceeds the maximum allowed applies must be sent back to the factory only to systems with absolute feedback A ra y aan e exceeds Increase machine cycle size or reduce E02 Velocity Exceeds Position Rollover 2 illisecon R only RES velocity profile This error only applies to machine cycle position rollover is enabled firmware versions prior to 1 10 Publication 2098 INOO3E EN P April 2004 4 4 Troubleshooting Status Indicators a Problem or Symptom Possible Cause s Action Solution The motor position exceeds 2047 e Decrease application range of motion E03 Absolute Feedback Range Exceeded revolutions from the home position applies s Up r dafi only
181. n 2098 INOO3E EN P April 2004 Ultraware user manual P 3 unpacking modules 1 5 V ventilation 1 7 W who should use this manual P 1 wiring building your own cables 3 2 cable shield clamp 3 18 connecting DeviceNet to a network 3 29 connecting fiber optic cables 3 26 connecting your DeviceNet cable 3 30 external shunt resistor 3 22 grounded power configuration 3 3 grounding 3 9 I O connections 3 23 input power 3 16 determining type 3 3 motor brake 3 21 motor power 3 11 3 12 3 19 3 20 motor power and brakes 3 18 power wiring requirements 3 13 3 14 requirements 3 1 routing power and signal wiring 3 2 terminal block connections 3 13 3 14 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local
182. n CN2 Interpolated Outputs are square wave A quad B signals reflecting the interpolation value chosen in software The minimum interpolation value allowed is x4 which gives the same output as selecting buffered as described above Divided Outputs are the result of a divisor selected in software and an interpolation value also selected in software For example with an interpolation value of x8 and a divisor of 2 the CN1 buffered output will be the x4 square wave representation of the original incoming SIN COS signal from CN2 IMPORTANT The interpolation value selected in software is what the drive uses internally to close the feedback loops regardless of any divisor value chosen to condition the signals present on CN1 Figure 2 52 Ultra3000 Connector Data 2 49 Interpolated and Divided Absolute High Resolution Encoder Counts One Cycle Voltage 4 VAX 4 Voltage 12 N DA Voltage 29 Time CN1 10 SIN AM Unbuffered encoder feedback signal to drive 1024 cycles rev CN1 12 COS BM Unbuffered encoder feedback signal to drive 1024 cycles rev CN1 16 SIN AMOUT x8 Interpolated output from drive CN1 18 COS BMOUT x8 Interpolated output from drive Divided output from drive divisor 2 Understanding Auxiliary The Ultra3000 can accept an auxiliary encoder signal of the following Encoder Feedback types Specifications Figure 2 53
183. nals CN1 pins 10 15 Contact your Allen Bradley sales representative if these signals are required for your application Publication 2098 IN003E EN P April 2004 Interconnect Diagrams B 23 Ultra3000 to IMC S Compact Cable and Interconnect Diagram This section provides information to assist you in wiring the IMC S 23x xx Compact Controller when connecting the 4100 CCS15F feedback cable and 4100 CCAI5F I O cable to your Ultra3000 Figure B 24 Ultra3000 to IMC S 23x xx Compact Controller Configuration Ultra3000 44 pin Breakout Board IMC S Class Compact Controller Ns SERCOS interface IMC S 23x xx 4100 CCS15F Feedback Cable CN1 Connector WHITE 16 Ae A BLACK 7 M d X GREEN 18 B H BLACK 19 B SH XX BLUE 20 Z Axis Servo and Feedback Connector SH BLACK XX noz located on bottom of controller 3 ENCPWR 3 ENC 5V g_enccom_ SII BLACK 2__ENCCOM 8 SHED L 2 STROBE S af 1 REFS s gt 25 CMD 7 RE ss XX 26 CMD 4100 CCA15F 1 0 Cable 4 24 s i 30 24V 1 0 PWR 1 HOME WHITE od 29 424V 1 0 PWR 2 POT GREEN 3 NGOT S BROWN V Axis I O Connector amp ou coy BLACK 28 24VI 0 COM located on top of controller 5 DRIVE en K BLUE gt 27 24V 1 0 COM 6 DRVEEN y ORANGE 31 DIGITAL INPUT 1 g DRIVE FLT PURPLE 2 DRME
184. ne Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR 5V 7 Encoder Power 49V EPWR 9V 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 2 6 Ultra3000 Connector Data Use the figure below to locate the front panel connections on the Ultra3000 230V 7 5 and 15 kW Figure 2 3 Ultra3000 Front Panel Connections for 2098 DSD 075 075X 150 and 150X ee O 9 pin CN3 d Serial Connector Seven Segment 2 8 P a Status LED Passive Shunt gll Et Resistor Connections i 2 f Logic Power LED 15 pin CN2 Feedback Connector i CN3 9 pin gt Pin 10 E i lt Serial Port 3 Pin 5 Elfe Connector Motor Power ene a Pin 1 Connections gt CN2 15 pin lle lt Motor Feedback sn El o Connector E 44 pin CN1 Eje CN1 44 pin 1 0 Connector Eje lt User l O AC Input Power o Ee C Connections gt aga onngetor amp 3 ax E ar Motor Power Cable Shield Clamp al N Serial Port Connector The following table provides the signal descriptions and
185. nfiguring and troubleshooting your Ultra3000 Read This Document Ultra3000 Digital Servo Drives Integration Manual Catalog Number 2098 INO05x EN P Ultraware Installation Instructions Ultraware CD Installation Instructions 2098 IN002x EN P nformation on configuring your Ultra3000 using Ultraware Ultraware User Manual 2098 UM001 x EN P nformation on communicating with the Ultra3000 using DeviceNet Ultra3000 DeviceNet Reference Manual 2098 RMO001 x EN P nformation on attaching Ultra3000 drives to a DeviceNet network DeviceNet Cable System Planning and Installation Manual DN 6 7 2 A description and specifications for the Ultra Family including motors and motor accessories Motion Control Selection Guide GMC SG001 x EN P Application sizing and configuration information Motion Book Servo Sizing CD v4 0 service pack 4 or above Motion Book mmmyy More detailed information on the use of ControlLogix motion features and application examples ControlLogix Motion Module Programming Manual 796 RM086x EN P ControlLogix SERCOS interface module installation instructions 3 8 or 16 Axis SERCOS interface Module Installation Instructions 756 IN572x EN P ControlLogix Analog Encoder Servo module installation instructions Analog Encoder AE Servo Module Installation Instructions 756 IN047 x EN P SoftLogix SERCOS interface PCI card installation inst
186. ng table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector CNiPin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 5V EPWR 23 Programmable Analog Output AOUT 7 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Command COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common I0COM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUTS 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUT4 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUT5 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS 20 Buffered Motor
187. nsions Motor Feedback Specifications Specification Description Encoder Types Incremental Sine Cosine Intelligent and Absolute 100 kHz Sine Cosine Input Maximum Input Frequency 2 5 MHz TTL Input per channel Commutation Startup Hall Sensor or None Auxiliary Feedback Specifications Specification Description Input Modes A quad B Step Direction CW CCW Maximum Signal Frequency 2 5 MHz Input Types Incremental only differential single ended open collector 1 1 Differential input types are recommended Connector Specifications The table below lists connector specifications Refer to Appendix C for a list of drive connectors available from other suppliers Connector Description Specification CNI User Input Output ARTON Density Female D Sub CN2 Motor Feedback Connector ae Density Female D Sub CN3 Serial Port Connector 9 pin Female D Sub Connector Tero Yanana Anaon Dr som Tema Ba Publication 2098 INOO3E EN P April 2004 AC Line Filter AC Line Filter Specifications Specifications and Dimensions A 11 The following AC line filters are compatible with the Ultra3000 drives Specifications Catalog Number Voltage Phase Current Puig ru Humidity Vibration Toners 2090 UXLF 106 US d C asw nd 2090 UXLF 110 UT UE 27W Us 280Vac 23A Q 50 C 2090 UXLF 123 caeor Single xen 10W 3 5
188. ommon External 5V dc power supply connections should be made to CN1 2 and CNI1 3 TTTTTUeP Using the drive mounted breakout board with 24V to 5V auxiliary power converter is preferred to using an external 5V dc power supply The following table provides a description of the requirements for an external 5V dc power supply used to power the logic Voltage Voltage tolerance of the external logic supply 5 1V 5 25V Current output capability of the external 5V dc power 15A Current supply Digital Inputs There are eight opto isolated digital inputs All digital inputs SERCOS and non SERCOS have the same configuration as shown in the figure below Figure 2 13 Digital Input Circuit Ultra3000 Drive INPUTS TLP121 10C0M 10C0M DGND L Ultra3000 Connector Data 2 29 The following table provides a description of the digital input specifications Parameter Description Minimum Maximum ON State Voltage Mua ERES UN SUR SERE af 26 4V ON State Current Current flow to guarantee an ON State 3 0 mA 12 0 mA OFF Sao Wo Hage gool ithe rug wth respects im 2o Propagation Delay nour tthe mwae accessble rageters 100ps On SERCOS drives the following inputs have dedicated functionality Pin Signal Description Drive Enable Input an active state enables the power electronics to control CN1 31 ENABLE ihe motor Home Sensor an active state indicate
189. onnector Data Encoder Phasing For proper motor commutation and control it is important that the motor feedback signals are phased properly The drive has been designed so that a positive current applied to a motor will produce a positive velocity and increasing position readings as interpreted by the drive Additionally if Hall signals are used to initialize the commutation angle the Hall signals must sequence properly and the phase relationship to the motor back EMF signals must be understood Figure 2 43 shows the proper sequencing of the Hall signals when positive current is applied to the motor If the Hall signals are out of phase with the back EMF signals the drive can be configured through software to compensate for the phase offset as long as the sequencing of the Hall signals is correct Figure 2 44 shows an example where the Hall signals have an offset of 60 degrees Figure 2 43 Sequencing and Phasing of the Hall Signals Figure 2 44 Sequencing and Phasing of the Hall Signals 60 Hall Offset Example Publication 2098 INOO3E EN P April 2004 Encoder Ultra3000 Connector Data 2 45 Figure 2 45 shows the proper phasing of TTL A B encoder signals when positive current is applied Figure 2 45 Phasing of TTL A B Encoder Signals adJ LI LI LTL bel LIT LNI Lr L Figure 2 46 shows the proper phasing of Sine Cosine encoder signals when positive current is applied Notice that the Sine Cosine encoder signal p
190. ons 2 53 Restoring Drive Communications 2 54 Chapter 3 Chapter Objectives s cw ivi ews aad wa o cage aw Oh a 3 1 Understanding Basic Wiring Requirements 3 1 Building Your Own Cables ced sm 3 ty tr dor ERE 3 2 Routing Power and Signal Wiring 3 2 Determining Your Type of Input Power 3 3 Three Phase Power Wired to Three Phase Drives 3 3 Single Phase Power Wired to Single Phase Drives 3 5 Three Phase Power Wired to Single Phase Drives 3 6 Grounding Your LIItasUD us coda osos asfaeu o po ORC 3 9 Grounding Your System to the Subpanel 3 9 Grounding Multiple Subpanels sss s 3 10 Motor Power Cable Shield Termination 3 10 Power Wiring Requirements llle 3 13 Connecting Input POWer 4429 nexa44 een eee we ERU 3 16 Connecting Motor Power and Brakes 3 18 Applying the Motor Cable Shield Clamp 3 18 Wiring Motor Power llle 3 19 Understanding Motor Brake Connections 3 21 Understanding Shunt Connections 3 22 Understanding Feedback and I O Cable Connections 3 23 Motor Feedback Connector Pin outs 3 24 Connecting Your SERCOS Fiber Optic Cables 3 26 Connecting to a DeviceNet Network 3 29 Connecting Your DeviceNet Cable os i scene ae s 3 30 Troubleshooting Status Indicators Specifications and Dimensions Interconnec
191. ons and has the CE mark the following regulations apply Note Declarations of Conformity DOCs to European Union Directives are available on line at www ab com certification ce docs The web site is the authoritative source for verifying compliance and suitability for use of this and other Rockwell Automation Allen Bradley products EMC Directive This unit is tested to meet Council Directive 89 336 EEC Electromagnetic Compatibility EMC using a technical construction file and the following standards in whole or in part N 50081 2 EMC Emission Standard Part 2 Industrial nvironment N 50082 2 EMC Immunity Standard Part 2 Industrial nvironment e t mtr nmt N 61800 3 Adjustable Speed Electrical Power Drive Systems Part 3 EMC Product Standard including specific test methods The product described in this manual is intended for use in an industrial environment Meeting CE Requirements To meet CE requirements the following components are required e Install an AC line filter 2090 UXLF xxx or HVxxx between the AC power source and the drive input and as close to the drive as possible refer to Appendix C for available AC line filters The supply must be grounded for the filter to operate properly e Connect auxiliary input power Cif required from the load side of the AC line filter to the drive e Use 2090 series motor power and feedback cables and terminate the motor power cable shields to the chass
192. ontactor cycles per minute Power initialization requires a short period of inrush current processor controlled via soft start circuitry Dual element time delay slow blow fuses are recommended refer to Fuse Specifications on page 6 8 The inrush current limiting circuitry is limited in the number of power cycles it can withstand within a set period of time If you exceed these limitations the circuitry will be damaged Publication 2098 DU003B EN P September 2006 6 Ultra3000 Digital Servo Drive Installation Manual Page B 2 Replace notes 6 and 7 in the Ultra3000 Interconnect Diagram Notes with the ones shown below The new versions include information regarding the placement of ac line filters and routing of wires Note Information May be used to maintain power to logic section of drive and status LED indicators when main ac input power is removed A separate ac line 6 source may be used if voltage is between 88 265V ac rms on 2098 DSD xxx 230V drives or 207 528V ac rms on 2098 DSD HV xxx 460V drives In this configuration a separate line filter for logic power may be required Place the ac EMC line filter as close to the drive as possible and do not route very dirty wires in wireway refer to Establishing Noise Zones on 7 page 1 13 If routing in wireway is unavoidable use shielded cable with shields grounded to the drive chassis and filter case For ac line filter specifications refer to AC Line Fi
193. ood Grade Motor Configuration MPF A 230V SERVO MOTORS WITH HIGH RESOLUTION FEEDBACK Motor Feedback Ultra3000 Drive Green Yellow D CN2 Connector Notes 13 14 Blue C W lt lt W L GND posu ees Black BA FAW 20 x RS ee ee DA lt lt Three Phase 1 T A Br a sins V 1 Brown A U Motor P s gt BLACK Motor Feedback lt Dror Tower 2 WHT BLACK XY SIN 2 15 pin Connector 2090 XXNPMF xxSxx gt gt CN2 Motor Power Cable 3 S RED COS ME 3 Note 12 as WHT RED XX COS 4 Motor Feedback 3 s gt GREEN DATA 5 WHT GREEN 6 lt XX DATA 10 3 Note 1 oe G 9 5 gt GRAY 5VDC 14 4 jac E H M F lt Motor 10 2 wem XX ECOM Control Interface 44 J BR 3 Brake 11 ORANGE 9VDC 7 44 pin Connector White V KE 5 13 4 WHT ORANGE XX TS 11 SM Thermostat ETSI 14 5 ye COM 24V Power e Cable Shield i FBI Clamp Dest Supplied ee m Note 9 1A max Publication 2098 IN003E EN P April 2004 24V dc Power Supply 2090 XXNFMF Sxx Feedback Cable Notes 12 16 18 MPF B 460V Motor Feedback SERVO MOTORS WITH CN2 Connector HIGH RESOLUTION FEEDBACK gc EE Er CH o eS Te yy EA I 1 us Mur AM
194. or Power Motor Connections Motor Power Cable Shield Clamp Publication 2098 INOO3E EN P April 2004 JAAA iliis Serial Port Connector Logic Power LED CN3 9 pin Serial Port Connector CN2 15 pin Motor Feedback Connector CN1 44 pin User 1 0 Connector 9 pin CN3 Serial Connector 15 pin CN2 Feedback Connector Pin 10 Pin 5 Pin 1 Pin 15 Pin 11 Pin 6 44 pin CN1 1 0 Connector Pin 30 er Pin 15 Pin 31 Pin 16 Pin 1 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved 1 0 Connector Ultra3000 Connector Data The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector CN1 Pin
195. our cabinet and locating your Ultra3000 drive s inside the cabinet Figure 1 4 Minimum Clearance Requirements 50 8 mm 2 0 in clearance for airflow and installation Do not mount drive on its side oe 5 D 0 GB 0 Co e eee J Allow 12 7 mm 0 5 in side clearance Minimum cabinet depth 243 8 mm 9 6 in LJ U Minimum front clearance 76 2 mm 3 0 in TA i o GERE o 0 8 o Motor cable entry area for ground clamp 50 8 mm 2 0 in clearance for airflow and installation IMPORTANT If the cabinet is ventilated use filtered or conditioned air to prevent the accumulation of dust and dirt on electronic components The air should be free of oil corrosives or electrically conductive contaminates Refer to Appendix A for Ultra3000 power dissipation specifications Publication 2098 INOO3E EN P April 2004 1 8 Installing Your Ultra3000 Publication 2098 INOO3E EN P April 2004 Sizing an Enclosure As an additional aid in sizing an enclosure with no active method of heat dissipation either of the following approximate equations can be used Metric _ 0389 L8T 1 1 Standard English Where T is temper
196. ower Specifications e Ultra3000 General Specifications e Dimensions The Ultra3000 is certified for the following when the product or package is marked e UL listed to U S and Canadian safety standards UL 508 C File E145959 e CE marked for all applicable directives Note Refer to www ab com certification ce docs for more information Publication 2098 INOO3E EN P April 2004 A 2 Specifications and Dimensions Ultra3000 Power Specifications The following sections provide power specifications for the Ultra3000 Ultra3000 230V Power Specifications The table below lists general power specifications and requirements for the Ultra3000 230V drives 2098 DSD 005x xx 010x xx and 0202 xx Description Specification 2098 DSD 005 2098 DSD 010 2098 DSD 020 AC Input Voltage 1 100 240V ims Single Phase AC Input Frequency 47 63 Hz AC Input Current 2 9 Nominal Arms 9A ms 18A qs Maximum inrush 230V ac input 100A 0 peak 100A 0 peak 100A 0 peak Continuous Output Current 2 5A 0 peak 5A 0 peak 10A 0 peak Intermittent Output Current 7 5A 0 peak 15A 0 peak 30A 0 peak Bus Capacitance 1410 uF 1880 pF 1880 pF Internal Shunt Resistance N A N A N A Shunt On N A N A N A Shunt Off N A N A N A Bus Overvoltage 400V dc 400V dc 400V dc Energy Absorption Capability 115V ac input 93 Joules 125 Joules 230V ac input 38 Joules 51 Joules Continuous Power Output 115V ac in
197. p millisecond applies only when the velocity profile machine cycle position rollover is enabled e Decrease application range of motion The motor position exceeds 2047 E03 Absolute feedback range exceeded revolutions from the home position applies e Upgrade firmware only to systems with absolute feedback This error only applies to firmware revisions prior to 1 10 Detection occurs during a fault reset e Cycle power Lost motion fault D VO MEER Absolute position in the drive is incorrect d ive if dri E44 only applies to applications with e Cycle power and re home drive if drive a Diesen devices and the motion has been lost due to line was homed in the same power cycle loss condition that the lost motion fault occurred Publication 2098 DU003B EN P September 2006 Ultra3000 Digital Servo Drive Installation Manual 3 Page A 2 Replace the Ultra3000 230V Power Specifications table on page A 2 with the one shown below The new table includes inrush current specifications configured as Series A B or C e Ultra3000 drive firmware revision 1 45 is required to support the Series C hardware e Ultraware software version 1 63 is required to download firmware to Series C drives containing the new power board Ultra3000 Drive 230V Power Specifications 2098 DSD 005x xx 2098 DSD 010x xx and 2098 DSD 020x xx Description Specification 2098 DSD 005 2098 DSD 010 2098 DSD 020
198. pecification Commutation Description 3 Phase Sinusoidal Space Vector Modulated SVM Current Regulator Digital Pl 125 us update rate Velocity Regulator Digital PID 250 us update rate Position Regulator Digital PID with feed forward 1 ms update rate PWM 4 or 8 kHz space vector modulation Velocity Loop Bandwidth maximum 300 Hz Specifications and Dimensions A 9 Inputs and Outputs Specifications Specification Description Digital Inputs 8 Optically Isolated 12 24V Inputs Active High Current Sinking Digital Outputs 4 Optically Isolated 12 24V Outputs Active High Current Sourcing Normally Open Relay 30V dc Maximum Voltage Relay Output A Maximum Current 0 Response 100 psec Digital 1 0 Firmware Scan Period 1 mS Analog Inputs COMMAND 4 bit A D 10V ILIMIT 0 bit A D 0 to 10V Analog Output 10V 8 bits 2 mA maximum Communication Specifications Specification Description SERCOS option Baud Rates 4 and 8 Mbit Node Addresses 01 99 DeviceNet option Power Consumption from Network 60 mA Data Rates 125 250 and 500 kps and auto baud Node Addresses 00 63 Messaging Capabilities Explicit Polled I O Change of State and Cyclic Messaging Serial Ports One RS 232 RS 422 RS 485 Baud Rates 1200 2400 4800 9600 19200 and 38400 baud Publication 2098 INOO3E EN P April 2004 A 10 Specifications and Dime
199. protected by 240V maximum high interrupting capacity current limiting fuses meeting UL 198C Class CC G J L R T Suitable for use on a circuit capable of delivering Suitable for use on a circuit capable of delivering not more than 200 000 rms symmetrical not more than 5000 rms symmetrical amperes amperes 480V maximum when protected by 480V maximum high interrupting capacity current limiting fuses meeting UL 198C Class CC G J L R T Wiring to the auxiliary power terminals L1 AUX and L2 N AUX of the drive should be 2 5 mm 14 AWG minimum and fusing for the auxiliary power should be selected to properly protect the wire For example if 60 C 140 F wire is used the fuse should not exceed 8A If 75 C 167 P wire is used the fuse should not exceed 13A Refer to Fuse Specifications in Appendix A for fuse examples Bonding is the practice of connecting metal chassis assemblies frames shields and enclosures to reduce the effects of electromagnetic interference EMD For more information on the concept of high frequency HF bonding the ground plane principle and electrical noise reduction refer to the System Design for Control of Electrical Noise Reference Manual publication GMC RMOO01x EN P Installing Your Ultra3000 1 11 Bonding Modules Unless specified most paints are not conductive and they act as insulators To achieve a good bond between modules and the subpanel
200. put 0 25 kW 0 5 kW 1 0 kW 230V ac input 0 5 kW 1 0 kW 2 0 kW 1 Specification is for nominal voltage The absolute limits are 10 or 88 265V ms The 2098 005x xx 010x xx and 020x xx 230V drives are limited to one contactor cycles per two minutes 3 Power initialization requires a short period of inrush current Dual element time delay slow blow fuses are recommended refer to Fuse Specifications on page A 5 IMPORTANT Publication 2098 INOO3E EN P April 2004 Only the 2098 DSD 005 010 and 020 models support an auxiliary 5V logic supply since an auxiliary AC input is not available Refer to Auxiliary 5V Logic Supply on page 2 26 for more information Specifications and Dimensions A 3 The table below lists general power specifications and requirements for the Ultra3000 230V drives 2098 DSD 030x xx 075x xx and 150x xx Specification Description 2098 DSD 030 2098 DSD 075 2098 DSD 150 100 240V 100 240V HH 1 rms rms AC Input and Auxiliary Input Voltage Single Phase Three Phase AC Input Frequency 47 63 Hz Main AC Input Current 4 Nominal 28A cms SOA ims 46 Arms Maximum inrush 230V ac input 50A 0 peak 50A 0 peak 68A 0 peak Auxiliary AC Input Current Nominal 115V ac input 10A rms 1 0Arms 1 0Arms Nominal 230V ac input 3 0 5A ms 0 5A ms 0 5A ms Maximum inrush 115V ac input 47A 0 peak 47A 0 peak 47A 0 pea
201. put and logic ground 7 12 Frequency of the AX or BX signal inputs Count frequency is 4 times this frequency for Signal Frequency A B type inputs and equal to this frequency 2 5 MHz for Step Dir and CW CCW type inputs Time interval that a Step Dir type input or Pulse Width CW CCW type input must remain in a single 200 nS state for detection Time interval that the Direction CW or CCW Setup Time must be stable before the corresponding 200 nS E Step CCW or CW signal changes state Understanding the Serial Interface Ultra3000 Connector Data 2 51 5V Auxiliary Encoder Power Supply All Ultra3000 drives supply 5V dc for the operation of an auxiliary encoder The following table provides a description of the auxiliary encoder power supply eii Voltage range of the external power supply for Parameter Maximum Output Voltage proper operation of an auxiliary encoder 5 25V Current draw from the external power supply for Output Current the auxiliary encoder 250 mA Pin Signal Description CN1 1 EPWR Auxiliary Encoder Power Out 5V CN1 2 ECOM Common IMPORTANT The internal 5V dc power supply has a resettable fuse that opens at 3 amps and automatically resets itself when the current falls below 3 amps There are no internal fuses requiring replacement The Ultra3000 includes one serial port that implements the standard NRZ asynchronous serial format and supports
202. quires use of drive mounted breakout board 2090 U3BB2 DM44 Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2Pin Description Sigal CN2Pin Description Signal 1 ChannelAsSineDifferenialInput AMe g PostiveOvetravellimt 4IMT 2 Channel A Sine Differential Input AM 10 Channel I Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 2 Commutation Channel S1 S1 5 Channel l Index Pulse IM 13 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR_5V 7 Encoder Power 9V EPWR_9SV 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 3 Publication 2098 INOO3E EN P April 2004 2 16 Ultra3000 Connector Data Use the figure below to locate the front panel connections on the Ultra3000 with SERCOS interface 460V drives 3 kW 5 kW 10 kW 15 kW and 22 kW Figure 2 8 Ultra3000 Front Panel Connections for 2098 DSD HVxxx SE O L Passive Shunt Resistor Connections 1 gt Motor Power Connections AC Input Power gt Connections Motor Power Cable Shield Clamp 3 e Ultrasoco Allen Bradley suus Extemal Shunt exists after power down
203. r 748366 1 748364 1 205204 4 eine 748333 4 748333 4 5 66506 7 2 Unshielded Backshell Kit 748678 3 748678 1 748678 1 Shielded Backshell Kit 745173 3 745171 5 745171 5 Ferrules 745508 1 745508 6 745508 6 Accepts 22 28 AWG wire 2 Accepts 20 24 AWG wire 3 Ferrules are only required for use with shielded backshell kits Catalog Numbers and Accessories C 7 Motor End Connector Kits Use the following table to identify the motor end connector kit for your motor power feedback and brake cable Motor Series a Connector Description 9101 0326 Straight Power Connector Kit F 4000 9101 0399 Right Angle Power Connector Kit 9101 0327 Straight Power Connector Kit F 6000 9101 0400 Right Angle Power Connector Kit 9101 0329 Straight Feedback Connector Kit 9101 0330 Straight Brake Connector Kit F Series 9101 0402 Right Angle Feedback Connector Kit 9101 0403 Right Angle Brake Connector Kit 50d 9101 0325 Straight Power Connector Ki 9101 0398 Right Angle Power Connector Kit T 9101 0325 Straight Power Connector Ki 9101 0398 Right Angle Power Connector Kit acta 9101 0326 Straight Power Connector Ki 9101 0399 Right Angle Power Connector Kit bee 9101 0327 Straight Power Connector Ki 9101 0400 Right Angle Power Connector Kit 9101 0328 Straight Power Connector Ki H 8000 9101 0401 Right Angle Power
204. r Feedback E GREEN IM 5 9101 0330 Brake Gable Connector Kit LESS Twi inv XX IM 43 Black R S WHT BROWN W TS 1 P BROWN S3 8 J Control Interface 44 Note 19 Motor Brake gt V 44 pin Connector White LI Tet GRAY 5VDC 14 W ONT COM 424V audi M User Supplied gt gt WHT GRAY ECOM 6 24V dc Power Supply gt gt Cable Shield 1A max BLUE 82 13 SuSE f WHT BLUE el e Clamp 5 gt h a S1 12 Note 9 O gt gt Thermostat Y AY 5 WHT VIOLET TS 6 I I i 2090 XXNFHF Sxx flying lead or 2090 UXNFBHF Sxx with drive end connector Feedback Cable Notes 12 15 16 Publication 2098 INOO3E EN P April 2004 B 14 Interconnect Diagrams In the figure below the Ultra3000 230V is shown connected to N Series 230V servo motors Figure B 14 Ultra3000 to N Series 230V Motor Configuration 2090 XXNPN 16S xx I I gaia 2090 XXNFN Sxx flying lead or 2090 UXNFBN Sxx with drive end connector Feedback Cable Notes 12 15 16 e aes N Series 230V ote SERVO MOTORS WITH INCREMENTAL FEEDBACK Ultra3000 230V Drive E lt we Motor Feedback Note 13 Green Yellow D CN2 Connector Blue CY W i GND MM XX NE Black B V Three Phase PN ee R LER Lm Brown JA gt y
205. ra eae 32 Amp 2090 UXLF 132 36 Amp 2090 UXLF 136 50 Amp 2090 UXLF 150 36 Amp 2090 UXLF 336 AC Line Filter three phase 240V 50 Amp 2090 UXLF 350 70 Amp 2090 UXLF 370 23 Amp 2090 UXLF HV323 AC Line Filter three phase 480V 30 Amp 2090 UXLF HV330 50 Amp 2090 UXLF HV350 Use the following table to identify the external shunt kit for your application Peale a Description Ultra3000 Drive Compatibility 2090 UCSR A300 Active Shunt Module 300W 2098 DSD 005 010 020 9101 1183 Passive Shun OW 2098 DSD 030 2090 UCSR P900 2098 DSD 075 150 2090 SR120 09 Passive Shun OW 2098 DSD HV030 and HV050 2090 SR040 09 2098 DSD HV100 2090 SR040 18 Passive Shun 00W M3575R H27B0 C Passive Shun OW 2098 DSD HV150 M3575R H27BF C Passive Shun 00W M3575R H33BF C Passive Shun 00W 2098 DSD HV220 Bonitron part number For more information contact Bon Tel 615 244 2825 www BONITRON com itron Inc 521 Fairground Court Nashville TN 37211 Publication 2098 INOO3E EN P April 2004 C 4 Catalog Numbers and Accessories Cables Description Use the following tables to identify motor power feedback interface and brake cables for your Ultra3000 drive Length of cable xx is in meters Refer to your Allen Bradley representative for available cable lengths Motor Power Cables Catalog Number H Series 230V non
206. re trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 2098 DU003B EN P September 2006 PN 0013 2069 002 Supersedes Publication 2098 DU003A EN P June 2005 Copyright 2006 Rockwell Automation Inc All rights reserved Printed in the U S A Preface Installing Your Ultra3000 Ultra3000 Connector Data Table of Contents Introduction RTT P 1 Who Should Use this Manual 0 06 6 sea a0 ye FCR esc od P 1 Purpose of this Manual a5 use vert OE RC YOU eC aee aw P 1 Contents of this Manual 34405 ceste m REC RU E o P 2 Product Receiving and Storage Responsibility P 2 Related Documentation oss we acsx o oe woe Ved e WS Po es P 3 Conventions Used in this Manual P 4 Allen Bradley Support s 1 44 4 de ao eom aee eee ees P 4 Local Product Support 32402 2 6 x Be ae a P 4 Technical Product Assistance 4 uoa equ ek wa P 4 Comm
207. re version 1 29 or above Requires use of drive mounted breakout board 2090 U3BB2 DM44 Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2Pin Description Sigal CN2Pin Description Signal 1 ChannelAsSineDifferenialInput AMe g PostiveOvetravellimt 4IMT 2 Channel A Sine Differential Input AM 10 Channel I Index Pulse IM 3 Channel B Cosine Differential Input BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 2 Commutation Channel S1 S1 5 Channel l Index Pulse IM 13 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR_5V 7 Encoder Power 9V EPWR_9SV 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 3 Publication 2098 INOO3E EN P April 2004 Ultra3000 Connector Data Ultra3000 with DeviceNet Front Panel Connections Use the figure below to locate the front panel connections on the Ultra3000 with DeviceNet Interface 230V drives 500W 1 kW and 2 kW Figure 2 9 Ultra3000 Front Panel Connections for 2098 DSD 005 DN 005X DN 010 DN 010X DN 020 DN and 020X DN Seven Segment Status LED D e Module Status _ ____ _ Network Status Node Address 00 63 PGM DC Bus Connections for Active Shunt Resistor Kit gt A
208. remove the plastic cover Refer to Understanding Ultra3000 Connectors in Chapter 2 for the front panel connections of your Ultra3000 drive IMPORTANT The auxiliary AC power inputs require dual element time delay slow acting fuses to accommodate inrush current Refer to the section Ultra3000 230V Power Specifications in Appendix A for the inrush current on the auxiliary AC power input 4 Using a screw driver loosen the screw for each of the terminal locations and attach wires as shown in the table below If you have this drive Insert this wire from the power supply L1 Into this terminal on TBI L1 2098 DSD 005x xx L2 010x xx or 020x xx Ground L1 L1 L2 L2 N 2098 DSD 030x xx Ground L1 auxiliary AC L1 AUX L2 auxiliary AC L2 N AUX 2098 DSD 075x xx L1 L1 150x xx L2 L2 L3 L3 Or Ground 2098 DSD HVxxx xx HVxoxxX xx L1 auxiliary AC L1 AUX IMPORTANT L2 auxiliary AC L2 N AUX The DC bus connections should not be used for connecting multiple drives together Contact your Allen Bradley representative for further assistance if the application may require DC power connections 5 Tighten each terminal screw Refer to the table on page 3 13 for torque value 6 Gently pull on each wire to make sure it does not come out of its terminal Re insert and tight
209. rent rating of the service capacity provided or a maximum of 100 000A The wiring interconnection in Figure A 1 provide examples of the needed protection and follows UL and NEC codes Full compliance is dependent on final wiring design and installation Requ Ra ired Protection under 110 10 of EC 1999 Preferred Fully ed Breakers for Breakers Selected Device Protection Fully Rated Short Circuit Interrupt Capability Figure A 1 Circuit Protection under NEC 1999 110 10 preferred fully rated devices Required Protection Oo o o 1 I under 110 10 of l Fully Rated Fully Rated Fully Rated NEC 1999 id id Fused Fused Fused Preferred Fully Disconnect Disconnect Disconnect Rated Breakers e e e Fully Rated Fully Rated Fully Rated Distributi l Breaker Breaker Breaker S DAUN T Blocks e Ti 02 Breakers Selected for Device Protection Fully Rated Short Circuit p p Interrupt Capability Drive Drive Drive Publication 2098 IN003E EN P April 2004 The table below lists circuit breaker examples recommended for use with the Ultra3000 460V drives Catalog Number Voltage Circuit Breakers 2098 DSD HV030x xx 140M F8E C16 2098 DSD HV050x xx 140M F8E C20 2098 DSD HV100x xx 460V 140M F8E C32 2098 DSD HV150x xx 140M F8E C45 2098 DSD HV220x xx N A ATTENTION Bulletin 140M circuit Deseos shoul
210. resentative e Reduce acceleration rates e Reduce duty cycle ON OFF of E m commanded motion E36 Power Circuitry Overtemperature Excessive heat exists in the power circuitry Increase time permitted for motion e Use larger Ultra3000 and motor e Check tuning E37 AC Line Loss One or more phases of the input AC power Check input AC voltage on all phases is missing 38 RESERVED Call your local Allen Bradley representative Publication 2098 INOO3E EN P April 2004 4 8 Troubleshooting Status Indicators Eno Problem or S Possible C Action Soluti Code roblem or Symptom ossible Cause s ction Solution e Verify that there are no impediments to motion at startup such as hard limits em Motion required for self sensing startup e Increase self sensing current if high E33 Self sensing Commutation Startup Error commutation was obstructed friction or load conditions exist e Check motor or encoder wiring using wiring diagnostics ei BuU nur Ineffective shunt resistor e Verify that the shunt resistor internal or unt Protection Fault external is connected Excessive regeneration e f an external shunt resistor is Ineffective shunt resistor connected verify that the shunt fuse is not blown e fa non Allen Bradley external shunt resistor is used verify that the E41 460V Shunt Protection Fault f resistance value is within Excessive regeneration specifications e Verify that the motor is
211. rt Connector Seven Segment Status LED Logic Power LED CN3 9 pin Serial Port Connector CN2 15 pin Motor Feedback Connector CN1 44 pin User 1 0 Connector 9 pin CN3 Serial Connector Pin 44 Pin 31 Pin 16 CN3Pin Description Signal 1 RS 422 RS 485 Input RCV 2 RS 232 Input RCV 3 RS 232 Output XMT 4 RS 422 RS 485 Output XMT 5 Common COM 6 Reserved 7 RS 422 RS 485 Input RCV 8 RS 422 RS 485 Output XMT 9 Reserved 15 pin CN2 Feedback Connector Pin 10 Pin 5 Pin 1 44 pin CN1 1 0 Connector Pin 1 The following table provides the signal descriptions and pin outs for the CN3 serial port 9 pin connector Ultra3000 Connector Data 2 5 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector CN1 Pin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 45V EPWR 23 Programmable Analog Output AOUT 7 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Command COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary
212. ructions 16 Axis PCI SERCOS interface Card Installation Instructions 784 IN041x EN P SoftLogix Analog Encoder PCI card installation instructions PCI 2 Axis Servo Card Installation Instructions 1784 INO05x EN P The instructions needed to program a motion application Logix Controller Motion Instruction Set Reference Manual 1756 RMO007x EN P nformation on configuring and troubleshooting your ControlLogix motion module ControlLogix Motion Module Setup and Configuration Manual 1756 UM006x EN P nformation on configuring and troubleshooting your SoftLogix PCI card SoftLogix Motion Card Setup and Configuration Manual 784 UM003x EN P nformation on proper handling installing testing and troubleshooting fiber optic cables Fiber Optic Cable Installation and Handling Instructions 2090 INO10x EN P nformation examples and techniques designed to minimize system failures caused by electrical noise System Design for Control of Electrical Noise Reference Manual GMC RMO01 x EN P For declarations of conformity DoC currently available from Rockwell Automation Rockwell Automation Product Certification website www ab com certification ce docs An article on wire sizes and types for grounding electrical equipment National Electrical Code Published by the National Fire Protection Association of Boston MA A glossary of industrial automat
213. s 2098 DSD HV150x xx or 2098 DSD HV220x xx External Passive Shunt Resistor Connections Shunt Wiring Methods Twisted pair in conduit 1st choice Shielded twisted pair 2nd choice Twisted pair 2 twists per foot min 3rd choice Maximum Length 3 05 m 10 ft 115VAC Fan l lt l START STOP cate i L iare 120Vac 50 60 Hz CR1 M1 i CR1 l l Refer to Attention statement Notes 10 11 Bonded Cabinet O Ground Bus S 115V ac Fan Power INDICATES USER SUPPLIED COMPONENT Publication 2098 INOO3E EN P April 2004 B 10 Interconnect Diagrams Ultra3000 Motor Interconnect Diagrams This section contains the motor power brake and feedback signal interconnect diagrams between the Ultra3000 and MP Series 1326AB M2L S2L F H N and Y Series motors In the figure below the Ultra3000 460V is shown connected to MP Series or 1326AB M2L S2L servo motors Figure B 10 Ultra3000 to MP Series or 1326AB M2L S2L Motor Configuration 2090 XXNPMP xxSxx Motor Power Cable Note 12 Power TB1 Ultra3000 460V Drive Note 14 MPL B and MPG B 460V or 1326AB M2L S2L SERVO MOTORS WITH HIGH RESOLUTION FEEDBACK
214. s potential causes and appropriate actions to resolve the problems If problems persist after attempting to troubleshoot the system please contact your Allen Bradley representative for further assistance To determine if your Ultra3000 drive has an error refer to the table below 2098 DSD xxx DN xxxX DN HVxxx DN HVxxxX DN drive Actively cycling segments in a full circle Yo Then ur Ultra3000 drive is ready Yo ur Ultra3000 drive is ready 2098 DSD xxx SE or HVxxx SE drive Displaying a fixed 4 Yo ur Ultra3000 drive is ready All drives Flashing E followed by two numbers Yo ur Ultra3000 drive has an error Proceed to the section Error Codes below Flashing L Yo Error Codes ur Ultra3000 drive is in an Overtravel condition and motion restrictions are in effect The following list of problematic symptoms no error code shown and problems with assigned error codes is designed to help you resolve problems When a fault is detected the seven segment LED will display an E followed by the flashing of the two digit error code one digit at a time This is repeated until the problem is cleared cu Problem or Symptom Possible Cause s Action Solution qu Verify AC power or auxiliary 5V logic Power PWR indicator not ON No AC power or auxiliary logic power power is applied to the Ultra3000 Internal power supply malfunctio
215. s to a homing sequence that the CN1 32 HOME sensor has been seen CN1 33 REG1 ee cae y CN1 34 REG2 Registration Sensor a transition is used to record position values CN1 37 OT_POS Overtravel Input an inactive state indicates that a position limit has been CN1 38 OT_NEG exceeded An active state occurs when 24V is removed from the input IMPORTANT oS limit input devices must be normally closed On non SERCOS drives digital inputs can be configured for a variety of functions using Ultraware Refer to Ultraware Help for digital input functionality Assigned Preselect Inputs Active or inactive states select one of 64 presets shown in the following binary table Active state indicates current flow through the input optocoupler Inactive state indicates no current flow Binary Code Preset Selects Selected Preset or Index 5 4 3 2 1 0 0 0 0 0 0 Preset 0 or Index 0 is selected 0 0 0 0 O0 1 Preset 1 or Index 1 is selected 0 0 0 0 1 O Preset 2 or Index 2 is selected Select up to 64 locations via preselect inputs 5 through 0 using BCD format 0 0 0 0 1 1 Preset 3 or Index 3 is selected codes for preset selects 1 and 0 are shown 1 1 1 1 1 1 Preset64 or Index 64 is selected Publication 2098 INOO3E EN P April 2004 2 30 Ultra3000 Connector Data Input Interface Examples for Active High Inputs Figure 2 14 Drive Input Connected to Switch Relay Contact Ultra3000 Drive I
216. s to the right 3 This isa dirty 24V dc available for motor brakes and contactors The 24V enters the dirty wireway and exits to the left Publication 2098 INOO3E EN P April 2004 1 14 Installing Your Ultra3000 Observe the following guidelines when installing your 1756 MxxSE SERCOS interface module refer to Figure 1 8 for zone locations e The clean zone C is beneath the less noisy modules C O analog encoder registration etc grey wireway e The dirty zone D is above and below the power supply and noisy modules black wireway e The SERCOS fiber optic cables are immune to electrical noise Figure 1 8 Establishing Noise Zones ControlLogix Dirty Wireway Clean Wireway Route dirty wireways directly above the ControlLogix rack shielded by the chassis EMC Filter Spare Slot s D C EMC filter power supply Dirty 1 0 Clean 1 0 connections segregated 24V de 1 0 AC 1 0 Analog Encoder not in wireway Registration etc Cable Categories for the Ultra3000 The table below indicates the zoning requirements of cables connecting to the Ultra3000 Zone Method Wire Cable Connector Very Dirty m Ferrite Shielded DC DC X L1 L2 L3 shielded cable a X X L1 L2 L3 unshielded cable X U V W motor power X X Registration Wiring CN1 X X Other 24V Wiring CN1 X Motor Feedback CN2 X X Serial Communications CN3 X X Fiber Optic Rx and Tx
217. s with 24V to 5V auxiliary power converter 209 ce 44 pin drive mounted breakout board for Ultra3000 CN1 connector with 24V to 5V 3 U3CBB DM44 auxiliary power converter 209 e 2090 U3BB D44 44 pin high density D shell for Ultra3000 CN1 control interface connector UXBB DM15 4 15 pin drive mounted breakout board for Ultra3000 5000 CN2 interface connector UXBB D15 15 pin high density D shell for Ultra3000 5000 CN2 interface connector UXBB DM09 9 pin drive mounted breakout board for Ultra3000 5000 CN3 serial interface N 09 09 09 ce N oO T N e 1 1 For specifications refer to the C1 Control Interface Breakout Boards Installation Instructions publication 2090 IN007 x EN P This breakout board accepts 1 0 14 mm 16 26 AWG wire For applications that require a 44 pin drive mounted breakout board that accepts 4 0 5 mm 12 22 AWG wire contact your local Allen Bradley representative 3 Only for use with the Ultra3000 2098 DSD 005x xx 010x xx 020x xx drives Requires an external 24V dc power supply refer to Auxiliary 5V Logic Supply on page 2 26 For specifications refer to the CN1 Control Interface Breakout Boards with Integral 24V to 5V Auxiliary Power Converter Installation Instructions publication 2090 INO08x EN P 4 For specifications refer to the CN2 Motor Feedback Breakout Board Installation Instructions publication 2090 INO06x EN P
218. se this document in conjunction with the Ultra3000 Digital Servo Drive Installation Manual publication 2098 INOO3E EN P To obtain a copy contact your local Rockwell Automation sales office distributor or online at http literature rockwellautomation com Publication 2098 DU003B EN P September 2006 2 Ultra3000 Digital Servo Drive Installation Manual Replace Figure 2 57 on page 2 52 with the one shown below The new figure correctly identifies the drive connector as CN3 Page 2 52 Figure 2 57 RS 232 to RS 485 Connection Diagram Common RS 232 232 to 485 Interface Adapter COM Note Pin outs vary by manufacturer This example uses a B amp B 485 adapter 4 8 RCV RCV XMT XMT RCV RCV XMT XMT RCV RCV XMT XMT CN3 CN3 CN3 Drive n Update the Error Codes table beginning on page 4 3 with the following entries Page 4 3 e Replace the error code entry for E02 In the new entry the reference to firmware revisions prior to 1 10 is removed e Replace the error code entry for E03 In the new entry the reference to firmware revisions prior to 1 10 is added e Add the lost motion fault E44 Error Codes eror Problem or S Possible C Action Soluti Code roblem or Symptom ossible Cause ction Solution The velocity command or feedback exceeds E02 Velocity exceeds position rollover 2 half the machine cycle length per Increase machine cycle size or reduce y
219. t Diagrams Table of Contents iii Chapter 4 Chapter Objectives v cadi wesc on eee ee UR we ee RR 4 1 Safety Precautions oua qu wa wea Reo eque fame eg a 4 2 General Troubleshooting 2 0 0 00 00005 4 3 Biot Codes saw is ios apex uei aw EARS hoes 4 3 Troubleshooting tor SERCOS DIHYGeS us s RW X 4 9 SERCOS Module Status LED 1 54 en hoe ho os Ra 4 9 SERCOS Network Status LED 4 53 ud vade A 4 9 Troubleshooting for DeviceNet Drives saa zh 4 10 DeviceNet Module Status LED nananana Rn 4 10 DeviceNet Network Status LED 4 10 Appendix A Chapter Objectives ccs eka the cee See RE ta de RA RN A 1 CE ICIGNe ee ee ko Gea oe amp ea ee bas A 1 Ultra5000 Power Specifications isses ehh A 2 Ultra3000 230V Power Specifications A 2 Ultra3000 460V Power Specifications A 4 Fuse Specifications n a s He date wae Seda hones ee A 5 Circuit Breaker Specifications llli A 6 Contactor Ratings llle A 7 Power Dissipation Specifications A 7 Ultra4000 General Specifications ac saca acre res A 8 Physical and Environmental Specifications A 8 Control Specifications i 85 Coe eee we eed wes A 8 Inputs and Outputs Specifications A 9 Communication Specifications vede derer ee A 9 Motor Feedback Specifications 00005 A 10 Auxiliary Feedback Specifications cue ero e A 10 Connector Specifications 2 0 0 0 0
220. te 12 ass WHT RED XX COS a4 Motor Feedback 9 GREEN DATA 5 i 8 gt where XX DATA 10 9 5 GRAY 5VDC 14 43 Note Black G lt BR de 10 WHr GRN XX ECOM 6 Control Interface 44 F lt BR i Brake 11 5 ORANGE 9VDC _ 7 44 pin Connector 5 13 5 WHT ORANGE XX TS 11 CN1 Thermostat AY M oy BLUE TS COM COM Bem Shield User Supplied pe qu 4pB U Note h 24V dc Power Supply PR 77nn i 1 OA max Refer to illustration lower left l for proper grounding technique 2090 XXNFMF S xx flying lead Feedback Cable Notes 12 16 18 MPL A B15xx and A B2xx Motor Feedback Servo Motors with CN2 Connector Incremental Feedback er ie I Ws te way eel tah we ate ate cs pate eh ee ae 1 Lors f EE es cs es ce _ Grounding Technique for 1 s gt BLACK AM 1 Feedback Cable Shield 7 5 WHT BLACK XX AM 2 D i 3 RED BM 3 CW Sew l GND 4 4 WHT RED XX BM 4 B V x Three Phase 5 gt GREEN IM 5 y Motor Power 6 WH GREN XX M 10 Exposed shield secured A U Ge gt under clamp g S5 GRAY 5VDC 14 Motor Feedback 10 witveray XX ECOM 6 11 gt gt t ORANGE Motor Feedback Breakout Board Th ior 13 SS wat oRANGE XX TS _ 11 2090 UXBB DM15 ermostat 9 14 BLUE TS Q ae BR 15 ali WHT BLUE XX Si 12 3 Motor 16 E m Hu 5 YELLOW g2 13 Fis lt q 3 17 WHT YELLOW XX S3 8 12 22 COM gt gt Ki tee deed rm Refer to illustration lower left for proper grounding tec
221. th ae Amount that the phase relationship between 25 MHz Line the AM and BM inputs can deviate from the 22 5 422 5 Frequency nominal 90 ae Amount that the phase relationship between pte the AM and BM inputs can deviate from the 45 45 1 MHz Line nominal 90 Frequency The following table provides a description of the AM and BM inputs for Sine Cosine encoders Parameter Description Minimum Maximum Sine and Cos Input Signal Frequency of the Sine or Cos signal inputs 100 kHz Frequency Sine and Cos Peak to peak input voltages of the Sine and Cos Input Voltage inputs 0 5V p p 20V p p Publication 2098 INOO3E EN P April 2004 2 42 Ultra3000 Connector Data Hall Inputs The Ultra3000 can use Hall signals to initialize the commutation angle for sinusoidal commutation Hall signals must be single ended and can be either open collector type or TTL type Figure 2 38 shows the configuration of the Hall inputs If the motor does not have Hall signals the drive can be configured through software to ignore the signals Figure 2 38 Hall Input Configuration Ultra3000 Drive 5V 1 82 or S3 COMMON COMMON Thermostat Input The Ultra3000 can monitor a thermostat signal from a motor and will generate a fault if the motor overheats Figure 2 39 shows the configuration of the thermostat input Figure 2 40 on page 2 43 shows a typical connection to a motor with a normally closed
222. three phase power at a neutral point Match your secondary to one of the examples and be certain to include the grounded neutral connection IMPORTANT Grounded power WYE secondary is the preferred configuration Examples with delta secondaries though not preferred are also shown Three Phase Power Wired to Three Phase Drives The following examples illustrate grounded three phase power wired to three phase Ultra3000 drives when phase to phase voltage is within drive specifications Figure 3 1 Three Phase Power Configuration WYE Secondary Transformer WYE Secondary 4 TB1 EL ul L1 u AC Line Filter Ultra3000 i 2 L2 Three Phase AC Input TB1 Terminals i 13 ISE B i E Bonded Cabinet o Bonded Cabinet Ground Bus A Ground Bus Ground Grid or Ground Grid or Power Distribution Ground Power Distribution Ground Note Feeder and branch short circuit protection is not illustrated Publication 2098 INOO3E EN P April 2004 3 4 Connecting Your Ultra3000 Publication 2098 INOO3E EN P April 2004 Figure 3 2 Three Phase Power Configuration Preferred Delta Secondary Transformer Delta Secondary 060 Bonded Cabinet Ground Bus Ho o Ground Grid or D Power Distribution Ground Note Feeder and branch short circuit protection is not illus
223. tra3000 2098 DSD 075x xx and 150x xx power wiring with 24V dc control string non SERCOS drives only is shown in the figure below For the control string diagram with 120V ac input refer to Figure B 18 For SERCOS drives input line contactor is part of the PLC program and output control Figure B 3 Typical Power Wiring of Ultra3000 System 2098 DSD 075x xx and 150x xx Ultra3000 Digital Servo Drives 2098 DSD 075x xx and 150x xx Note 13 External Passive Three Phase Shunt Connections Motor Power lt Motor Power 2 refer to figures Connections Connections beginning on B 7 Note 12 lt 3 Three Phase AC Line 50 60 Hz Three Phase T I Fused Disconnect e Note AC Input Power ENI or Circuit Breaker Connections N O Relay Output Note 1 N O Relay Output Note 20 Input Fusing Isolation Note 4 5 Transformer Cable Shield O Note2 Clamp O Bonded Cabinet Note 9 O Ground Bus Po Oo CN1 l 1 Three Phase Input i START STOP CRI 100 240V ac RMS cRI 24V de 44 l Mi CR1 Terminal Blocks Refer to Attention statement Notes 10 11 Note 3 VV To additional INDICATES USER SUPPLIED COMPONENT Ultra3000 drive Note Refer to Figure 2 26 in the chapter Ultra3000 Connector Data for more informat
224. trated Figure 3 3 TB1 L1 L1 ou AC Line K i Filter 2 12 L2 _ 13 L3 L3 L3 Ultra3000 Three Phase AC Input TB1 Terminals Three Phase Power Configuration Tolerated Delta Secondary Transformer Delta Secondary ee OROUE TB1 L1 L1 L1 L AC Line Filter L2 L3 L3 L3 E EE i E 13 L Es Bonded Cabinet Ground Bus o Ground Grid or Power Distribution Ground Note Feeder and branch short circuit protection is not illustrated Ultra3000 Three Phase AC Input TB1 Terminals Connecting Your Ultra3000 3 5 Single Phase Power Wired to Single Phase Drives The following examples illustrate grounded single phase power wired to single phase Ultra3000 drives when phase to phase voltage is within drive specifications Figure 3 4 Single Phase Grounded Power Configurations Transformer Secondary E L1 TB1 i H Melina T ieu 230Vac Filter ingle Phase Output 12 u L2 N TB1 Terminals m E j L 90 Bonded cabinet ground bus Ground grid or Power distribution ground Transformer Secondary du TB1 OAC Line Li Ultra3000 Va Filter Single Phase Output WIN L2N L2
225. u will install the Ultra3000 must not exceed 55 C 131 F e You must install the Ultra3000 vertically on the panel refer to Figure 1 4 for mounting orientation e You must install the panel on a flat rigid vertical surface that won t be subjected to shock vibration moisture oil mist dust or corrosive vapors e You need to maintain minimum clearances refer to Figure 1 4 for proper airflow easy module access and proper cable bend radius e The Ultra3000 can operate at elevations to 1000 m 3280 ft without derating however the continuous current rating must be de rated by 3 for each additional 300 m 984 ft up to 3000 m 9842 ft Consult your local Allen Bradley representative prior to operating above 3000 m 9842 ft Plan the installation of your system so that you can E perform all cutting drilling tapping and welding with the system removed from the enclosure Because the system is of the open type construction be careful to keep any metal debris from falling into it Metal debris or other foreign matter can become lodged in the circuitry which can result in damage to components Refer to Appendix A for mounting dimensions power dissipation and environmental specifications for the Ultra3000 Ultra3000 mounted vertically on the panel Allow 12 7 mm 0 5 in side clearance Installing Your Ultra3000 1 7 Ventilation Requirements This section provides information to assist you in sizing y
226. uffered Motor Encoder Ch B BM 35 Digital Input 5 INPUT5 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor Encoder Ch B BMOUT 40 Digital Output 2 OUTPUT2 19 Buffered Motor Encoder Ch B BMOUT 41 Digital Output 3 OUTPUTS 20 Buffered Motor Encoder Ch l IMOUT 42 Digital Output 4 OUTPUT4 21 Buffered Motor Encoder Ch l IMOUT 43 Normally Open Relay Output RELAY 22 Common ACOM 44 Normally Open Relay Output RELAY Motor Encoder Connector The following table provides the signal descriptions and pin outs for the CN2 motor encoder 15 pin connector CN2 Pin Description Signal CN2Pin Description Signal 1 Channel A Sine Differential Inputs AM 9 Positive Overtravel Limit LIMIT 2 Channel A Sine Differential Input AM 0 Channel I Index Pulse IM 3 Channel B Cosine Differential Inpute BM 1 Thermostat TS 4 Channel B Cosine Differential Input BM 12 Commutation Channel S1 S1 5 Channel l Index Pulse IM 3 Commutation Channel S2 S2 6 Common ECOM 14 Encoder Power 5V EPWR 5V 7 Encoder Power 49V EPWR 9V 15 Negative Overtravel Limit LIMIT 8 Commutation Channel S3 S3 Publication 2098 INOO3E EN P April 2004 2 8 Ultra3000 Connector Data Use the figure below to locate the front panel
227. um cable lengths for Ultra3000 drives with MP Series dow inertia and integrated gear motors are given in the table below MPL A 230V Motors MPL B 460V Motors DN Mat sie 3 dea Mx e Absolute 2 Absolute 2 Absolute Absolute High Res imd mental High Res Ineremental High Res High Res m ft m ft m ft m ft 90 295 3 45 147 6 90 295 3 45 147 6 90 295 3 60 196 8 1 Refers to MPL A BxxxxS M single turn or multi turn low inertia motors with absolute high resolution feedback 2 Refers to MPL A BxxxxH low inertia motors with 2000 line incremental feedback 3 Refers to MPG A BxxxxS M single turn or multi turn integrated gear motors with absolute high resolution feedback The maximum cable lengths for Ultra3000 drives with MP Series food grade motors are given in the table below MPF A 230V Motors MPF B 460V Motors Drive Family Absolute Absolute High Resolution 1 High Resolution 1 m ft m ft Ultra3000 90 295 3 90 295 3 1 Refers to MPF A BxxxxS M single turn or multi turn food grade motors with absolute high resolution feedback The maximum cable lengths for Ultra3000 drives with 1326AB M2L S2L and F H N and Y Series motors are given in the table below 1326AB M2L S2L F H N or Y Series 460V Motors 230V Motors Drive Family Absolute High Resolution 1 m ft Ultra3000 90 295 3 30 98 4 Incremental 2 m ft 1 Refers to 1326A
228. utput XMT 9 Reserved Ultra3000 Connector Data 2 9 1 0 Connector The following table provides the signal descriptions and pin outs for the CN1 I O 44 pin connector CN1 Pin Description Signal CN1 Pin Description Signal 1 Auxiliary Encoder Power Out 45V EPWR 23 Programmable Analog Output AOUT 7 Common ECOM 24 Analog Current Limit Input ILIMIT 3 Reserved 25 Command COMMAND 4 Auxiliary A Step CW AX 26 Command COMMAND 5 Auxiliary A Step CW AX 27 1 0 Common I0COM 6 Auxiliary B Dir CCW BX 28 1 0 Common IOCOM 7 Auxiliary B Dir CCW BX 29 1 0 Power IOPWR 8 Auxiliary Encoder Ch l IX 30 1 0 Power IOPWR 9 Auxiliary Encoder Ch I IX 31 Digital Input 1 INPUT1 10 Unbuffered Motor Encoder Ch A AM 32 Digital Input 2 INPUT2 11 Unbuffered Motor Encoder Ch A AM 33 Digital Input 3 INPUTS 12 Unbuffered Motor Encoder Ch B BM 34 Digital Input 4 INPUT4 13 Unbuffered Motor Encoder Ch B BM 35 Digital Input 5 INPUT5 14 Unbuffered Motor Encoder Ch l IM 36 Digital Input 6 INPUT6 15 Unbuffered Motor Encoder Ch I IM 37 Digital Input 7 INPUT7 16 Buffered Motor Encoder Ch A AMOUT 38 Digital Input 8 INPUT8 17 Buffered Motor Encoder Ch A AMOUT 39 Digital Output 1 OUTPUT1 18 Buffered Motor En
229. ve in the ring and thread the connector on finger tight Connecting to a DeviceNet Network Connecting Your Ultra3000 3 29 4 Insert the other end of the cable from step 3 into the Receive SERCOS connector on the ControlLogix module SoftLogix PCI Card and thread the connector on finger tight 5 Complete the ring by connecting the Transmit and Receive connectors from one drive to the next until all are connected refer to the examples above Refer to Appendix C for SERCOS fiber optic cable and bulkhead adapter catalog numbers A DeviceNet network is an arrangement of electrical power and device distribution A DeviceNet network is planned and adjusted for optimal communications Before proceeding to add devices you need to record the following e Network data rate e Network cable system map topology to which you are connecting e Distances between cable system components e Device current draw and voltage drop for each device on the network e Limitation of the trunk and drop cables Refer to the table below for recommended trunk and drop lengths Data Rates 125 Kbps 250 Kbps 500 Kbps Thin Trunk Lengths 100 m 328 ft 100 m 328 ft 100 m 328 ft Maximum Drop Length 6 m 20 ft 6 m 20 ft 6 m 20 ft Cumulative Drop Budget 156 m 512 ft 78 m 256 ft 39 m 128 ft Refer to the DeviceNet Cable System Planning and Installation Manual publication DN 6 7 2 for specific guidance in calculating and

2098-IN003 - Rockwell Automation

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