Home

Spec Sheet - The Reynolds Company

Contents

1. Y s exX Buisn ejqejreAe 6 0 suonogjes xepur euiu df yy sduiy 10 A wdi shun yenueyy u pepi oJd 151 Sueunu shay pue 1 Buisn ejqejreAe 7 0 sasad o1 dn sBunjes 1ndino Bojeuy uo payeinge eq suonoejes ulpiwpueg d1 sjoyoeiq ui suonoejes 0010 s Aup AjiooJoA Jando uo 4 H1OXPuI seyeolpul Buipeus Auq juepuedep Bul Buix pul seseujueJed ui suono l S 10 a SHUN 10 adAy Dunes apoy 9111 Y eui spon lt Aejdsiq pequonoy ag JEU 5 1ejeurered SJojouieJe 10 Ayoojan JOSUAS uo ji Y Buin eui pue syed ajqissod ejeorpur sunog yo yoreg L Ndu eu ae E S aU N uo juepuedep su INHYdAHd youesg ud g ueg bayu Ou
2. 5 10 Installation Figure 5 3 MIF Single Phase AC Line Filter Mounting Diagram I d 1 mo gt B2 B ES L Ln H Di f 2 F A1 a A x A2 A1 Le 100001 5 pe UU UU UUW UU UU UU A ds Table 5 3 MIF AC Line Filter Dimensions DIMENSION SINGLE PHASE SINGLE PHASE 10A 23 A mm in mm in A 214 8 43 214 8 43 Al 192 2 7 56 2 192 2 7 56 2 A2 11 2 0 43 2 11 2 0 43 2 B 145 5 71 204 8 03 B1 20 2 0 79 2 20 2 0 79 2 B2 104 2 4 09 2 164 2 6 46 2 C 40 1 57 47 1 85 C1 16 2 0 63 2 19 4 0 75 4 D1 5 4 0 20 4 5 4 0 20 4 D2 7 4 0 28 4 7 4 0 28 4 Connectors M4 4 Line filters are manufactured to millimeter dimensions inches are approximate conversions Publication 1398 5 0 October 1998 5 11 Installation 133 5 3715 31 25 500 171 1016 10 XX STVWIO3q ON Lud SNOLLOVHd S319NVI S319NV 3ONVH31O1 XV SLITI 20 539013 TV S3HONI NI SNOISNAWIG 31 28 LON OQ __
3. Description Identifier 1398 DDM 010 ana Terminal 1398 00 075 and Identifier Description 1398 DDM 010X 1398 DDM 075X 1398 DDM 020 and 1398 DDM 150 and 1398 DDM 020X 1398 DDM 150X 1398 DDM 030 and 1398 DDM 030X R phase power R 1 R R phase power to motor to motor S phase power S 2 S S phase power to motor to motor T phase power T 3 T T phase power to motor to motor Motor case 4 Motor case ground ground DC Bus DC BUS 5 DC BUS DC Bus voltage voltage DC Bus DC BUS 6 DC BUS DC Bus voltage voltage 100 240 VAC 11 7 L1 Line 1 100 240 VAC input power Line 1 input power 100 240 VAC 12 8 L2 100 240 VAC input power Line 2 Line 2 neutral N ERN N Neutral V Neutral Safety earth 9 L3 Line 3 100 240 VAC ground input power for three phase Auxiliary 100 L1 AUX 10 Safety earth 240 VAC input ground power Auxiliary 100 L2 N AUX 11 L1 AUX Auxiliary 100 240 VAC input 240 VAC input power power 1 12 L2 AUX Auxiliary 100 CAUTION When operating 240 VAC 1398 DDM 075 with a sin neutral for gle phase power input the three phase current limits must be set correctly Publication 1398 5 0 October 1998 7 2 Power Connections Publication 1398 5 0 October 1998 The 1398 DDM 075 1398 DD
4. enm TT ENCODER 24VDC FUSE 5VDC FUSE FUSE 45 of 229 Ju Publication 1398 5 0 October 1998 Firmware Upgrading Maintenance and Troubleshooting 11 5 ULTRA 200 Series drives may be upgraded in the field to the latest version of firmware Firmware versions are available from the Allen Bradley Product Support group The procedure describes how to reload the firmware installed in your drive using the Upgrade Firmware command available in ULTRA Master software ULTRA Master provides extensive checks and controls through message boxes which ensure that the loading of firmware is performed properly Messages ensure that e The drive is off line e The correct firmware file is used Firmware Upgrade Procedure using ULTRA Master 1 Copy the new firmware into the Firmware subdirectory of the ULTRA Master application directory 2 Start ULTRA Master 3 When the Drive Select window appears select Cancel The Drive Select window closes without connecting to the drive 4 Choose Upgrade Firmware from the File menu The Drive Select window will appear 5 Select the drive to upgrade and then select OK The Select Firm ware File window will appear 6 The Select Firmware File window contains a list of firmware files
5. Publication 1398 5 0 October 1998 Pin Signal Description Pin Signal Description Pin Signal Description 1 5 0 Encoder 5V 21 RESET Fault Reset 41 Reserved DC 2 ECOM Encoder 22 Analog 42 OUTPUT1 Selectable Common Command Output 1 3 5VDC_ Encoder 23 COMMAND Analog 43 OUTPUT2 Selectable 5V DC Command Output 2 4 ECOM Encoder 24 READY Drive Ready 44 Selectable Common Output 3 5 24VDC Isolated 25 READY Drive Ready 45 OUTPUT4 Selectable 24 VDC Output 4 24VCOM Isolated 24V 26 24VDC Isolated 46 Reserved Common 24 VDC 7 AOUT Motor Encoder 27 I LIMIT Positive 47 Reserved Output Current Limit Channel A 8 AOUT Motor Encoder 28 ACOM Analog 48 Reserved Output Common Channel A 9 BOUT Motor Encoder 29 I LIMIT Negative 49 BRAKE Brake Output Current Limit Enable Channel B 10 BOUT Motor 30 ANALOG1 Analog 50 BRAKE Brake Output Output 1 Enable Channel B 11 IOUT Motor Encoder 31 ANALOG2 Analog Output Output 2 Channel pin 50 o 25 12 IOUT Motor Encoder 32 INPUT1 Selectable Output Input 1 Channel 13 24VCOM Isolated 24V 33 INPUT2 Selectable Common Input 2 14 AX Auxiliary 34 INPUT3 Selectable Input 3 pin 26 pin 1 Channel A 15 AX Auxiliary 35 INPUT4 Sel
6. 1 Power AC Input Power Sizing Requirements Auxiliary Power 5 Auxiliary Power Sizing Requirements TB2 Shunt Regulator Internal Shunt Power Ratings for Drive Models Maximum External Shunt Power Ratings for Drive Models Minimum Ratings for Customer Supplied External Shunt Resistor c1 a u rd wer c IR EE ee e Application and Configuration Examples Preset Binary Inputs Tuning Velocity Loop Gains Position Loop Gains Status Display Run Time Error Power Up Error 4 5 Maintenance and Troubleshooting Troubleshooting Guide Options and Accessories Cable Diagrams Schematics and Examples 9 260 or 9 290 to Breakout Board 9 260 or 9 290 to J1 Connector 9 230 to Breakout 97230401 GonnectOE de eS Gea ee TouchPad Instructions TouchPad Fault Error Warning Displays TouchPad Motor Table Identification by Motor Series TouchPad Motor Table Identification by MotorID Option Selections forthe TouchPad
7. Table C 2 TouchPad Motor Table Identification by Motor Series Motor ID Motor ID Motor ID Motor ID B14H1050 551 B14H1056 558 B14H1060 560 B14H1066 562 B14J1050 559 B14J1050 559 B14J1060 563 B18H1070 564 B18H1076 566 B18H1080 568 B18H1086 570 B18J1070 567 B18J1080 571 90 1015 557 B9OH1025 561 B90H1035 565 B90H1045 569 F 4030 Q F 271 F 4030 Q H 15 F 4030 Q J 527 F 4030 Q K 783 F 4030 Q L 1039 F 4030 Q M 1295 F 4030 Q N 1551 F 4050 Q F 259 F 4050 Q H 3 F 4050 Q J 515 4050 771 F 4050 Q L 1027 F 4050 Q M 1283 F 4050 Q N 1539 F 4075 R F 272 F 4075 R H 16 F 4075 R J 528 F 4075 R K 784 F 4075 R L 1040 F 4075 R M 1296 F 4075 R N 1552 F 6100 R F 273 F 6100 R H 17 F 6100 R J 529 F 6100 R K 785 F 6100 R L 1041 F 6100 R M 1297 F 6100 R N 1553 F 6200 R F 274 F 6200 R H 18 F 6200 R J 530 F 6200 R K 786 F 6200 R L 1042 F 6200 R M 1298 F 6200 R N 1554 F 6300 R F 275 F 6300 R H 19 F 6300 R J 531 F 6300 R K 787 F 6300 R L 1043 F 6300 R M 1299 F 6300 R N 1555 H 2005 K F 276 H 2005 K H 20 H 2005 K J 532 H 2005 K K 788 H 2005 K L 1044 H 2005 K M 1300 H 2005 K N 1556 H 3007 N F 277 H 3007 N H 21 H 3007 N J 533 H 3007 N K 789 H 3007 N L 1045 H 3007 N M 1301 H 3007 N N 1557 H 3016 N F 278 H 3016 N H 22 H 3016 N J 534 H
8. SWEnable FW Ver DrvStat IndxCtri Software Enable Current Command Firmware Version Drive Status Index Control Selection Amps Release Level see Table On or Off TuneMode Avg Boot Ver InpFlags StrtCtrl Tuning Mode Current Average Boot Version Input Flags Setpoint Control 4 Path Selections Amps Release Level see Table Onor Off Manual Tuning Peak Reg Rev OutFlags A T I 1 Current Peak Regulator Board Output Flags Normal Auto Tune Position Step Amps Revision Level see Table z Setpoint Operation Velocity Step Peak Pwr Rev Control 1 Current Peak Power Board Distance Step Pos Distance Step Position mps eve or counts counts ID Assy Setpoint Index Index Step Period AES Control Control Control Step Current Time Limit Ami es Current Limit 4 i Amps Step Vel VelMtrFb Setpoint StrtHome Step Velocity Vel Mtr Feedback Setpoint Start Homing rpm rpm or Amps to start Period VelCmd IndexSel Time Velocity Command Index Select msec E Velocity Mode iti elError Auto Tune Velocity Step Position Step Velocity Error Serine Accel 2 to start TuneDir PosMtrFb Acceleration Rate A Motor Direction Pos Mtr Feedback mode rpm sec BiDirec Forward or Reverse counts SWEnable PosMastr Software Enable Position Master Velocity Mode Selecti
9. si 0026 0 juo uonisod 0001 y sI uoneoo 105 1 9 uA si 000g pue y si uidi 0026 duuex 104 uonisod Josuno y Jo 5 JO ay jou pue 5109 0 1SI P eui 1849H 5 eureu e e dsip 40440 Ady 191u3 polN 55914 pue 10413 e dsip Ajayeusayye 10 45 Sjeodde e que jejeureJed e J shay 437 pue eui Hulsn uonisod Josuno UMOG JO dn eui 10 151 eui Burjouos Aq suajoeseyo apow JIDON au suajoeseyo Bulysel4 Z skay pue eui YM 5 suajoeseyo 9 10613 enuen uomejejsu eui oi 1949H suononuasu jeyuawajddns 681
10. mojaq paule dxe ui Aoy p lo s Jeju3 epo y 10 swous pejoejes eui 2 JO eureu swous sapow ow Aejdsip ay 591660 uonounj Kay eui 1919 wesed uoee pue smoje JIDON JejeureJed 991 eui smoje e qejreAe Jo shay 0 10 5 e Buissaidap Aq spueululO eotouo sjoejes 8ul S9210u9 SMOE eotouo eui sepeoeud V p 19 s eq uoiuM 515 epi oJd SNLYLS pue dNLASAYG 9 uBis snuluu uwog JO dn 19 e pamasa SI 150 SUL 6 000b 01 1 UMOQ y Hulssaidap
11. eui jo eunjonujs eui Sjoidep epis eui uo eu e jo enjeA au 10 19 e Aejdsip shay y ssejdeg 79 JIDON 40 uoneJedo JO apo eui Ady 191u3 epo N eui sseudeq 76 OPIS si1 A 1 uo 991 JO peisi 194 1snui Jaquinu eu 1019 ue sesneo j2eJ10oul uy 109 409 51159 Jjes Duunp p eldsID 1 A 94 USA 7 pequono eui Aq sPunies WNOHd33 9e ug ON dois siiq 8 pneg 00261 0 sseippy pequono aaup amod Ajddeay 9 ug QAS 9 Uld aS 8 uid asuas peg ono 9uid usuel pasnion ee aren 2 6 uid pasnjoN Zuid ge p sul S Uld uld sdajg uone jeisu se eui 8154 Z BLAS pue UMOP 19 H pue 191541 90000
12. 8 8 Configuration y WR ER ES 8 8 MTM 8 10 Operation ss co mne s wie m RIS 8 11 Position Follower Master 8 12 Hardware Setup 5 roce 44k 40 y pm ees 8 12 Connection Diagram 8 13 8 13 DUM Se he Gee mu 8 15 Op ration eta ee 8 16 Position Follower Step Direction 8 17 Hardware 8 17 Connection 8 18 8 18 TORIS oris felt a Ae AG Za 8 20 Publication 1398 5 0 October 1998 Intro 4 Table of Contents Chapter 9 Chapter 10 Publication 1398 5 0 October 1998 5 duro ed Subuh 8 21 Position Follower Step Up Step 8 22 Hardware 8 22 Connection Diagram 8 23 Configuration 8 23 Tune a ce ae aus tne as a S Gedy her aoe a 8 25 us m ose ee ee Be 8 26 Incremental Indexing 8 27 Hardware Setup 4 sso RET eee 8 28 Connection Diagram 8 29 Configuration 8 29 DONIES 3c sod deo SE SUR
13. Drive Communications Parameter List for the TouchPad Baud Rate Parameter List for TouchPad Encoder Output Parameter List for TouchPad IO Mode Parameter List for Index Pointer Parameter List for TouchPad Index Termination Parameter List forTouchPad Appendix D Appendix E Appendix F Appendix G List of Tables Intro 13 Home Type Parameter List for C 14 Homing Auto Start Parameter List for TouchPad C 14 Reverse Enable for C 15 Digital Input Parameter List for TouchPad C 15 Digital Output Parameter List for TouchPad C 15 Analog Output Parameter List TouchPad C 16 Drive Status List TouchPad 16 Input Flags Parameter List for 17 Output Flags Parameter List for TouchPad C 17 Creating Custom Motor Files Electromagnetic Compatibility Guidelines for Machine Design AC Line Filter E 4 Dynamic Braking Resistor Selection Dynamic Braking Resistor Parameters 1 Specifications ULTRA 200 Series Power Ratings G 5 Publication 1398 5 0 October 1998 Intro 14 List of Tables Publication 1398 5 0 October 1998 Preface This manual provides a step
14. MARK WITH AND REV MANUFACTURER S PART NO AND DATE CODE Figure B 23 CABLE SINE ULT MAX KA 50962 90 C 600 VOLT SHIELDED 4 C 8 AWG 05 GRN YEL BLACK 250 12 5 25 12 9 5 25 8000 H Series Power Cable P N 9101 1384 WIRING DIAGRAM BACK sur cov haan mm IO THE MOLDING ADAPTER AND WRAP WITH ALUMINUM FOIL TAPE BETWEEN THE SHIELD AND THE ADAPTER THE TAPE MUST MAKE CONIACT WITH THE ENTIRE SHIELD CIRCUMFERENCE AND VIEW A ADAPTER CIRCUMFERENCE L 893 020 DIA E FEET 4 7 FERRULE INSULATED 6 38 APPROX 20818 22150 294 1 75 10184 LABEL BRADY 12 R IOA Y GRN EL be 4 1 8 GLUE SHRINK OVERMOLDING PVC BLACK BLACK 8 1 8 MOLDING ADAPTER MARK WI 250 1 2218 ALUMINUM BLACK AND REV MANUFACTURER S PART NO AND DATE CODE 5 25 1 8 9 5 1 4 Publication 1398 5 0 October 1998 B 24 Cable Diagrams Schematics and Examples Figure 24 Y Series Power Cable P N 9101 1385 FERRULE INSULATED ALTECH 2205 0 325 256
15. 6 4 Drive Input Connected to a Switch Relay Contact 6 7 Drive Input Connected to an Opto Isolator 6 7 Drive Input Connected to an Active High Sourcing Transistor 6 7 Drive Input Connected to Active Low Output using a Switch Relay oe y a ae k dee 8 6 7 Drive Input Connected to Active Low Output using Opto Isolator 6 8 Drive Input Connected to Sourcing Output 6 8 READY and BRAKE 6 9 Digital Output 6 10 Drive Output Connected to an Opto Isolator 6 11 Drive Output Connected toan LED Indicator 6 12 Drive Output Connected toa Resistive Load 6 12 Drive Output Connected toaSwitch Relay 6 12 Drive Output Connected to Active Low Input using Relay eins 6 13 Drive Output Connected to Active Low Input using an Opto Isolat r kem hm RR ER d 6 13 Drive Output Connected to Active High Sinking Input 6 13 Positive and Negative Current Limit Circuits 6 14 Analog COMMAND Input Circuit 6 15 ANALOG 1 and ANALOG 2 Output Circuits 6 16 Output Encoder Interface Circuit 6 17 Auxiliary Encoder Input Types 6 19 Auxiliary Encoder Input Circuit 6 19 Publication 1398 5 0 October 1998 Intro 8 List of Figures
16. L 10 uidi ux uidi feng ps ASIC 1 195 0 Y 195 0 URIS juodies IA deis e op 5 TOs ung 10 A Sduuy 10 judi SWOHLIS deis anova 8 910 PON ajeos pueuuuloo ogey 1895 8040 1 4 le59S n i A i vno en H oneuio4 it 18S 1d ywr uo uo sesu sduy o Say deis oye 995 m M P u 955 10 1 09 Aiquiessy 19915 ndul 1 1ne4 I jepoou3 x pul 6 Assy ama ISH jno sua JO 5 Hoftsod CIS ees aqe oos aide oes peog yg qlu uno 50 dais 9ou amp isiq y Ndu eoInos A H 42d oolgA uonej sdo USPIO lespneg juiodjes 595 6 8 deis uonisoq eun ojny euJoN aqel 995 Jo DOPA 542 995 serg indino preog UUNO idul jeyBiq 1 sBelino Bulun enuen edujbiq
17. FASTENS DIRECTLY BOARD CONNECTOR GRAY 16 AWG 28 AWG WHITE GRAY 16 AWG 28 AWG 1 28 AWG BLUE 28 AWG 28 AWG WHITE BLUE 28 AWG BLACK 28 AWG X WHITE BLACK 28 AWG RED 28 AWG WHITE RED 28 AWG GREEN 28 AWG x WHITE GREEN 28 AWG YELLOW 28 AWG WHITE YELLOW 28 AWG ORANGE 28 AWG WHITE ORANGE 28 AWG BROWN 28 AWG NC WHITE BRONW 28 AWG NC VIOLET 28 AWG WHITE VIOLET 286 AWG DRAIN Publication 1398 5 0 October 1998 x DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 PIN 1 THIS END Cable Diagrams Schematics and Examples B 19 Figure B 17 2 to N Series Encoder Cable P N 9101 1468 CABLE SINE KA 50203 ULTIMAX 80 C 30 VOLT ONE 16 AWG TWISTED PAIR EIGHT 28 AWG TWISTED PAIRS FOIL SHIELD WITH 100 COVERAGE BRAIDED SHIELD WITH 85 MINIMUM COVERAGE AND 28 AWG DRAIN WIRE E ft OVERMOLDING CONNECTOR ITT CANNON PVC BLACK MARK WITH ASSY P N amp REV SKESEOSETA TOS ATT MFG P N REV amp DATE CODE MOLDING ADAPTER ALUMINUM BLACK COBALT PLATED 2 6 x 0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR 20 POSITION PLUG CABLE CONNECTOR 11
18. MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE M2 6 x 0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR 4 WHITE BLACK 5 5 BLACK WHITERED 4 L3 RED M VIOLET 8 15 5 WHITEMIOLET i te WHITE BLUE 15 WHITEIGREEN y WHITEORANGE 22 _ ORANGE DRAIN 1 Y y we we 5 6 N C 8 9 wc 10 wie 11 we we 12 13 20 21 we we 24 w e 25 ae 26 we we we we we DENOTES TWISTED PAIR 0 CONNECTOR BACKSHELL SHIELDED 360 BOTH ENDS 1 THIS END NP 26 THIS END Publication 1398 5 0 October 1998 B 4 Cable Diagrams Schematics and Examples PIN 1 THIS END Figure B 2 J1 to No Connector Interface Cable P N 9101 1370 E E fest ji us
19. RS 485 RS 422 Communication Comparison Four Wire RS 485 Daisy Chain Connection Diagram RS 232 to RS 485 Multi Drop Connection Diagram ANALOG 1 and ANALOG 2 Output Circuits 1398 DDM Interface Connection Power Connections Motor Power EMC Shield Connection Pigtail Ground rus sus Emergency Stop Contactor Wiring External Shunt Wiring Examples External Shunt Mounting Application and Configuration Examples Analog Controller Connection Diagram Preset Controller Connection Diagram Master Encoder Connection Diagram Step Direction Controller Connection Diagram Step Up Step Down Controller Connection Diagram Incremental Indexing Examples Incremental Indexing Connection Diagram Registration Indexing Examples Chapter 9 Chapter 10 Chapter 11 Appendix A Appendix B List of Figures Intro 9 Registration Indexing Connection Diagram 8 35 Absolute Indexing Examples 8 39 Absolute Indexing Connection Diagram 8 40 PC Display Units Default 8 45 Tuning Velocity Loop Structure 9 3 Torque Current Conditioning
20. 3SVHd 338HL 051 59 SNOYOL LON 118 NOLLONGSY V NI LINS3Y TIM 39VLT0A 39 VETOA LAN 30 SONI VH INSHEND STVNINH31 NOILdO 1NDHS 1VNH31X3 JO TWNIWHAL 8261 1016 33S LNDHS AHOLO V Q3TTVLSNI 9393 Q3HOLIMS 38 AVN L1ATNO Xnv H3MOd 8314Y 30 SNLYLS OLLSON VIG NIVL3H OL 3 1dWVX3 STVNINH31 1 2121 LY 340 OINYNL SI ATddNS HO1ON H3L4V QG3H3MOd 5319915 FINGOW 30 NOILOSS 21007 OL G3SN 38 AVN TWNIWHAL SALON SNE NOWOO 3NIHOVIN SIXv INO N31SAS V H3I ITdWV 404 LNIOd H3WHO4SNVHL SNIGNnOH9 ann 3 18VTIVAV 15 ENE SI39VIIOA 9341539 aSVHd N3HM LON 1VNOLLdO Y3WYOISNVHL OLNY HO NOIIV1OSI LINDHIO HO LOANNOOSIC Q3Shd xnv Na N 87 2101 STVNINYSL 3n080L N Seues jo 510 Luly 0 8 9NV 9 21 suoddns Ke peJg ue lv NI 87 OL TV 3noHOL J LON __ 50 01 22 wuyqonv 318v14300v 151 TVNWH3L WNOILdO 1ndNI samodan w n 7 H3MOd SHVNINH31 Q3aN3Woo3u S3HIM 83MOd LONI
21. Publication 1398 5 0 October 1998 7 4 Power Connections Publication 1398 5 0 October 1998 Y Series Power Cables Y Series motors have a short pigtail cable which connects to the motor but is not shielded The motor power cables have a 6 inch shield termination wire with a ring lug which should be connected to the closest earth ground This shield termination 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 Figure 7 2 Pigtail Ground Motor Power Cable Connectors lt Pigtail Cable 6 Shield Termination Motor ATTENTION High voltage may be present on the ter minals of the ULTRA 200 Series drive Remove power and disconnect the power cable before making or removing any connection ATTENTION Do not tin solder the exposed leads on cables Solder contracts over time and may loosen the connection Power Connections 7 5 Table 7 2 Motor Power Contact and Wire Sizing Recommendations Motor Motor Power Mating Minimum Maximum Recommended 90 C Contact Size Power Wire mm AWG mm AWG H 2005 1 5 16 1 5 16 3007 1 5 16 1 5 16 3016 1 5 16 1 5 16 H 4030 F 4030 4 0 12 1 5 16 H 4050 F 4050 4 0 12 2 5 14 H 4075 F 4075 4 0 12 2 5 14 H 6100 F 6100 10 0 8 4 0 12 H 6200 F 6200 10 0 8 10
22. 9 3 Signal Nomenclature 9 10 Underdamped Signal 9 11 Cyerdamped Signal oe sares a Pee d 9 11 Critically Damped Signal Ideal Tuning 9 12 Status Display Maintenance and Troubleshooting Fuse and Jumper Locations 11 4 Options and Accessories Cable Diagrams Schematics and Examples to J3 Interface Cable P N 9101 1367 B 3 J1 to No Connector Interface Cable P N 9101 1370 B 4 J3 to J3 Interface Cable P N 9101 1463 B 5 J3 to No Connector Interface Cable P N 9101 1368 B 6 JA to 50 pin Terminal Block Kit Diagram P N 9101 1391 9101 1560 B 7 to 50 pin D Connector Cable P N 9101 1369 B 8 2 to 25 pin Terminal Block Kit Diagram P N 9101 1392 B 9 J2 to 25 pin D Connector Cable P N 9101 1371 B 10 J5 to 9 pin D Shell Interface Diagram P N 9101 1372 B 11 J5 to J5 Serial Interface Cable P N 9101 1374 B 12 J5 to No Connector Serial Interface Cable P N 9101 1379 B 13 F or H Series Motors to No Connector Encoder Cable P N 9101 1365 zn pA eA Ewa ak TIR B 14 J2 to F or H Series Encoder Cable P N 9101 1366 B 15 J2 to Y Series Encoder Cable P N 9101 1375 B 16 No Connector to Y Series Encoder Cable P N 9101 1373 B 17 J2 to No Connector Encoder Cable P N 91
23. Pigtail cable to This wiring method should be used to run cables through a bulkhead enclosure without removing the connectors Cable 9101 1375 has connectors on both ends The connectors are molded and potted to the cable and may not be disassembled Adaptor Kit 9101 1391 includes the 3 foot cable screw terminal strip and mounting bracket The cable has a 50 pin Mini D ribbon connector at the drive end and a 50 pin D connector at the terminal strip end Motor Power Cables Use ULTRA Series cable 9101 1385 for applications requiring the CE mark The shield on the motor power cable must be properly grounded at both ends Publication 1398 5 0 October 1998 Cable Diagrams Schematics and Examples B 29 Figure B 29 Motors to ULTRA 200 Series Drive using P2 Terminal Strip Enclosure Cabinet Y Series Motor Encoder Connectors 9101 1373 XXX Screw Terminal Strip m CPC connectors z 9101 1391 8 To lt Control Motor Power connectors 9 Nnterface Screw Terminal Strip Pigtail cable to
24. __WHITENELLOW 28 AWG z _ vi DRAIN Publication 1398 5 0 October 1998 f 1 X DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 Cable Diagrams Schematics and Examples B 15 Figure B 13 2 to F or H Series Encoder Cable P N 9101 1366 3 80 START OF BEND RADIUS E fest AAT 1225 THEE e uu N 55 AN HL 436 STRUCTURAL ADAPTER BLACK L MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE M2 6 x 0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR 28 AWG 28AWG GRAY 20 AWG A 1 28AWG U s V y 28 AWG q 28 AWG 2 1 WHITEJGRAY 20 awe 2 3ANG BLUEZBAWB _ 7 5 WHITEIBLUE 28 AWG T T 9 H T BLACK 28 AWG ly WHITE BLACK 28 AWG 5 RED28AWG 4 WEUITEFRED 26 AWG 8 45 PIN 1 THIS END 6 GREEN BANG 4 WHITEIGREEN 26 Awe 2 YELLOW 28 AWG 13 WHITE YELLOW 28 AWG 9 0 44 PIN 11 THIS END ORANGE 28 AWG a 6 1 y X WHITEIORANGE 28 Away i BROWN NOTE USED We F20 208 LI T WHITEIBROWN NOT USED FACE VIEW 18 VIOLET 28AWG 9 49 WHITENIOLET 28 awe 20 DRAIN L
25. 013119395 5 SSTINN jowo s s Y es see 8 baton sonvHo eser 0 0 020 010 INQQ SNOLLO3NNOO SNIHIM H3MOd OVI SIXV Yad W31SAS HO LNIOd SNIQNnOHD NOWOO SHO1ON 30193 09 H3MOd HOLOW HOLO3NNOO H3MOd HOLOW 1 201 OL 9NIQHOOOV 03193735 38 LSNW 53215 3515 53515 MOS Av 130 3LL 1N3W313 LAGNI VS6 ONY LNNI YOS JO 1 HSNYNI 30 QOlH3d V SSYINOAY NOILVZITVILINI H3MOd 3LON SION 092 0011 OW Sowy 0 87 OV SHOA 072 001 12 OY sduiy 061 SIOA 095 001 19 OV Sawy 0701 OV SHOA 0 12 OV 670 OV SIOA SLL 12 Ov O L SINSW3YINDOSY INSYYND LNdNI JAYA WLIDIG 7 01 HH3AO 310801 H3A3N N3IH LLH3AO LON OG SM3HOS 133OVtig INNS GASN S318VO Q3Q THIHS NON 3l 431734 NiVH1S 303 Q3Sf1 38 NVO 1330V88 SIHL 133OVt8 JHL 3AIHQ JHL OL SNIdIWVTO CTSIHS 318 2 H3MOd HOLOW JHL 5 38 5 1 201 30 SLNSWSYINOSY SSN WA a3aN3AWOO3H WAWINIW 38V 53215 38IM 31815904 SV OL 38010 38 HV SNA NOWWOO TIAISSOd
26. 2 1 Drive Power 2 1 25222245542 suu utu SE Ge SES 2 2 ULTRA 200 Series 2 2 Stand alone 2 2 High Performance Microcontroller Technology 2 2 IPM Technology 2 2 Analog and Digital InterFfa ces 2 2 Encoder Control 2 2 Encoder 2 3 Digital RE DS 2 3 Analog MO 2 448454 2 3 AC Input 222252 22 2 3 Personality Module 2 3 Multiple Protection 5 2 4 ULTRA Master Software 2 4 Publication 1398 5 0 October 1998 Intro 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Table of Contents Publication 1398 5 0 October 1998 5 2 4 Autotuning 2 5 Agency 5 2 5 Op ohS SS 2 5 eee 2 6 European Union Requirements 2 7 ULTRA Master Installation Hardware and Software Requirements 3 1 Installing ULTRA 3 2 Starting and Quitting ULTRA 3 3 Versi
27. 515 F 4050 Q J 527 F 4030 Q J 528 F 4075 R J 529 F 6100 R J 530 F 6200 R J 531 F 6300 R J 532 H 2005 K J 533 H 3007 N J 534 H 3016 N J 535 4030 536 4030 537 H 4050 P J 538 H 4075 R J 539 H 6100 Q J 540 H 6200 Q J 541 H 6300 Q J 542 H 8350 S J 543 H 8500 S J 593 N 3406 2 J 594 N 3412 2 J 595 N 4214 2 J 596 N 4220 2 J 597 N 5630 2 J 598 N 5637 2 J 599 N 5647 2 J 771 F 4050 Q K 783 F 4030 Q K 784 F 4075 R K Publication 1398 5 0 October 1998 C 12 TouchPad Instructions Table C 3 TouchPad Motor Table Identification by Motor ID continued ID Motor ID Motor ID Motor ID Motor 785 F 6100 R K 786 F 6200 R K 787 F 6300 R K 788 H 2005 K K 789 H 3007 N K 790 H 3016 N K 791 H 4030 P K 792 H 4030 M K 793 H 4050 P K 794 H 4075 R K 795 H 6100 Q K 796 H 6200 Q K 797 H 6300 Q K 798 H 8350 S K 799 H 8500 S K 849 N 3406 2 K 850 N 3412 2 K 851 N 4214 2 K 852 N 4220 2 K 853 N 5630 2 K 854 N 5637 2 K 855 N 5647 2 K 1027 F 4050 Q L 1039 F 4030 Q L 1040 F 4075 R L 1041 F 6100 R L 1042 F 6200 R L 1043 F 6300 R L 1044 H 2005 K L 1
28. WIRING DIAGRAM 20 AWG K GRAY 16 AWG 28 AWG 20 AWG 28 AWG J kaja 20 AWG ANA EA nenne P 20AWG VN BLUE 28AWG 2846 BLACK 28 AWG 2 SN A NHITEIBUACK 28 AWG i gt 8 RED 28 AWG yy WWHITE RED 28 AWG zsawa Q HITEIBROWN 28 AWG BROWN 28 AWG 5 05 14 195 71 CONNECTOR u 28 AWG Ww PIN 11 THIS END FACE VIEW v 18 ORANGE 28 AWG 16 17 we s 20 POSITION r VIOLET 28 AWG 11 PLUG CABLE CONNECTOR WHITEIVIOLET 28 AWG 2 Nic F DRAIN UI FACE VIEW 5 DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 BOTH ENDS Publication 1398 5 0 October 1998 B 20 Cable Diagrams Schematics and Examples Figure B 18 Connector to N Series Encoder Cable P N 9101 1469 ULTI MAX 80 C 30 VOLT ONE 16 AWG TWISTED PAIR EIGHT 28 AWG TWISTED PAIRS FOIL SHIELD WITH 100 COVERAGE BRAIDED SHIELD WITH 85 MINIMUM COVERAGE AND 28 AWG DRAIN WIRE J CABLE SINE KA 50203 I E ft 4 70 3 28 KPSE05E14 19S A71 UN 1 33 0 94 OVERMOLDING MARK WITH ASSY
29. 42 15 sz vpo ENCODER PWR SENSE BM IM ABSOLUTE J2 16 J2 17 J2 18 J2 19 J2 20 5VDC J1 1 5VCOM J1 2 J1 3 45VDC Y 5VCOM J1 4 IOPWR EZ FAST 5VDC SIGNAL MOTOR OVERTEMPERATURE PS IOPWR J1 5 IOPWR v IOCOM gt J1 6 AOUT 41 7 AOUT INCREMENTAL J1 8 BOUT ENCODER J1 9 BOUT INPUT 41 10 IOUT 41 11 IOUT IOPWR DRIVE J1 12 94 43 IOCOM 41 14 Y IOCOM AX x J1 15 BX J1 16 MASTER ENCODER 41 17 41 18 IX ENABLE COMMAND FAULT RESET J1 19 J1 20 J1 21 ENABLE DIGITAL RESET INPUTS IOPWR COMMAND DEDICATED 20KQ COMMAND 41 22 COMMAND G TYPICAL DIGITAL OUTPUT 1 OF 4 cIOPWR Ee FORWARD CURRENT REVERSE CURRENT VELOCITY MONITOR LIMIT LIMIT A J1 23 READY aw J1 24 READY J1 25 IOPWR IOPWR N O DRIVE DRIVE yay READY IOCOM J1 26 ILIMIT 20KQ 5V READY CURRENT LIMIT 1 OF 2 41 27 41 28 ILIMIT ACOM CURRE
30. G NG N DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 BOTH ENDS Publication 1398 5 0 October 1998 B 16 Cable Diagrams Schematics and Examples Figure 14 2 Encoder Cable P N 9101 1375 E 2 43 BEND RADIUS N l i jg T 0 38 61 16 MOLDING 28 POSITION CPC SHELL SIZE 17 WITH FEMALE SOCKET CONTACTS FACE VIEW Publication 1398 5 0 October 1998 22 10 11 13 14 15 17 19 24 16 18 20 21 25 26 27 28 L MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE 2 5 0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR N GRAY 16 AWG B 28 AWG 3 WHITE GRAY 16 AWG 28 awe 6 BROWN 28 AWG 6 0 WHITE BROWN 28 AWG 5 i BLACK 28 AWG 6 7 WHITEIBLACK 28 0 i PIN 1 THIS END REDK 28 AWG 9 WHITE RED 28 AWG 1 GREEN 28 AWG 6 14 WHITEIGREEN 28 AWG i i ORANGE 28 AWG 6 13 PIN 11 THIS END I WHITE ORANGE 28 AWG BLUE 28 AWG 15 20 AWG DRAIN n c 16 M 17 N C 18 n c 19 20 N C N C DENOTES TWISTED PAIR N C CONNECTOR BACKSHELL
31. gt J 6 36 5 E 6 34 WARNING HIGH VOLTAGE AFTER REMOVING POWER oses O n page 6 34 J R S 5 09 D page 6 31 DC Bus bi DC Bus L1 g uN 8 page 6 27 8 L1 AUX 25 L2 N AUX TB1 1 8 i page 6 1 cU 8 Models Ji T SF 1398 DDM 010 and 1398 DDM 010X 1398 DDM 020 and 1398 DDM 020X 1398 DDM 030 and 1398 DDM 030X Publication 1398 5 0 October 1998 Intro 22 Preface page 7 11 page 7 6 page 7 3 page 7 6 page 7 7 page 7 10 Publication 1398 5 0 October 1998 Product Parts Explained sheet 2 of 3 Go E _ 7X status 77 z gr 57 1 3 3 SY CJ LB as 1 es 35 lt gt E T A2 E 3 EA TB2 E E z 8 a WARNING VOLTAGE MAY EXIST FOR UP TO EIGHT MINUTES AFTER REMOVING POWER DCBus lt lt 8 5 9 5 T 5 D gt gt DC Bus 5 DC Bus 100 240 50 60 Hz 5 eo 5 2 L2 N AUX bg EL M
32. uiuo 0910 ees sduy 500109 95 v 9142 ees suojas Wed ze gt 9 Juodas indu 9 1009 apon Buun Idul eysa jeounos eAug 1008 Bay 915 pui ees sduy uoiosjes 9142 ees enbio 10 DOJA eos x pul sniels e ug UOISI A 1lu uno lqeu3 andul eysa enug Uono9jes 10104 1 9 ISM J9A Md pui 9 qeu3MS dulia 19510101 lt lt Snivis OANIAYG ONINNL Bd INHVdAHGa m SS gt Installation and Operation Appendix C TouchPad Instructions The optional TouchPad is a compact and rugged device for interfacing with ULTRA 200 Series drives It provides the operator with a convenient device for accessing status information program variables and control functions plus message display capabilities on any ULTRA 200 Series drive An 8 character dot matrix display and a sealed membrane type keyboard are housed in a compact case A locking tab and a single 9 pin D shell serial connector on the backpanel connects the TouchPad to any ULTRA 200 Series drive via four wire RS 485 communications Four cursor keys and a Mode Enter key provide access to the TouchPad menus and enable th
33. Clamp exposed y machine chassis ground motor cable shield to the ch around terminal 9101 1385 Notes This wiring method provides the option to run cables through a restrictive bulkhead or enclosure Cable 9101 1373 XXX has a connector on the motor end only The cable connector is molded and potted to the cable and may not be disassembled Adaptor Kits 9101 1391 and 9101 1392 include a 3 foot cable 50 pin 9101 1391 or 25 pin screw 9101 1392 terminal strip and mounting bracket The cables have a 50 or 25 pin Mini D ribbon connector at the drive end and a 50 or 25 pin D connector at the terminal strip end Motor Power Cables Use ULTRA Series cable 9101 1385 for applications requiring the CE mark The shield on the motor power cable must be properly grounded at both ends Y Series Motors have 1 meter 39 inch cables attached Publication 1398 5 0 October 1998 B 30 Cable Diagrams Schematics and Examples Allen Bradley 9 Series CNC The tables below list the connections necessary between the Family Connections connectors on Allen Bradley 9 Series CNC Controllers The controller may be wired to either a Breakout Board connection from the J2 connector or directly to the J1 connector on a ULTRA 200 Series drive Table B 1 9 260 or 9 290 to Breakout Board 9 260 or 9 290 8520 ASM 3 Drive Connections J1 J2 J3 Signal J2 Signal Pin Pin 3
34. Refer to Figure 6 23 6 24 6 25 6 26 6 27 6 28 and 6 29 for additional details on the Control Interface Cable Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F or P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display codes Start ULTRA Master on the PC Choose Cancel from the Drive Select dialog box Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings Publication 1398 5 0 October 1998 8 14 Application and Configuration Examples Publication 1398 5 0 October 1998 5 8 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are different correct the Port Settings to allow communications with the drive Factory default communications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions Select Read Drive Parameters from the Communications menu Verify the Drive Name and Address are correct for the
35. poN dn duuex 104 104 99 peioejes eui jo eui SI yey Jojoejeuo y dn jejeureJed y sjoejes snolAaJd v g oez I8S10 0N d NLASAYG ejdurexe 104 ejdurexe 104 p lo l s si JO y 1919818 49 seseaJoe xeu 15995 9 1X N 0024000 0026000 104 IWVHVdAHG c 5 1 Bum s jdwex 104 eui 6uuewo 3uBu y oi uonoejes 1ejoe1euo eu S AON y uoueJq 1xeu eui sioejes AON 1X9N 0029000 0029000 ejdurexe 104 dNLASAYC gt NVHVdAHG 437 10 104 ay eui uonoejes uoueJq snolA81d eui 5 29 95 191 youeig Key uonejedo JO Syu pue s Bueu 10 djeu 19159 YHN ull uo eui 1942H epis y uo Pajoidap 991
36. we Allen Bradley ULTRA User 200 Series Digital Servo M anu al Drives Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or in part without written permission of Allen Bradley Company Inc is prohibited Throughout this manual we use notes to make you
37. MARKED WITH 2 E FEET GLUE SHRINK PART AND REV MANUFACTURERS PART REV AND DATE CODE WIRING DIAGRAM onu 2 sip N ATACHIO THE MOLDING ADAPTER AND WRAP WITH ALUMINUM FOIL TAPE BETWEEN THE SHIELD AND THE ADAPTER THE TAPE MUST MAKE CONTACT WIH THE ENTIRE SHELD CIRCUMFERENCE AND ADAPTER CIRCUMFERENCE FERRULE INSULATED ALTECH 2211 0 2 0 41 8 1 0418 LABEL BRADY BROWN BLACK BLUE 2 GNML 4 18 18 8 18 12418 5 25 1 8 7 25 14 Cable Diagrams Schematics and Examples Figure B 22 T CABLE SINE ULT MAX KA 50962 90 C 600 VOLT SHIELDED 4 C 8 AWG B 23 6300 H Series Power Cable P N 9101 1399 WIRING DIAGRAM BACK Sos smo ATTACH TO THE MOLDING ADAPTER AND WRAP WITH ALUMINUM FOIL TAPE BETWEEN THE SHIELD AND THE ADAPTER VIEW A He APE MUSI MAKE CONIACI WIH THE ENTRE SHIELD CIRCUMFERENCE AND ADAPTER CIRCUMFERENCE L_ 745 020 DIA E FEET FERRULE INSULATED 2213 0 2 44 1 62 LABEL BRADY OVERMOLDING 12 20 1 BROWN PVC BLACK e N N 50 10 12 N 25 12 BLUE R MOLDING ADAPTER ALUMINUM BLACK
38. 24 Volt 6 3 5 Volt 6 3 Input Frequency 7 7 Main G 5 Output Continuous G 6 Peak G 6 Ratings G 5 Source Separation 7 9 7 10 Supply 5 Volt G 2 Power Up Error Codes 10 3 Faults 6 3 Preset Binary Inputs Programmable Speed Inputs 8 6 Preset Controller 8 6 Procedure Manual Mode Position Loop 9 9 Velocity Loop 9 8 PWM Carrier Frequency G 2 R RAM G 2 Readme File 3 4 READY see Specifications Registration Indexing 8 33 Requirements Input Power 7 9 Transformer 7 9 7 10 Wire Size 7 9 7 10 Resolution see Specifications Revision Level Software 3 3 Ripple see Specifications RS 232 Communication Test 11 11 Single Axis Set up 6 38 RS 485 Multiple Axes Set up 6 41 Run Time Error Codes 10 2 Faults G 4 s Safety Guidelines 1 1 Sample Application see Example Selectable O Digital Inputs G 4 Digital Outputs G 4 Selectable see Specifications Self Test C 2 Separation of Power Sources 7 9 7 10 Serial Communications Drive Addressing 6 36 6 38 RS 232 Single Axis Set up 6 38 RS 485 Multiple Axes Set up 6 41 Hardware Addressing 6 36 Ports J4 J5 6 34 Serial Interface Cables Schematics and Diagrams 13 Serial Ports G 1 Serial Protocol G 3 Shock G 1 Shunt Power Continuous G 5 Peak G 5 Shunt Regulator 7 11 Connecting External 7 14 Minimum Resistance 7 13 Power Ratings External 7 12 Internal 7 12 Terminals 7 11 Signal Extension Kits 6 1 Single Point Ground Example E 5 Types 5 Software Installation 3
39. A ABS Input G 1 Absolute Indexing 8 39 AC Bus 7 7 Line Filters 5 7 Power 7 7 see also Power Accessories 1 Address Switch G 1 Agency Approvals G 1 Allen Bradley 9 Series B 30 Altitude G 1 AM Line 11 8 Analog 6 44 Connections 6 44 Controller 8 1 Inputs G 2 COMMAND signal G 2 Current Limit 6 14 Outputs 11 14 G 2 Analog Controller 8 1 Application Example see Example Auto Tune Guidelines 9 4 Overspeed Parameter 9 5 Procedure 9 4 Auxiliary Encoder Error see Troubleshooting Auxiliary Encoder Signal Inputs G 2 Auxiliary Power see Power B Backlash 9 3 Bandwidth see Specifications BM Line see Troubleshooting BRAKE see Specifications Breakout Board J1 50 pin 6 26 J2 25 pin 6 30 Bus Capacitance G 5 Overvoltage 11 8 Undervoltage 11 8 Voltage G 5 see also Troubleshooting C Cabling European Union Directives 5 6 Index Examples B 26 Schematics and Diagrams 3 Caution defined Intro 20 Command Mode display 10 1 COMMAND signal G 2 Command Source G 3 Command Summary C 3 Common Mode Choke 4 Configuration Example see Example Connecting to Alen Bradley 9 Series B 30 Connection Diagram Absolute Indexing 8 40 Analog Controller 8 2 Incremental Indexing 8 29 Position Follower Master Encoder 8 13 Step Up Down 8 23 Step Direction 8 18 Preset Controller 8 8 Registration Indexing 8 35 Current Limit 6 14 G 2 Regulation G 2 Custom Motor Compatible Components 2 6 Creating Files D 1 D Dange
40. October 1998 A 2 Fuses Options and Accessories Description 1 Ampere fast acting inline Littelfuse R451001 or equivalent for 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 030 or 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X NOTE Contact Littelfuse at 847 824 1188 for part numbers Options and Accessories Description TouchPad AC Line Filter 6 Continuous Single Phase for 1398 DDM 005 or 1398 DDM 005X AC Line Filter 10 A Continuous Single Phase for 1398 DDM 009 or 1398 DDM 009X 1398 DDM 010X or 1398 DDM 010X AC Line Filter 23 Continuous Single Phase for 1398 DDM 019 or 1398 DDM 019X 1398 DDM 020 or 1398 DDM 020X AC Line Filter 30 Ams Continuous Single Phase for 1398 DDM 030 or 1398 DDM 030X AC Line Filter 55 Continuous Single Phase for 1398 DDM 075 or 1398 DDM 075X AC Line Filter 50 Continuous Three Phase for 1398 DDM 150 or 1398 DDM 150X AC Line Filter 36 Continuous Three Phase for 1398 DDM 075 or 1398 DDM 075X J1 to 50 pin Terminal Strip Breakout Board includes 1m 3ft cable and mounting hardware J2 to 25 pin Terminal Strip Breakout Board includes 1m 3ft cable and mounting hardware External Shunt Resistor for 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 030 or 1398 DDM 030X Fuse for External Shunt Resistor Littelfuse CCMR 4 5 for 1398 DDM 010 or 139
41. pin 26 TO pin 14 6 31 13 pin 1 J3 is a 26 pin female mini D ribbon connector AMP 2 178238 4 It duplicates the first 26 pins of J1 the Controller connector which are discussed in detail beginning on page 6 1 Contact between the connector shell and the grounded chassis provides shield termination Allen Bradley cables are available in various lengths for connecting between J3 and an auxiliary unit Options and Accessories on page A 1 lists the cables that are available Publication 1398 5 0 October 1998 6 32 Interfaces Table 6 23 J3 Auxiliary Connector Pin Outs Motor Encoder Pin Number Description Internal Connections 5V J3 1 Encoder 5 VDC 250 mA power source J1 1 J1 3 J3 3 for auxiliary encoder electronics J3 1 J3 3 The output is fused internally by a 1 Amp fast acting fuse F2 Refer to 5 Volt Power Supply Specifications on page 6 4 ECOM J3 2 Encoder common Signal reference for the J1 2 J1 4 J3 4 auxiliary encoder J3 2 J3 4 Refer to 5 Volt Power Supply Specifications on page 6 4 24V J3 5 Isolated 24 VDC 500 mA power source J1 5 J3 26 for external I O connection J1 26 This output is fused internally by a 1 Amp fast acting fuse F1 Refer to 24 Volt Power Supply Specifica tions on page 6 3 24VCOM J3 6 Isolated 24 Volt common J1 6 43 13 Refer to 24 Volt Power Supply Specifica 41 13
42. 10 1 314 Time vector t 0 0 01 0 5 Time Constant seconds 0 866 R 2 7 1 t 0 083 T Publication 1398 5 0 October 1998 F 4 Dynamic Braking Resistor Selection Current Calculation Amps Kg 0 0 866 R 2 i t 40 i t 20 Instantaneous Power Calculation Watts ee eee m eis M NA uim R 2 R 110 7500 P t 5000 2500 0 0 05 0 1 0 15 0 2 Average Power Watts Kg oe plo zl 1116 Publication 1398 5 0 October 1998 Appendix G Specifications Item Agency Approvals UL and cUL CE mark Environmental Operating Temperature 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 050 or 1398 DDM 050X 1398 DDM 075 or 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Storage Temperature Humidity Altitude Vibration Shock Weight 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 050 or 1398 DDM 050X 1398 DDM 075 or 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Dielectric Withstanding Voltage HI Pot Main AC Auxiliary AC Motor Encoder Interface Power Output Encoder Inputs Thermostat Inputs Hall Inputs ABS Input User Interface Serial Port Status Display Address Switch Digital Inputs Specification UL508C File E145959 Low Voltage Directive and Electromagnetic Compatibility Directive Certificate of Conformit
43. 10 1 Chapter 11 Appendix A Appendix B Appendix C Table of Contents Intro 5 Error Messages du ed Eb um xU wa wk ae 10 2 Run Time Error 5 10 2 Power Up Error 5 10 3 Maintenance and Troubleshooting Maintenance 11 1 Periodic Maintenance 11 1 Fuse Replacement 11 1 EEPROM Personality Module 11 2 Firmware Upgrading 11 5 Firmware Upgrade Procedure using ULTRA Master 11 5 Troubleshooting s 000000004 11 6 Error Codes sss ka ore Bee REE epo RUP Rp S 11 6 RS 232 Communication 11 11 Testing Digital Outputs 11 12 Testing Digital Inputs 11 14 Testing Analog 5 11 14 Testing Positive and Negative Current Limits 11 15 Testing Encoder 11 17 Options and Accessories ULTRA 200 Series A 1 vta Ua ee ES aar A 2 Options and Accessories A 2 Publications 24 4 0 44 644 84444 004405044 S EY v E A 3 Interface on E ER a A 3 Serial Interface Cables A 3 Encoder Feedback Cables A 4 Motor Po
44. 20 VDC 28 VDC ON state ON state Current Current flow into the input to guarantee an 3 5mA 5 5 mA ON state OFF state Voltage Voltage applied to the input to guarantee an 1 VDC 3 VDC OFF siate OFF state Current External leakage current into the input to 0 5 mA 0 5 mA guarantee an OFF state Publication 1398 5 0 October 1998 Interfaces 6 7 Input Interface Circuit Examples Figure 6 2 Drive Input Connected to a Switch Relay Contact J1 Drive 24 VDC imu 24COM Figure 6 3 Drive Input Connected to an Opto Isolator J1 Drive 24VDC 2 yw 5K ZN A 24VCOM Figure 6 4 Drive Input Connected to an Active High Sourcing Transistor J1 Drive 26 24VDC W 5K ONG gt 24VCOM Figure 6 5 Drive Input Connected to Active Low Output using a Switch Relay OUTPUT INPUT pe Fj Drive 24VDC ES c M 4 4 x 24VCOM EE Publication 1398 5 0 October 1998 6 8 Interfaces Figure 6 6 Drive Input Connected to Active Low Output using an Opto Isolator OUTPUT 24VCOM L we zva 24 INPUT Drive 24VDC 5K AM x a NY 24VCOM Figure 6 7 Drive Input Connected to Sourci
45. Chapter 8 Table of Contents Intro 3 J2 Terminal Strip Breakout Board 6 30 13 Auxiliary Port 6 31 J5 Serial Port 6 34 Serial Communications Overview 6 36 RS 232 Connections i243 ee x va EY CURE S 6 38 Four Wire RS 485 6 40 A2 and COM Analog Outputs 6 44 Interface 6 45 Power Connections TBi DCBusand 7 1 Motor Power Cabling 7 3 Motor Overload Protection 7 5 Emergency Stop 7 6 DC Bus EER ees 7 6 AC Power 7 7 Auxiliary Power 7 10 TB2 ShuntRegulator 7 11 External Shunt Connection 7 14 Application and Configuration Examples Analog Control 8 1 Hardware Setup s 2 6 ke et aes 8 1 Connection 8 2 8 3 zu SRE EM OS 8 4 Operation k ath paga Oe a Pu a 8 5 Pr esetController ay ee eS 8 6 Hardware Setup s ec esre a 8 6 Connection
46. Parameter Data Retention Microcontrollers 2 EPROM RAM User Parameter Memory 2 Motor Overload Protection PWM Carrier Frequency 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 050 or 1398 DDM 050X 1398 DDM 075 1898 DDM 075X 1398 DDM 150 or 1398 DDM 150X Current Regulation Type 3dB Bandwidth 45 Bandwidth Resolution Speed Regulation Type Publication 1398 5 0 October 1998 Specification 24 Volt Optically Isolated Single ended Active High Current Sinking 4 5 mA nominal 24 Volt Optically Isolated Single ended Active High Current Sinking 4 5 mA nominal 24 Volt Optically Isolated Single ended Active High Current Sourcing 50 mA maximum 24 Volt Normally Open Relay 1 A 24 Volt Normally Open Relay 100 mA Isolated 24V 250 mA fused 0 to 10 Volt 10 bit single ended 5 kOhm input Imped ance 0 to 10 Volt 10 bit single ended 5 kOhm input Imped ance 10 Volt Differential 16 bit 13 kOhm input Impedance offset software adjustable 0 to 10 Volt 12 bit 2 mA maximum O to 10 Volt 8 bit 2 mA maximum 26LS33 Input 4 MHz Count Frequency Differential Single ended A B Step Direction CW CCW 5V 250 mA fused AM26C31 or AM26LS31 Differential Driver Divide by 1 2 4 or 8 Differential output is 2 0 Vdc across a 100 Ohm load 20 years Motorola 68HC16 128 kB Flash Memory 34 kB 512 kB Serial EEPROM Motor overload protection operates withi
47. Publication 1398 5 0 October 1998 L 3 as 3715 331138 815 803 0350 38 NWO L332V 0301 083 1345948 FHL OL SNIdW 19 AB 0131 5 5 011 11918 1 201 2 83101 SNOI LO XVW 20 KYW 20 4 S3HONT 95 66 1 S NnOH ONY SNE QNnONO NOWNOD WAOW3H 83804 133W 01 38100938 38 31815504 SV 1HOHS SV 193 38 0 39uvH2SIO 3810938 ONY 51 3 8 5 5 015 3 410 3 5310008 30 JHL 9NIAOUGNTI 312345 35TMH3HIO 1 NO 038 30 IN3S3Hd SI Od 1 1 Q3AOH3H SI JHL 0L 112 Installation SHOLOM 0123 02 AM u3MOd NO104 S0123NNO2 H3MOd 010 xn Xm 11 INO WY 804 15 OVA 338 ifd S SE NI NOLLINI STWNIWHAL 30 4831 803 8261 1016 9 03573 HO 13H21 803 03811038 03483580 38 01 0 5 SNOIIV7093H 10207 NMOQO H3MOd ET Jw Q3H3M0d AlddNS EOl0H 9NIONnOSNS 1193108d 01 1339vuH INNS S30 VA 030N34N02 1H 3181550 138 ONIMIM 831714 123010 411718 Q3sn 01 318V2 80 M3MOd NIV N3 M 03 340 38 1575 LOANNOD HzMOd 371004 JAIXO NIVHI AST W3idV 310004 3 1 0 30 5 1 15 21150
48. Publication 1398 5 0 October 1998 Hardware Setup Make the connections described below and shown in the Figure 8 9 The appendix Options and Accessories on page 1 lists the interconnect cables available from the factory 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series A simple 3 wire cable is depicted in the figure below Connect a Motor Feedback cable from the motor to the J2 connec tor on the ULTRA 200 Series Connect a Power cable from the motor TBI terminals R S and on the drive Connect the Index Sensor to the drive as shown in the diagram Connect a jumper wire with a toggle switch between the follow ing pins J1 20 ENABLE and J1 26 PWR e J1 32 INPUT1 J1 26 I O PWR J1 33 and J1 26 PWR 11 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches Connect the drive to a 100 240 VAC 50 50 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Application and Configuration Examples 8 35 Connection Diagram Figure 8 9 Registration
49. Sv 1HOHS SV 143 38 CINOHS 831714 MINON N33M138 31713 SVH LONI IHL H3MOd NOdN SOUVHOSIC SLNSYYND 39V3v31398V 13AVH SH311I3 INIT Ov NOLLOVO 3AI1O3HId A 1ITISVIVdWOO O9I13NOVWOH10313 NV3dOHn3 3HL 133A OL G3HI O3H OLLANOWWOYLOS T3 STINGOW JAYA SNIAOHdNWI HO G3Sn 38 OL 318 0 HOLOW lt H311I4 INIT Ov JOYNOS AlddNS OW H3H1O HO H3NHO4SNVH1 INO WOU G3H3MOd 38 AVN 54 31dLLT0W H0OO9O LINW4 JAYA Y lt SI G3AON3H SI H MOd NIVW N3HM G3N3dO 38 LSNW 1 AlddNS OV 3H1 OL 193 SNOLLO3NNOO 31VHVd3S SAV SNOLLO3NNOO H3MOd JINON 3AIHQ NIVHO ASIYA LON OG 15 OVA 082 SOVLIOA LndNI 3SVHd 3T9NIS SWH OVA 092 001 G3LWH anOuO1 LON LNG 03395 NOLLONGAY V NILINSSY SOVLIOA 1 ndNI 30 LN30N3d3QNI SONILVH 1 STVNIWYAL NOLLdO LNNHS TVNH31X3 JO TVNINH31 8281 1016 33S 1 TVNH3LNI AHOLOV4 1V G3TIV1SNI 0135 Q3HO IMS 38 AVIA 7 XNW 21 21 30 GVALSNI G3SN SI TWHLNAN Q3qN Ot 9 Q3At3S8O 38 TINOHS 1V901 AL33VS 9 GSYINOSY SI 391430 SNLLO3NNOOSIG AlddNS V SWH OWA S9
50. ferential quadrature or TTL level J3 19 encoder inputs The input circuits shown in the following diagrams support connections to differential TTL line drivers single ended TTL line drivers and open collector devices These inputs are selectable under software control Table 6 20 Quadrature Interface Specifications Specification Description Minimum Maximum ON State Voltage Voltage difference between the and Volts inputs that indicate an ON state 1 0 15 OFF State Voltage Voltage difference between the and Volts inputs that indicates an OFF state 1 0 15 Common Mode Voltage difference between an encoder sig Voltage Volts nal input and the reference ground of the 15 15 drive Current Draw Current draw into the input or input mA 5 5 A or B Signal Frequency of the A or B line inputs Count Frequency MHz frequency is 4 times this frequency since the 1 circuitry counts each of the four transitions in a single line Index Pulse Width Pulse width of the index signal The index nsec signal is active for a percentage of the revo 500 lution therefore the speed of the encoder dictates the pulse width Publication 1398 5 0 October 1998 Interfaces Interface Cable Examples 6 21 The use of differential signals is highly recommended This is due to the immunity of differential signals to common mode interference Single ended encoder interface circu
51. 0 125 of a motor revolution is 1000 counts given that the motor has a 2000 line 8000 count encoder 4 Select the Acceleration Label cell and change RPM sec to Revs sec Publication 1398 5 0 October 1998 8 46 Application and Configuration Examples Publication 1398 5 0 October 1998 5 Select the Acceleration Conversion Factor cell and change 1 to 016 Mathematically 1 6 x 107 revs sec is 1 RPM sec given the motor has a 2000 line 8000 count encoder 6 Choose OK to exit the PC Display Units dialog The modified units will be displayed where appropriate within the ULTRA Master windows For example these changes cause the Indexing tab in the Drive Parameters window to display e Distance in Mtr Revs e Acceleration Revs sec e Deceleration in Revs sec The following units were not effected by the changes Dwell in msec e Velocity in RPM Tuning Guidelines Chapter 9 Tuning ULTRA 200 Series drives are tuned quickly and easily for a wide variety of applications Two tuning modes are available through the software e Auto Tune e Manual Tune The following tuning guidelines briefly describe the tuning adjustments These guidelines provide you with a basic reference point should the application require additional adjustments General Tuning Rules 1 Tune the velocity loop first and then if the drive uses following or step direction commands tune the position loop 2 To widen th
52. 10 Motor Encoder Output Signals Figure 6 20 Output Encoder Interface Circuit J1 Drive AMOUT AMOUT AMOUT AM26C31 261 531 The motor quadrature encoder signals are supplied to an external position controller The signals are differential quadrature and TTL level The output resolution is selectable and can be divided by 1 2 4 or 8 The signal frequency fout of the motor encoder output in Hertz Hz can be calculated with the equation Vm linecount fout 60 2 where Vm is the motor encoder velocity in rpm inecount is the number of encoder lines revolution of the motor mounted encoder and N is the output divider from the soft ware selected parameter 1 2 4 or 8 If the device connected to the motor encoder output counts all edges the count frequency is four times fout Publication 1398 5 0 October 1998 6 18 Interfaces For example a motor with a 2000 line encoder is rotating at 3000 rpm and the Motor Encoder Output signal is set to Divide by 1 the encoder signal frequency is _ 3000 2000 out 60 1 100kHz A counter counting all edges registers 400 kHz for this example Table 6 17 Motor Encoder Output Signal Encoder Pin Description Internal Output Number Connections AOUT J1 7 Motor Output Channels A and A Differential J3 7 AOUT J1 8 TTL levels from line driver Signal r
53. 1500 lines rev Maximum Speed 4000 RPM Index Offset 0 degrees Hall Offset 120 degrees Startup Commutation Hall Hall Invert Direction Unchecked Troubleshooting Custom Motor Files Problem Possible Causes Motor locks at a certain location Motor jumps once at startup Motor runs away Low torque production 1 Motor phasing is incorrect 2 Hall Offset is incorrect 3 Incorrect startup commutation 4 Incorrect encoder phasing 5 Incorrect pole count 6 Incorrect encoder linecount High audible noise from motor Velocity loop difficult to stabilize Shaft vibration 1 Incorrect motor resistance 2 Incorrect motor inductance 3 Inductance too low 4 Electrical time constant too low 5 Low encoder linecount Underdamped velocity response Overdamped velocity response 1 Incorrect motor inertia 2 Incorrect torque constant Publication 1398 5 0 October 1998 Appendix E Electromagnetic Compatibility Guidelines for Machine Design This appendix provides background information about Electromagnetic Interference EMI and machine design guidelines for Electromagnetic Compatibility EMC The ULTRA 200 Series installation requirements for compliance to the European Electromagnetic Compatibility Directive are specified in European Union Requirements on page 2 7 AC Line Filters necessary for European EMC compliance are listed in Chapter 5 Installation Perhaps no other subject rela
54. 19 50 20 12 4 1398 DDM 020X 1398 DDM 030 28 50 30 10 6 1398 DDM 030X 1398 DDM 075 28 50 30 10 6 1398 DDM 075X single phase 1398 DDM 075 28 50 30 10 12 1398 DDM 075X three phase 1398 DDM 150 46 68 60 6 20 1398 DDM 150X 1 In the United States the National Electrical Code NEC specifies that fuses must be selected based on the motor full load amperage FLA which is not to be confused with the drive input current The largest fuse allowed under any circumstances is four times the motor FLA Therefore the largest fuse permissible for use with the ULTRA 200 Series is four times the motor rated continuous current converted to an RMS value The ULTRA 200 Series has been evaluated and listed by Underwriters Laboratories Inc with fuses sized as four times the continuous output current of the drives FLA according to UL 508C In almost all cases fuses selected to match the drive input current rating will meet the NEC require ments 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 The fuse sizes listed are recommended values but local regulations must be determined and adhered to The ULTRA 200 Series utilizes solid state motor short circuit protection rated as follows Short Circuit Current Rating with No Fuse Restrictions Suitable for use on a circuit capable of delivering not more tha
55. 5 a setup and then press ENTER A message box will appear saying that the setup is initializing The message box may be present for up to 40 seconds depending on the speed of the PC 6 A dialog box requires you to confirm whether or not ULTRA Master should be installed on the hard drive C drive of the PC To install ULTRA Master choose Continue or press ENTER and continue with the next step To stop the installation choose Exit You are returned to Win dows 7 Setup then asks where you would like to install ULTRA Master To accept the path that Setup proposes in the Path box c ultramst choose Continue To choose another directory type a new path in the Path box and then choose Continue You will have the opportunity to confirm your entry so type carefully To return to the initial Setup window choose Back To stop the installation choose Exit You will return to Win dows To obtain on line help with the installation Choose Help 8 status bar will keep you informed of the installation progress When Setup is complete choose OK or press ENTER to return to Windows Publication 1398 5 0 October 1998 Starting and Quitting ULTRA Master ULTRA Master Installation 3 3 Version Level The release level and date for ULTRA Master may be displayed by selecting About ULTRA Master from the Help menu This information also appears in the initial ULTRA Master s
56. Chapter 7 Chapter 8 Publication 1398 5 0 October 1998 External Encoder Interface via TTL Differential Line Drivers Complementary Encoder Interface via 7406 Line Drivers with 5 Complementary Encoder Interface via Standard TTL Logic Single Ended Encoder Interface via Open Collector Transistor without Pull up not recommended Single Ended Encoder Interface via Standard TTL Signals not recommended Single Ended Encoder Interface via Open Collector Transistor with 5 VDC to 12 VDC Pull up not recommended Single Ended Encoder Interface via Open Collector Transistor with 24 VDC Pull up not recommended External Step Direction Interface via TTL Differential Line Drivers qo Gow SES PES kuk SH SSS OES External Step Direction Interface via Single Ended TTL Line Drivers not recommended External CW CCW Step Up Step Down Interface via TTL Differential Line Drivers External CW CCW Step Up Step Down Interface via Single Ended Line Drivers not recommended Motor Encoder Interface Circuit Hall Effect Sensor Circuit ULTRA 200 Series Motor Encoder Connections RS 232 485 Interface Circuit Sixteen Position Rotary Addressing Switch RS 232 Connection Diagrams
57. Disable the drive manually Choose Normal Drive Operation from the Tuning window Enable the drive Choose Close to exit the Tuning window Note Auto tuning does not have a velocity limit but it does adhere to the motor Overspeed setting in the Drive Parameters window Publication 1398 5 0 October 1998 9 6 Tuning Manual Tune Mode Manual tuning may be used to adjust the gain settings and filter frequency of the velocity regulator The following sections briefly explain these settings An understanding of the function for each type of gain and filtering will allow you to effectively tune the system Two types of manual tuning are available e Velocity tuning e Position tuning Before manual tuning is invoked the Velocity Distance and Motor Direction parameters must be set Refer to Auto Tune Mode on page 9 4 for information on setting these parameters The velocity loop should always be tuned before the position loop as velocity loop tuning affects the position loop response Gain settings and signal filtering are the primary methods to electrically tune a system A understanding of the types of gain and their purposes as well as a general understanding of filtering are essential background knowledge to properly tune a servo system Gains Table 9 1 Velocity Loop Gains Parameter Description P gain Proportional gain of the velocity regulator P gain controls the bandwidth of the velocit
58. Offset Use B for Horizontal Motor Yeocity npe For Help press Fl On Line 02 20PM OVERDAMPED Motor Velocity consistently undershoots the Velocity Command To correct Increase I gain Increase P gain Publication 1398 5 0 October 1998 9 12 Tuning Figure 9 6 Critically Damped Signal Ideal Tuning Unnamed Oscilloscope File Communications Window Help Ss aT ele 8 1S1 Channel A T Motor Vasca umm seat 8 v 6 v Channel Input Command Velocity Loo D d Scale E m Use B for Horizontal Sample Penod E mee Trigger H lode uso 206 mo 2003 For Help press F1 On Line 02 22PM CRITICALLY DAMPED Motor Velocity quickly settles to the Velocity Command Publication 1398 5 0 October 1998 Operating Messages Chapter 10 Status Display Two front panel indicators display the status of the drive on a continuous basis e The Status display shows the operating mode of the drive e The DC Bus LED lights whenever the bus is energized The 7 segment Status display indicates the drive status and operating mode After power up or reset the operating mode is indicated by a single letter message In the event of a fault a flashing code is displayed The drive operates in one of five command modes The mode of operation is dis
59. PWR J1 33 and J1 26 PWR 11 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches 5 Connect the drive to a 100 240 VAC 50 50 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Connection Diagram Figure 8 11 Absolute Indexing Connection Diagram DRIVE J4 XMT Motor 2 RCV Encoder ROV 3 XMT COM M Phase 1 Phase 2 Ji PhaseT 3 26 PWR Motor Gnd 4 Close to ENABLE Drive 20 ENABLE Close to RESET Fault h 21 FAULT RESET Close to Start INDEX N 32 INPUT1 100 240 VAC 50 50 Hz Close to Define LN 33 INPUT2 Single Phase Power Source or 100 240 VAC 50 50 Hz Three Phase Power Source Publication 1398 5 0 October 1998 Application and Configuration Examples 8 41 Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F o
60. START OF BEND RADI US y d 1 00 DIA MOLD NG 6 5 BRING TERMINAL 3 Ll 9 POSI TI ON CPC SHELL SIZE 13 W TH FEMALE SOCKET CONTACTS FACE VI EW Publication 1398 5 0 October 1998 BET 9 lt 6 CONDUCTOR LENGTH PRIOR FOLDING L MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE 4 12 85 12 7 25 25 5 25 12 W RI NG DI AGRAM BLACK PRINTED 1 BLACK PRINTED 2 BLACK PRINTED 3 GREEN YELLOW BLACK PRINTED 7 BLACK PRINTED 9 BR BLACK 16 AWG BR CONNECTOR ITT CANNON KPSE05E14 5S A71 Figure B 25 Cable Diagrams Schematics and Examples B 25 N Series Power Cable P N 9101 1467 CABLE SINE KA 50960 ULTI MAX 90 C 600 VOLT 4 16 AWG BRAIDED SHIELD 85 MINIMUM COVERAGE WIRING DIAGRAM moow gt aom ATTACH TO THE MOLDING ADAPTER AND WRAP WITH ALUMINUM FOIL TAPE BETWEEN THE SHIELD AND THE ADAPTER THE TAPE MUST MAKE CONTACT WITH THE ENTIRE SHIELD CIRCUMFERENCE AND ADAPTER CIRCUMFERENCE FERRULE INSULATED ALTECH 2205 0 MARK WITH ASSY P N amp REV 3 28 MFG 1 33 0 94 OVERMOLDING PVC BLACK MOLDING ADAPTER ALUMINUM BLACK COBALT PLATED P N amp REV amp DATE CODE 12 20 01 GLUE SHRINK 10 40 12 GRN YEL B
61. TouchPad also may be used The following examples depict a simple incremental index move and a batched multiple move using incremental indexing Figure 8 6 Incremental Indexing Examples INCREMENTAL INDEXING Batch count 1 Defined Velocity aa Velocity Defined Defined Acceleration Deceleration Dwell Outputs In Motion INCREMENTAL INDEXING BATCHED Batch count 3 Defined Velocity Defined Velocity Defined Velocity s un i Defined Defined Defined velocity Deceleration Deceleration X Defined Defined x Defined Acceleration Acceleration Acceleration Dwell Dwell Dwell Outputs In Motion Publication 1398 5 0 October 1998 8 28 Application and Configuration Examples Publication 1398 5 0 October 1998 Hardware Setup Make the connections described below and shown in the Figure 8 7 The appendix Options and Accessories on page 1 lists the interconnect cables available from the factory 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series A simple 3 wire cable is depicted in the figure below Connect a Motor Feedback cable from the motor to the J2 connec tor on the ULTRA 200 Series Connect a Power cable from the motor terminals R S and on the drive Connect a jumper wi
62. e One dedicated control ENABLE current sinking optically isolated active high input e Four selectable 24 Volt current sourcing optically isolated active high outputs e Two dedicated BRAKE and DRIVE READY normally open relay outputs Analog I O Two analog inputs are dedicated to current limits and two analog outputs can be customized to fit the application e Two dedicated 10 bit 0 10 Volt analog inputs I LIMIT and I LIMIT e Two selectable 10 Volt analog outputs one 12 bit and one 8 bit ANALOGI and ANALOG2 AC Input Power ULTRA 200 Series drives are powered directly from a main 100 240 VAC line e 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 and 1398 DDM 030X require single phase main power e 1398 DDM 075 1398 DDM 075X require either single phase or three phase main power e 1398 DDM 150 and 1398 DDM 150X require three phase main power Personality Module EEPROM electrically erasable programmable read only memory stores both motor and application specific settings and parameters for the drive in a removable personality module This module simplifies installation set up maintenance and reduces spares requirements Publication 1398 5 0 October 1998 2 4 Selecting Other System Components Publication 1398 5 0 October 1998 Multiple Protection Circuits Device and circuit protection and diagnostic information is provided by e Seven seg
63. each connector Each signal or set of signals is identified by Power requirements for driving the signal Functions performed by the signal Specifications including ON and OFF states Schematic depictions of the circuit design for each signal type The signals are grouped under the following connectors J1 Controller Diagrams show cable connections needed for common interfaces J2 Encoder Details information about the encoder signals Hall Effect switches and thermostat connections available through this connector e J3 Auxiliary Port Provides a second controller connection that duplicates the first 26 pins on J1 the Controller connector e J4 and J5 Serial Port Diagrams and instructions detail how to connect one or more drives using RS 232 communications in a single or daisy chain connection or to connect several drives using Multi Drop RS 485 A1 A2 and COM Analog Outputs Describes the connections that allow monitoring of the analog com mand signals with external equipment Additional Instructions and Manuals Title Power Connections Application and Configuration Examples Tuning Status Display Maintenance and Trouble shooting Options and Accessories Cable Diagrams Schemat ics and Examples TouchPad Instructions Creating Custom Motor Files Electromagnetic Compatibil ity Guidelines for Machine Design Dynamic Braking Resistor Selection Specifications Pref
64. identified by version information Only the files that can be applied to the connected drive are displayed which minimizes the danger of transferring an incorrect file To select the firmware files Select the appropriate file to upgrade the drive firmware Select OK when the file is highlighted A visual indicator traces the progress of the firmware upgrade Note Do not remove power or reset either the drive or the PC during the upgrade Any interruption of the firmware upgrade could cause the drive to become inoperable 7 When the upgrade is complete a dialog box confirms completion of the upgrade and reminds you that the drive must be reset at this time Select Yes if you want to perform a software reset of the drive Select No if you wish to reset the drive by removing power Publication 1398 5 0 October 1998 Troubleshooting Maintenance and Troubleshooting continuous basis Two front panel indicators display the status of the drive on a The Status display indicates the operating mode of the drive A F P etc The DC Bus LED lights whenever the main AC input is connected to line voltage A table of problems potential causes and appropriate actions to take to resolve the problem is included below Error Codes If problems persist after attempting to carefully troubleshoot the system please contact your local distributor for further assistance Table 11 1
65. no velocity command will be allowed in the forward direction If motion is in progress when the input is pulled low or disconnected the drive halts immediately without deceleration control The COMMAND sig nal is clamped internally to 0 Volts Reverse Enable Active state allows reverse commands in velocity mode only If this input is inactive or not connected no velocity command will be allowed in the reverse direction If motion is in progress when the input is pulled low or disconnected the drive halts immediately without deceleration control The COMMAND sig nal is clamped internally to 0 Volts Operation Mode Override Active state selects the Operation Mode Override setting as the command source Inactive state selects the Operation Mode setting as the command source Table 6 4 on page 6 5 lists the valid Operation Mode and Operation Mode Override combinations Publication 1398 5 0 October 1998 6 6 Interfaces Table 6 4 INPUT1 INPUT2 INPUT3 INPUT4 and FAULT RESET Functions continued Function Description Preset Select A Preset Select B Active or Inactive states select one of the eight presets shown in the follow ing binary table Preset Select C BINARY CODE C B A Description Preset 0 0 0 0 Preset 0 or Index 0 is selected Preset 1 0 0 1 Preset 1 or Index 1 is selected Preset 2 0 1 0 Preset 2 or Index 2 is selected Pr
66. 030 Gnd Pin 10 for DDM 075 using single phase or TB1 100 240 L2N 8 50 60 Hz L3 9 Three Phase Gnd10 Power Source Drive Checkout Test This test sequentially verifies that e Drive power wiring is correct and start up logic is functioning e The drive and motor are correctly wired e Drive serial communications are operational ATTENTION prepared to disable the drive or remove input power if excessive motor motion occurs while per forming the following steps Before beginning Initial Power up please check the following e All wiring and mounting to verify correct installation e Input voltages to ensure they do not exceed specifications for the drive or motor Unpacking Inspecting and Storing 4 5 Initial Power up 1 2 6 Verify the AC power is within specifications Switch the AC Power to ON and verify green DC BUS LED is ON display is not flashing Switch the power OFF and wait until the DC Bus Voltage is below 30 Volts to prevent electrical shock Connect the motor windings to R TB1 1 for the Phase R winding S 1 2 for the Phase S winding T TB1 3 for the Phase T winding 5 TB1 4 for the Ground connection Switch AC Power ON again and verify e green DC BUS LED is ON e display is not flashing Switch the power OFF and wait until the DC Bus Voltage is below 30 Volts to prevent electrical shock Communications Ve
67. 10 Transistor Output Specifications 6 11 Analog Inputs I LIMIT ILIMIT 6 14 Positive and Negative Current Limit Imput Specification 6 14 Analog Command Input 6 15 Analog Command Input Specifications 6 15 Analog Outputs ANALOG 1 and ANALOG2 6 16 Analog Output 6 17 Motor Encoder Output 6 18 Motor Encoder Output Specifications 6 18 Auxiliary Encoder Step and Diection CW amp CCW Step amp Down 6 20 Quadrature Interface Specifications 6 20 Step Direction CW CCW Step Up Step Down Interface 5 6 24 J2 Motor Encoder Connector Pin Outs 6 28 J3 Auxiliary Connector Pin Outs 6 32 J4 and J5 Serial Port Connector Pin Outs 6 35 Drive Addressing cp xe a Beg cas 6 36 Analog outputs ANALOG 1 2 6 44 Publication 1398 5 0 October 1998 Intro 12 List of Tables Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Appendix A Appendix B Appendix C Publication 1398 5 0 October 1998 Power Connections TB1 Motor Power 5 Motor Power Contact and Wire Sizing Recommendations 1
68. 3016 N K 790 H 3016 N L 1046 H 3016 N M 1302 H 3016 N N 1558 H 4030 M F 280 H 4030 M H 24 H 4030 M J 536 4030 792 H 4030 M L 1048 H 4030 M M 1304 H 4030 M N 1560 H 4030 P F 279 H 4030 P H 23 H 4030 P J 535 4030 791 H 4030 P L 1047 H 4030 M N 1560 H 4030 P M 1303 H 4030 P N 1559 H 4050 P F 281 H 4050 P H 25 H 4050 P J 537 4050 793 H 4050 P L 1049 H 4050 P M 1305 H 4050 P N 1561 H 4075 R F 282 H 4075 R H 26 H 4075 R J 538 H 4075 R K 794 H 4075 R L 1050 H 4075 R M 1306 H 4075 R N 1562 H 6100 Q F 283 H 6100 Q H 27 H 6100 Q J 539 H 6100 Q K 795 H 6100 Q L 1051 H 6100 Q M 1307 H 6100 Q N 1563 H 6200 Q F 284 H 6200 Q H 28 H 6200 Q J 540 H 6200 Q K 796 H 6200 Q L 1052 H 6200 Q M 1308 H 6200 Q N 1564 H 6300 Q F 285 H 6300 Q H 29 H 6300 Q J 541 6300 797 H 6300 Q L 1053 H 6300 Q M 1309 H 6300 Q N 1565 H 8350 S F 286 H 8350 S H 30 H 8350 S J 542 H 8350 S K 798 H 8350 S L 1054 H 8350 S M 1310 H 8350 S N 1566 H 8500 S F 287 H 8500 S H 31 H 8500 S J 543 H 8500 S K 799 H 8500 S L 1055 H 8500 S M 1311 H 8500 S N 1567 Publication 1398 5 0 October 1998 TouchPad Instructions C 11 Table C 2 TouchPad Motor Table Identification by Motor Series continued Motor ID Motor 10 Motor 10 Mot
69. 8 I I U THIS ER WHITE GREEN PIN THIS END 8 i EDEN 5 ORANGE A 9 POSITION 45 D SUB PLUG gt g iv WITH MALE PIN CONTACTS x WHITE ORANGE V ii T FACE VIEW DRAIN 6 9 X DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 Publication 1398 5 0 October 1998 B 14 Cable Diagrams Schematics and Examples Encoder Feedback Cables Figure B 12 P N 9101 1365 3 80 N N 01 36 STRUCTURAL ADAPTER F or H Series Motors to No Connector Encoder Cable E feet 8 38 1 MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE BLACK 28 AWG 0 ot Ji WHITE BLACK 28 AWG B Q 9 RED 26 AWS A 0 0 1 WHITE RED 28 AWG A D o 9 _ GREEN 28 AWG 6 ___WHITE GREEN 28 AWG A ORANGE 28 AWG H V A WHITE ORANGE 28 AWG v V NIC 18 AWG K GRAY 16AWG Az isaws MV L Aa 18 AWG Na 46 awe iz 7 MS3106F20 298 CONNECTOR SY BLUE 28 AWG N lt 9 9 FACE VIEW EN WHTEIBLUE 28 AWG AT X gt BROWN 28 AWS 17 WHITE BROWN 28 AWG VIOLET 28 AWG 7 __WHTEMOLET 28 AWG 5 V 5 YELLOW 20 AWG
70. CHA_HI 7 MtrEncdr Input Chnl A 4 9 MtrEncdr Input Chnl B 5 CHZ HI 11 MtrEncdr Input Chnl Index 12 CHA LO 8 MtrEncdr Input Chnl A 13 CHB LO 10 MtrEncdr Input Chnl B 14 CHZ LO 12 MtrEncdr Input Chnl Index NOTE A B 845 encoders are usually wired with the A signal into the A signal on the Allen Bradley drive Table B 2 9 260 or 9 290 to J1 Connector 9 260 or 9 290 8520 ASM 3 Drive Connections J1 J2 J3 Signal J1 Signal Pin Pin 3 CHA HI 7 Mtr Output Chnl A 4 CHB HI 9 Mtr Output Chnl B 5 CHZ HI 11 Mtr Output Chnl Index 12 CHA LO 8 Mtr Output Chnl A 13 CHB LO 10 Mtr Output Chnl B 14 CHZ LO 12 Mtr Output Chnl Index 9 DRIVE 22 Analog Cmd 18 DRIVE RET 23 Analog Cmd NOTE A B 845 encoders are usually wired with the A signal into the A signal on the Allen Bradley drive Table B 3 9 230 to Breakout Board 9 230 8520 ASM 4 Drive Connections Pin Signal J2 Pin Signal 11 CHA HI 7 MtrEncdr Input Chnl A 10 CHB HI 9 MtrEncdr Input Chnl B 39 CHZ HI 11 MtrEncdr Input Index 41 CHA LO 8 MtrEncdr Input Chnl A 40 CHB LO 10 MtrEncdr Input Chnl B 9 CHZ LO 12 MtrEncdr Input Chnl Index NOTE A B 845 encoders are usually wired with the A signal into the A signal on the Allen Bradley drive Publication 1398 5 0 October 1998 Cable Diagrams Schematics and Examples B 31 Ta
71. Continuous Output Current Amps 5 10 15 15 18 65 35 39 Peak Shunt Power built in resistor kWatts 4 5 4 5 4 5 10 0 18 0 Continuous Shunt Power built in resistor Watts 50 50 50 50 180 Peak Shunt Power external resistor kWatts 6 0 6 0 6 0 10 0 19 0 Continuous Shunt Power external resistor kWatts 2 4 2 4 2 4 4 0 8 0 Bus Capacitance Energy Absorption from 325 420 Vdc Bus Joules 41 69 97 152 266 Publication 1398 5 0 October 1998 G 6 Specifications Table G 1 ULTRA 200 Series Power Ratings continued 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010 020 030 075 150 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010X 020X 030X 075X 150X Bus Capacitance 1170 1950 2730 4290 7520 Peak Power Output kWatts 120 Vims 1 25 2 5 3 75 kWatts 240 Vims 2 5 5 7 5 14 19 36 20 3 Continuous Power Output kWatts 120 Vims 0 6 1 2 1 8 3 5 kWatts 240 Vims 1 0 2 0 3 7 5 30 15 32 a Bus capacitance energy absorption is based on the following equations 1 1 3C 9 53 _ 1 1 2 sC 420 5 325 if C 7520uF 266 b Power outputs are based on the following equation C 4202 3252 C 35387 Output Power in Watts rms Volts output Amps Publication 1398 5 0 October 1998 Power Dissipation Specifications The ULTRA 200 Series controller dissipates power t
72. END PIN 11 THIS END Cable Diagrams Schematics and Examples B 11 Serial Interface Cables Figure B 9 J5 to 9 pin D Shell Interface Diagram P N 9101 1372 E 2 st 28 1 MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE gt 15 FASTENS TO FEMALE SCREWLOCKS RED A 5 o U T rif WHITERED S a 3 7 6 31 31 2 PINT THSEND f WHITE GREEN N 1 5 E z 2 BLACK 2 tT 3 hi WHTEBLACK 1 7 1 PIN THIS END 9 POSITION 180 p SUB RECEPTACLE 4 8 WITH FEMALE SOCKET CONTACTS 9 POSITION 45 D SUB PLUG FACE VIEW WITH MALE PIN CONTACTS 6 1 FACE VE 7 4 I I 8 6 9 9 DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 Publication 1398 5 0 October 1998 B 12 Cable Diagrams Schematics and Examples Figure B 10 J5 to J5 Serial Interface Cable P N 9101 1374 NS Ji l x f 2 12 THREAD PROTRUSION b N X amp N f
73. Flag Publication 1398 5 0 October 1998 C 18 TouchPad Instructions Publication 1398 5 0 October 1998 Appendix D Creating Custom Motor Files Each motor controlled by a ULTRA 200 Series drive requires a unique parameter set The parameter set provides the drive with information about the motor necessary for proper commutation precise control and protection Two types of motor parameter sets can be selected for a ULTRA 200 Series drive using ULTRA Master software e Standard motors parameters reside in a motor lookup table stored in the drive Up to 65535 motors may be stored in the drive Custom motor parameters are created off line and downloaded to the drive s personality module EEPROM Only one custom motor may be stored in the drive Note Additional custom motors may be stored off line as files acces sible via a personal computer This appendix defines the motor parameters and explains how the drive uses the parameters to control the motor A step by step example details how to set up a motor file for an application using the motor s parameters Difficulties commonly encountered when creating custom motor files also are explained Note ULTRA Master Advanced is required to access Custom Motor features The Help menu in ULTRA Master explains how to access the Advanced features Publication 1398 5 0 October 1998 D 2 Creating Custom Motor Files Drive and Motor File Configuration with ULTRA
74. HOLO3NNOO H3MOd HOLOW JO 19945 swepe Bun amod ww0 9 LOMY 9 WWO SC OMY 0058 5 WWO OL OMV 8 lt WWO SZ OMY t OSE8 S H ES 00251 WWO OL OMY 8 WWO O OMY 8 EIE pcs 00195 INGQ 86EL tuuyaonv 3715 LOVINOO 10 103 HOLON 0SL INQQ 86 I WANININ YAMOd HOLOW QNO L S H S3HIM YIMOd HO LON psomby Publication 1398 5 0 October 1998 5 14 Installation Publication 1398 5 0 October 1998 J1 Controller Chapter 6 Interfaces This chapter provides information about e Interface signals available on the ULTRA 200 Series drive e Commonly encountered interface cabling methods e Optional signal extension kits and standard Allen Bradley cables Jl is a 50 pin female mini D connector AMP 2 178238 7 for connecting a host computer or controller to the ULTRA 200 Series drive Contact between the connector s shell and the grounded chassis provides shield termination This section lists the connector pin outs and provides signal specifications Allen Bradley cables are available in various lengths for connecting between J1 and a suitable controller Appendix A Options and Accessories lists the cables J1 Terminal Strip Breakout Board on page 6 26 details the optional signal extension kit that is available Publication 1398 5 0 October 1998 6 2 Interfaces
75. Index Pointer AOut2Cfi In Position Window Anal Out 2 counts Term see Table D Index Termination AOut2Scl Out 2 Scale Analog or Presets units V A Hore Type AOut2Ofs Y ese vo Anal Out 2 Offset Home Vel mV OSpdWin Over Spd Homing Velocity Zero Speed Windo Overspeed Window Numeric rpm HomeAcel SpeedWin Home Accel Decel Speed Window Average Current Numeric rpm Amps Home Pos UpToSpd VelErTim Home Position Up To SpeedLimit Velocity Error Time Numeric rpm msec Home Ofs I Limit VelErLim Home Offset Move Dist Pos Current Limit Velocity Error Limit Numeric Amps rpm HomeAuto Limit Homing Auto Start Neg Current Limit see Table Amps Back off A Reverse if on sensor see Table Indexing Up to eight presets 0 7 are available using and keys e Up to nine index selections 0 9 are available using keys Publication 1398 5 0 October 1998 TouchPad Instructions 5 Figure C 3 TouchPad Command Tree sheet 2 of 2 oe E o _ ER BAL STATUS Lm gt DISPLAY
76. Input 1 Not Assigned as Inputs 2 through 4 Not Assigned as Outputs 1 through 4 20 Choose Close to exit the I O Configuration window Tuning Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 Choose the Tuning command icon from the Drive window 2 Select AutoTune from the Tuning mode group 3 Select the appropriate values for the following Auto Tune com mands Distance and Step Current 4 Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive Publication 1398 5 0 October 1998 8 16 Application and Configuration Examples Publication 1398 5 0 October 1998 7 Choose Normal Drive Operation from the Tuning window 8 Open the switch between J1 26 and J1 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Operation The drive is now configured as a Position Follower Master Encoder e The current loop is compe
77. J1 26 to start Index 0 3 Close the switch between J1 33 and J1 26 to define the Home position Modifying User Units Application and Configuration Examples 8 45 The units displayed for any ULTRA 200 Series drive may be modified using a PC with ULTRA Master software The PC Display Units help menu defines the various parameters displayed by ULTRA Master Default settings for Units are shown in Figure 8 12 Figure 8 12 Display Units Default Dialog Parameter Velocity Torque Position Unit Definitions PC Display Units Display System Units Cancel Label Conversion Factor RPM 1 RPM 1Amp counts 1000 counts Acceleration RPM sec 1 RPM sec Changing the Display Units Settings The following example changes the Label and Conversion Factor for the Position and Acceleration parameters This example assumes a 2000 line encoder 8000 pulses revolution e Position from Counts to Motor Revolutions e Acceleration from RPM sec to Revs sec Choose the Drive Parameters command icon from the Drive window and then select the Units button The PC Display Units dialog appears with default settings as shown 2 Select the Position Label cell and change counts to Mtr Revs Note Labels are limited to 8 characters 3 Select the Position Conversion Factor cell and change 1000 to 0 125 Mathematically 1 8
78. Motor Phasing The phasing of the back EMF and Hall feedback signals must be verified before a custom motor file can be created Allen Bradley motors use back EMF and Hall feedback signals phased as shown in Figure D 2 Motors not manufactured by Allen Bradley require the back EMF and Hall feedback signals be phased to match those of Allen Bradley motors Often this requires swapping of the R and T phase control signals with each other as well as swapping the Hall A Hall B and Hall C signals with each other Back EMF and Hall Signals Figure D 2 a shows the required phasing of the line to line back EMF signals and Figure D 2 b shows the proper phasing of the Hall feedback signals when the motor is rotating clockwise CW as seen looking at the motor shaft from the load The relationship of the Hall signals to the back EMF signals is not important at this stage However the sequencing of the back EMF signals must conform to Figure D 2 a and the sequencing of the Hall feedback signals must conform to Figure D 2 b Publication 1398 5 0 October 1998 D 4 Creating Custom Motor Files RS ST TR Figure D 2 Required Back EMF and Hall Signal Phasing for Clockwise Rotation a Required Back EMF Phasing b Required Hall Feedback Phasing Publication 1398 5 0 October 1998 Many motor manufacturers include drawings in their data sheets that identi
79. N WKY MARKED WITH XV PART AND REY MANUFACTURERS PART REV AND DATE CODE N MACH HUMBSC MACHINED THUMBSCREW FASTENS TO FEMALE SCREWLOCKS FASTENS TO FEMALE SCREWLOCKS Y RED HITE wwmmED 8 PIN 1 THIS END PIN 1 THIS END 1 1 7 WHITEIGREEN 9 L 7 H 2 Nic 2 3 PER 5 5 PIN THIS END PIN 6 THIS END I 9 POSITION 45 D SUB PLUG we 6 WITH MALE PIN CONTACTS 3 9 9 POSITION 45 D SUB PLUG Dii WITH MALE PIN CONTACTS FACE VIEW DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 BOTH ENDS Publication 1398 5 0 October 1998 Cable Diagrams Schematics and Examples Figure B 11 B 13 J5 to No Connector Serial Interface Cable P N 9101 1379 2 127 5 N 45 x S g 12 THREAD PROTRUSION EN DN N gt MARKED WITH BART AND REV NN MANUFACTURERS PART REV AND DATE CODE 2 K gt 4 40 RETRACTABLE MACHINED THUMBSCREWS FASTENS TO FEMALE SCREWLOCKS BLACK B y PIN 1 THIS END N A WHITE BLACK A 7 7 V 2 RED U X X A WHITE RED 4 J 3 J 7 GREEN A 4 8
80. Publication 1398 5 0 October 1998 Status Display 10 3 Table 10 1 Run Time Error Codes continued Status Display Error Code Fault Description 1 8 18 Motor Overspeed E 1 9 19 Excessive Following Error E 2 0 20 Motor Encoder State Error E 42 5 1 21 Auxiliary Encoder State Error 2 2 22 Motor Thermal Protection E2239 23 IPM Thermal Protection 2 4 24 Velocity Error E2255 25 Commutation Angle Error E 2 6 26 Reserved E27 27 Axis not Homed E 2 8 28 No Motor Selected E 2 9 29 Motor Selection not in Table 9 0 30 Personality Write Error E 31 Service Write Error E 9 2 32 CPU Communications Error Power Up Error Codes A power up error indicates in almost all cases that the drive should be returned to the factory for service In general any occurrence of a Power up error should be treated with extreme caution It may indicate the hardware is marginal Situations that may cause drive hardware errors and which can be remedied outside the factory include The drive is powered down while a firmware upgrade is loading into flash memory A program memory error occurs when power is reapplied To remedy the problem reload the firmware using ULTRA Master A watchdog time out error may result from electrical noise electromagnetic interference EMI a firmware error or a hardware malfunction The context of the watch
81. SHIELDED 380 BOTH ENDS N C N C Cable Diagrams Schematics and Examples 28 POSITION CPC SHELL SIZE 17 WITH FEMALE SOCKET CONTACTS FACE VIEW PART AND REV MANUFACTURERS PART REV AND DATE CODE WIRING DIAGRAM Figure B 15 Connector to Y Series Encoder Cable P N 9101 1373 E 2 10 MES J 038 bs 1 16 MOLDING Publication 1398 5 0 October 1998 GRAY 16AWG 22 2 WHITE GRAY 16 AWG A BROWN 28 AWG WIEJBROWN 28 AWG YELLOW 28 AWG A WHIIENELIOW 28 AWG U V 5 BLACK 28 AWG WHITE BLACK 28 AWG RED A 28 AWG 45 WHITE RED 28 AWG T GREEN 28 AWS WHITE GREEN A 28 AWG ORANGE 28 AWS WHIIEIORANGE 28 AWG o BLUE 28 AWG _ 0 WHITE BLUE 28 AWG VIOLET 28 AWG T WHITE VIOLET 28 AWG 20 AWG DRAIN 1 NC 2 sir NC 5 7 18 20 21 25 26 27 28 B 18 Cable Diagrams Schematics and Examples Figure B 16 2 to No Connector Encoder Cable P N 9101 1380 0 38 d MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE
82. The ULTRA 200 Series drives do not require an isolation transformer The recom mended transformer sizes are the minimum that is adequate for most servo applica tions Larger transformers provide an additional safety factor The additional safety factor may occur in applications that require minimum bus voltage sag when the tinuous power requirements Publication 1398 5 0 October 1998 motor must accelerate to high speed in minimum time or in applications with high con TB2 Shunt Regulator Power Connections 7 11 The ULTRA 200 Series drive has a built in shunt regulator The figure depicts the internal shunt selection with a factory installed jumper between terminals TB 1 and TB 2 Removal of the internal shunt jumper and installation of an external shunt between terminals TB 1 and TB 3 allows voltage to be dissipated at a faster rate than possible with the internal shunt Terminal Identifier Description TB2 1 1 Positive DC bus Internal or z3 1 External 2 2 2 2 Internal shunt z Internal regulator resistor 2 3 3 Shunt regulator External transistor collector The shunt regulator is enabled when the DC bus increases to a specific value 420 VDC An increase in DC bus voltage always occurs when the drive decelerates the motor and its load This is due to the current flow from the
83. TouchPad may be used to monitor and configure the ULTRA 200 Series drive The TouchPad command structure is similar to the structure of ULTRA Master but operates through an abbreviated keypad interface The card TouchPad Instructions is provided with the TouchPad It describes the installation and operational instructions in a pocket sized directory The TouchPad Command Tree Card and additional instructions for the TouchPad are included in the section titled TouchPad Instructions which begins on page C 1 The TouchPad Command Tree Card is a graphical presentation of both the operational instructions and the command structure for the ULTRA 200 Series drives You may find it convenient to refer to the card when using the TouchPad with a drive Symbols and Conventions Preface Intro 19 Typographical and Wording Conventions This manual uses the following typographical and wording conventions Example Description gt Text preceded by right guillemet explains how to access the particular function in the preceding paragraph For example To Start ULTRA Master in Windows gt Choose the icon ULTRA Master Drive Set Up Text shown in this font and underlined indicates a Hot Key keystroke combina tion to quickly access a command For example Choose Drive Set Up indicates typing ALT D followed by ENTER accesses this command ULTRA Master Text shown in this font is information to enter in a window or dialog
84. Tuning Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 2 Choose the Tuning command icon from the Drive window Select AutoTune from the Tuning mode group Select the appropriate values for the following Auto Tune com mands Distance and Step Current Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only Publication 1398 5 0 October 1998 8 32 Application and Configuration Examples Publication 1398 5 0 October 1998 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive 7 Choose Normal Drive Operation from the Tuning window 8 Open the switch between J1 26 and J1 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Operation The drive is now configured as an Incremental Indexing controller e The servo parameters have been setup with the unloaded motor e Motion is commanded through the inputs The firmware saves the parameters in EEPROM memory Thus
85. all lines must be filtered to be effective The situation is similar to a leaky boat All the holes must be plugged to prevent sinking Publication 1398 5 0 October 1998 E 4 Electromagnetic Compatibility Guidelines for Machine Design CONDUCTED EMI Table E 1 POOR AC Line Filter Installation DRIVE lt AC CONDUCTED EMI LINE it lt RADIATED EMI FILTER h A RADIATED EMI Publication 1398 5 0 October 1998 GOOD FILTER DRIVE RADIATED EMI CONDUCTED EMI 4 ATTENTION Before applying power the filter must be safety grounded Without a proper ground current leakage could build to a hazardous level The only reasonable filtering at the drive output terminals is the use of inductance Capacitors would slow the output switching and deteriorate the drive performance A common mode choke as is used in the ULTRA 200 Series can be used to reduce the HF voltage at the drive output This will reduce emission coupling through the drive back to the AC line However the motor cable still carries a large HF voltage and current Therefore it is very important to segregate the motor cable from the AC power cable More information on cable shielding and segregation is contained in the section on shielding Electromagnetic Compatibility Guidelines for Machin
86. and Troubleshooting Table 11 1 Troubleshooting Guide continued Problem or Symptom Error Code Possible Cause s Action Solution Channel BM line 07 Bad connections Verify continuity of the encoder cable and connec tors Verify continuity of the BM and BM wiring signals Bad Encoder Replace the motor or the encoder Channel AM line 08 Bad connections Verify continuity of the encoder cable Verify continuity of the AM and AM wiring signals Bad Encoder Replace the motor or the encoder Bus Undervoltage 09 Low AC line AC power input Verify voltage level of the 100 V AC minimum for safe incoming VAC power drive operation Check main VAC power source for glitches or line drop below 90 VAC Install an uninterruptible power supply UPS on your VAC input Bus Overvoltage 10 Excessive regeneration of Change the deceleration or power motion profile and or reduce When the drive is driven by the reflected inertia of your an external mechanical mechanical system power source it may regen Use a larger system motor erate too much peak energy ang drive through the drive s power supply The system faults to save itself from an overload Excessive AC input voltage Verify input is below 264 VAC Output short circuit Check for shorts Motor cabling wires shorted Check for shorts together Internal motor winding short Check for shorts circuit Illegal Hall State 11 Inco
87. and the SENSE signal must be connected to the ECOM sig nal at the encoder for the motor encoder signals to be received properly by the drive A J2 7 Motor Encoder Input Channel A and Channel A Accepts TTL J2 8 level signals from a line driver B J2 9 Motor Encoder Input Channel B and Channel B Accepts TTL J2 10 level signals from a line driver J2 11 Motor Encoder Input Channel I and Channel Accepts TTL 42 12 level signals from a line driver Output pulse occurs once per motor shaft revolution Publication 1398 5 0 October 1998 Table 6 22 Interfaces 6 29 J2 Motor Encoder Connector Pin Outs continued Motor Encoder Pin Number Description HALL A J2 13 Hall Effect A sensor logic level input Internally pulled up to 5VDC through a 1 kOhm resistor The input signal interfaces to both a differential and single ended Hall effect sensor using either a TTL level signal or open collector signal A differential output connects only the output to the drive Software determines when the hall effect sensors are in an illegal state HALL B J2 14 Hall Effect B sensor logic level input Internally pulled up to 5VDC through a 1 kOhm resistor The input signal interfaces to both a differential and single ended Hall effect sensor using either a TTL level signal or open collector signal A differential output connects
88. box For example Choose the icon ULTRA Master win Text in lower case bold is information to enter at a keyboard For example To start Windows from the DOS prompt type win and then press ENTER ALT F48 Keys that should be pressed simultaneously are shown with a plus sign between the key names This example closes the active window ALT F N Keys that should be pressed in sequence are shown with a comma between the key names This example opens the File menu and then opens a new file Choose The wording indicates that an icon or a command is to be selected from a window or a command box For example the instruction for accessing the command icon Drive Set Up states Choose Drive Set Up Select The wording indicates that options are to be defined or selected from a list For example the instruction for accessing or entering information states Select Drive Type and Motor Model from the respective list box Type The wording indicates that commands are to be entered into a command box For example the instruction for loading ULTRA Master states Type a setup and then press ENTER gt Tips provide hints or shortcuts that are useful to know For example Note ULTRA Master always displays the Help menu Quick Start when it is first accessed To disable this automatic display choose the menu item Show Quick Start from the Help menu a Microsoft Windows res
89. cable through a restricted bulkhead Publication 1398 5 0 October 1998 B 10 Cable Diagrams Schematics and Examples q T J2 to 25 D Connector Cable P N 9101 1371 DB6 1 87 START OF BEND RADIUS EMALE SCREWLOCKS PIN THIS END PIN 14 THIS END Publication 1398 5 0 October 1998 FASTENS TO FEMALE n Ag 28 AWG 28 AWG MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE M2 6 x 0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR D GRAY 20 AWG ry 0 J aa WHITE GRAY 20 AWG D 28 ANG 12 5 228 _ 28 BLUE 28AWG WHITEJBLUE 28 AWG BLACK 28 AWG gt lt b WHITEPBLACK 28 AWG RED 28 AWG wemremep 20 aw y GREEN 28 AWG waeren 2eawo n YELLOW 28 AWG WHITEIYELLOW 28 AWG gt lt SRANGE 2B AWG WHITEJORANGE 28 AWG lt _WHITE BROWN 28 AWG _ gt i VIOLET 28 AWG 25 11 DRAIN we 8 DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 380 BOTH ENDS 1 THIS
90. drop down Motor Selection box Choose OK when the message appears advising that the drive must reset A change in motor parameters requires a software reset Choose Close from the Drive Setup window Select the Control Panel icon from the Drive Window The drive displays H Control Panel mode Refer to Operating Mes sages on page 10 1 for an explanation of drive displays Close the connection between J1 26 and J1 20 to enable the drive Holding torque should be sufficient so that the shaft is either immovable or very resistant to rotation Move the Slide Bar in the Control Panel window to the right and then to the left Verify that the motor rotates CW as the Slide Bar is moved right of center and e CCW as the Slide Bar is moved left of center If the motor rotates in the wrong direction CCW when the slide bar is set to the right of center or jumps and locks up motor phasing and encoder feedback phasing may be incorrect If necessary refer to Chapter 11 Maintenance and Troubleshooting for instructions on how to correct the motor power connections at TB 1 1 2 3 and 4 or the encoder feedback connections at J2 Choose Set to Zero The motor will stop rotating Choose Drive Disable and verify the motor shaft can be rotated by hand Storing the Unit Unpacking Inspecting and Storing 4 7 24 Choose Drive Enable and verify the motor shaft has holding torque i e The shaft cannot be moved or
91. each drive to an unassigned address If physical addressing is used set the rotary switch to a previ ously unused address 1 A If software addressing is used set the rotary switch to address F and then select a previously unused address 1 32 in ULTRA Master 2 Connect cables between The host computer and the serial port on the initial drive J4 in the multiple drive configuration The other serial port on the initial drive J5 and the serial port on the next drive J4 in the multiple drive configuration 3 Verify the communication settings on the computer are correct e Start ULTRA Master on the attached PC Choose CANCEL from the Drive Select window Select Communications from the menu Select PC Set Up from the pull down menu Verify the port settings and if necessary change them then choose OK Note Address 0 is the preferred address for the initial configuration of a drive It forces the drive to the default communications parameters 4 Verify the ability to communicate between the computer and the connected drives by Switch drive power to ON Select Communications from the menu Select Read Drive Parameters from the pull down menu Select the drive to communicate with from Drive Select win dow the drive must have an address that matches one of the drive addresses in the chain e Choose OK in the Drive Select window 5 Verify that ULTRA Master loads the drive param
92. from either output when the relay contacts 0 01 mA are open OFF state Voltage Voltage difference between the outputs with open relay 50 Volts contacts Publication 1398 5 0 October 1998 6 10 Interfaces Table 6 7 BRAKE Output Specifications Parameter Description Maximum ON state resistance Internal resistance between J1 49 and J1 50 when 1 Ohm the contacts are closed ON state current Current flow through the relay when contacts are closed 1A OFF state current Leakage current from either output when the relay contacts 0 01 mA are open OFF state Voltage Voltage difference between the outputs with open relay 50 Volts contacts Figure 6 9 Digital Output Circuit J1 Drive 24VDC Selectable Output Circuits Table 6 8 General and Dedicated Outputs Digital Pin Function Description Internal Con Output Number nections READY J1 24 J1 Relay closure indicates the drive does not have a J3 24 25 fault Refer to READY Output Specifications on J3 25 page 6 9 BRAKE J1 49 J1 Relay closure releases the brake Delay time is 50 selectable Refer to BRAKE Output Specifications on page 6 10 OUTPUT 1 J1 42 General purpose output Selectable from one of sev OUTPUT 2 J1 43 eral drive functions Refer to Table 6 9 OUTPUT 3 J1 44 OUTPUT 4 J1 45 Table 6 9 OUTPUT1 OUTPUT2 OUTPUT3 a
93. gain defined 9 6 Illegal Hall State 11 8 IM Line see Troubleshooting Incremental Indexing 8 27 Indexing Absolute 8 39 Incremental 8 27 Registration 8 33 Indicators DC Bus 10 1 Status 10 1 Inertia 9 2 Input Frequency 7 7 Power 7 9 Inrush Current Fusing 7 10 Inspection Procedures Checkout Test 4 4 Communications Verification 4 5 Hardware Set Up 4 3 Initial Drive Operation 4 6 Initial Power up 4 5 Shipping Damage 4 1 Installing External Shunt Regulator 7 14 Software 3 2 TouchPad C 1 Instructions see Software Interconnect Cables European Union Directives 5 6 Schematics and Diagrams B 3 Interface Connections 5 5 Signals 6 1 IPM see Troubleshooting Isolation Transformer 7 9 7 10 Index 3 Analog Command Signal 6 15 Inputs 6 14 Outputs 6 16 Auxiliary Encoder Inputs 6 19 Circuit Examples 6 7 Dedicated Relay Outputs 6 9 Digital Inputs 6 4 Outputs 6 9 Interface Cable Examples 6 21 Motor Encoder Signal 6 17 Output Circuit Examples 6 11 Pin outs 6 1 Power 6 3 Selectable Outputs 6 9 J2 Pin outs 6 27 Terminal Strip Breakout Board 6 30 J3 Pin outs 6 31 J4 Pin outs 6 34 J5 Pin outs 6 34 Jumper Locations 11 1 K Kd gain 9 7 Kff gain 9 7 Ki gain 9 7 Kp gain 9 7 L LED DC Bus 7 6 10 1 Status 10 1 Line Filters 5 7 Location of Fuses 11 1 Jumpers 11 1 Low Pass Filter G 3 Main Power see Power Maintenance 11 1 Cleaning 11 1 Fuses 11 1 Manual Tune Filter Adjustment 9 7 Guidelines 9 6 Publ
94. gt or key For example If the Over Spd in the Modify mode displays 5200 and 52 is flashing pressing the key causes 520 to flash e Press the 7 or key to increment or decrement these numbers For example If the Over Spd value is 5200 and 52 is flashing pressing the key causes the setting to increment by 100 rpm each time the key is pressed e Parameter values may not exceed the maximum or minimum limits regardless of the cursor position TouchPad Instructions C 7 For example If the SpeedWin setting is 5000 rpm and the Maximum Speed in the motor table is 5200 pressing the key increases the parameter to 5200 the upper limit but pressing the lt key decrements the parameter to 4000 The most significant digit is reserved when a parameter allows a negative setting or the parameter provides a list of possible selections The 7 or key toggles the minus sign List The most significant digit is reserved for an active inactive selection marker when a parameter provides a list of possible selections e A filled arrow in the most significant digit indicates the active setting from a list of possible settings Inactive settings are indicated by unfilled arrow For example If the drive is functioning as Preset Controller in the Velocity mode pressing the key from DRVPARAM scro
95. moves with resis tance 25 Open the connection between J1 26 and J1 20 to disable the drive 26 Choose Close from the Control Panel window A drive completing these steps is functional If the ULTRA 200 Series drive did not pass the steps above refer to Troubleshooting on page 11 6 Note For information on testing digital and analog signals refer to Testing Digital Outputs on page 11 12 Testing Digital Inputs on page 11 14 Testing Analog Outputs on page 11 14 and Testing Pos itive and Negative Current Limits on page 11 15 Return the ULTRA 200 Series drive to its shipping carton using the original packing materials to enclose the unit Store the drive in a clean dry place that will not exceed the following ranges e Humidity 5 to 95 non condensing e Storage temperature 40 to 70 C 40 to 158 F Publication 1398 5 0 October 1998 4 8 Unpacking Inspecting and Storing Publication 1398 5 0 October 1998 Mechanical Installation Requirements Chapter 5 Installation Mount the unit in an enclosure providing protection to IP54 pro tected against dust and splashing water or IP65 dust free and protected against water jets if the work environment is poor Many NEMA National Electrical Manufacturers Association Type 4 cabinets provide this level of protection Minimum cabinet requirements are e Depth 30 5 cm 12 in Adequate sizing and or ventilation to d
96. of 10 to 10 Volts ATTENTION The user may need to provide an external circuit to delay output of the analog signal when the signal is used to perform an operation After reset both analog outputs may be in an indeterminate state for a short period before they stabilize at the setting stored in memory Failure to observe this precaution could result in severe bodily injury Table 6 15 Analog Outputs ANALOG 1 and ANALOG 2 Analog Output Pin Description Internal Number Connections ANALOG 1 J1 30 Selectable analog output with 12 bit resolution Dis 1 plays the selected firmware variable along with selectable scale and offset refer to the ULTRA Master Configuration section ANALOG 2 J1 31 Selectable analog output with 8 bit resolution Dis A2 plays the selected firmware variable along with selectable scale and offset refer to the ULTRA Master Configuration section ACOM J1 28 Analog Common return COM Publication 1398 5 0 October 1998 Interfaces 6 17 Table 6 16 Analog Output Specifications Specification Description Minimum Maximum ANALOG 1 Number of units that the ANALOG1 output Output Resolution voltage is converted into Bits 12 ANALOG 2 Number of units that the ANALOG2 output Output Resolution voltage is converted into Bits 8 Output Current Allowable current draw of the load 2 mA 2 Output Signal Range Voltage range of the signal Volts 10
97. potential sources of severe electrical shock Follow the safety guide lines to avoid shock 4 Refer to Figure 11 1 for the location of the personality module 5 Grasp the EEPROM with an IC chip puller to remove the person ality module To install the EEPROM on a drive 1 Remove all power from the drive 2 Remove all connections to the front of the drive 3 Remove the protective cover by removing the screws attaching the right side cover to the chassis ATTENTION Electronic components are subject to damage by static electricity Follow Electrostatic Discharge ESD practices while handling components 4 Refer to Figure 11 1 for the location of the personality module Maintenance and Troubleshooting 11 3 5 Align the notch on the front of the personality module and the matching notch on the socket 6 Place the properly orientated personality module in the IC chip insertion tool Ensure the chip and socket notches are aligned 7 Pushthe personality module firmly into the socket 8 Install the protective cover and tighten the screws 9 Reconnect the cables to the front of the drive 10 Reapply power to the drive Note Some combinations of firmware and personality modules are incompatible they will generate an error message after replacement Consult Error Codes on page 11 6 for the recommended action solution Data Transfer After you have configured the drive and tuned the drive the data sto
98. ratio requires more than eight characters the ratio is displayed in two parts a Master Ratio and a Follower Ratio The position of the colon after or before each numeric value indicates Master or Follower for these larger ratios The and keys toggle between the Master Ratio and the Follower Ratio For example A Master to Follower ratio on 1001 1000 is displayed in two separate displays The Master Ratio is displayed as 1001 and pressing displays the Follower Ratio 1000 TouchPad Instructions C 9 Fault Error Warning Table C 1 lists the possible fault error and warning messages that may appear on the TouchPad The items below describe the different types of messages e The TouchPad displays Fault and a description A Fault message requires additional troubleshooting of the drive Clear the fault display by depressing the 7 and keys simultaneously Fault codes are stored in the TouchPad parameter DrvStat and are explained with troubleshooting guidelines in Table 11 1 on page 11 6 e The TouchPad alternately displays Error and the error name Clear an error by pressing the key e The TouchPad momentarily displays and then clears a warning when an invalid entry is made Table C 1 TouchPad Fault Error Warning Displays Display Level Description BufOvFlo Error Communications buffer overflowed Can tDo Error An inval
99. read approximately 1 Vdc Maintenance and Troubleshooting 11 15 6 Repeat step 11 1 using different positive or negative values for the D A Level Verify the meter reads the values you enter Testing Analog Output 2 1 Disable the drive by opening the connections between the ENABLE input and the 24 VDC Disconnect the connections to J1 31 Select Output Diagnostics icon from the Drive Window From the Output Diagnostics window select Analog Output 2 Enter 1000 in the D A level box Sy Connect a DC voltmeter across analog test points 2 The meter should read approximately VDC 7 Repeat step 11 1 using different positive or negative values for the D A Level Verify the meter reads the values you enter If either output is defective return the unit for repair Testing Positive and Negative Current Limits The following tests verify the functionality of the analog I LIMIT and I LIMIT inputs The tests require a PC running ULTRA Master and 10 kOhm potentiometer Testing Positive Current Limit 1 Verify the accuracy of the potentiometer with ohmmeter before installing 2 Disable the drive by opening the connections between the ENABLE input and 24VDC 3 Disconnect the connections to J1 27 and 71 28 4 Connect the 10K potentiometer between J1 27 and J1 28 Refer to J1 Controller on page 6 1 for a diagram showing the location of the pins and Figure
100. termination Figure 6 37 5 232 485 Interface Circuit INT EXT XMT RECEIVE ROV RS 232 TRANSMIT AMT XMT TRANSMIT RCV b RCV RS 485 The serial interface of the ULTRA 200 Series uses the standard NRZ asynchronous serial format and supports both the RS 232 and the four wire RS 485 communications standards e Standard baud rates include 1200 2400 4800 9600 and 19200 baud 9600 is the factory default setting Interfaces 6 35 Even odd and no parity generation checking are supported No parity is the factory default setting The maximum number of ULTRA 200 Series drives allowable on an RS 485 bus is 32 The maximum length of an RS 232 cable is 15 meters 50 feet The maximum length of an RS 485 cable is 1220 meters 4000 feet with 0 20 mm 24 AWG wire Allen Bradley cables are available in various lengths for connecting to the serial port of an ULTRA 200 Series drive and a control unit such as a PC Options and Accessories on page 1 lists the cables and the male and female connectors for the cables gt Note The shell of the connector is grounded to the chassis for shield termination The following table lists the pin outs for J4 and J5 Table 6 24 J4 and J5 Serial Port Connector Pin Outs Signal Pin Number Description Internal Connecti
101. the connector e The allowable load is lt 250 mA e The pin outs are 5 VDC J1 1 J1 3 J3 1 ECOM J1 2 J1 4 J3 2 This supply is intended for powering an auxiliary encoder J3 3 J3 4 The 5 Volt power supply is internally fused by F2 a 1 Amp fast acting fuse Refer to Fuse and Jumper Locations on page 11 4 for the location of F2 Publication 1398 5 0 October 1998 6 4 Interfaces Table 6 2 5 Volt Power Supply Specifications Parameter Description Minimum Maximum Output Voltage Voltage between 5VDC and 5VCOM VDC 4 75 5 25 Output Current Current flow mA 0 250 Publication 1398 5 0 October 1998 Digital Inputs ULTRA 200 Series drives have active high current sinking inputs which prevent disconnects and ground faults from activating a drive Figure 6 1 Digital Input Circuit J1 Drive 5K 1K s 24VCOM Two discrete input circuits types are available on the 71 connector Both circuits support logic type interfaces with 24 Volt optically isolated single ended and active high current sinking characteristics Dedicated Control Circuits The ENABLE input interfaces with switch closures or sourcing type outputs The input channel sinks 4 5 mA nominal Selectable Circuits INPUT 1 INPUT 2 INPUT 3 INPUT 4 and FAULT RESET operate with switch closures or sourcing type circuitry Each input channel sinks 4 5 mA nominal Select
102. the motor power cable must be properly grounded at both ends the shield is grounded at the motor end when the MS connector is mated Publication 1398 5 0 October 1998 Cable Diagrams Schematics and Examples B 27 Figure B 27 F or H Series Motors to ULTRA 200 Series Drive using P2 Terminal Strip Enclosure Cabinet F or H Series Motor Y Motor Power Connector Encoder Connector 9101 1391 89 P1 lt Control e interface 89 Screw Terminal Strip Clamp exposed motor cable shield to the chassis ground terminal m Motor Power Cable NOTES This wiring method provides the option to run cables through a restrictive bulkhead or enclosure Cable 9101 1365 XXX has a connectors on the motor end only The cable connector is molded and potted to the cable and may not be disassembled Refer to the schematic for cable 9101 1366 for information on wiring this cable to the J2 Terminal Strip Adaptor Kit 9101 1391 includes the 3 foot cable screw terminal strip and mounting bracket The cable has a 50 pin Mini D ribbon co
103. then returns you to Windows The ULTRA Master program group provides access to the ULTRA Master application icon Publication 1398 5 0 October 1998 3 4 ULTRA Master Installation Publication 1398 5 0 October 1998 From the C gt Prompt 1 Type win c ultramst ultramst exe The ULTRA Master start up screen will open Note This step assumes that ULTRA Master was loaded into the c ultramst directory during setup From Windows 1 Choose the ULTRA Master program group from the Program Manager in Windows Note If the ULTRA Master window is not active hold down ALT and press TAB ALT TAB until the ULTRA Master title bar and icon are highlighted or select ULTRA Master from the list in the Window menu 2 Choose the ULTRA Master icon from the ULTRA Master pro gram group The ULTRA Master start up screen will open The readme File A file titled README may be included in the ULTRA Master directory This file contains installation instructions change notes from previous revisions and information that became available after this manual was printed After you install ULTRA Master you can access this file by choosing the Read Me icon in the ULTRA Master window or by using Microsoft Write or an equivalent application program to view the file readme wri in the directory path where ULTRA Master is installed Firmware Files Firmware files are supplied in the Miscellaneous directory on the ULTRA Master diskette
104. used to adjust the gain control parameters P I D and the filters A square wave is generated by the drive to assist in the adjustment Manual velocity tuning requires the following e Step Period value to be specified e Step Velocity value to be specified Note Always tune the velocity loop before the position loop as Veloc ity loop tuning affects the position loop response Tuning the Velocity Loop The Auto Tune procedure provides a starting point for velocity loop tuning Manual tuning is desirable when very precise adjustments are required The following steps describe how to manually tune the velocity loop These steps precede the manual position loop tuning procedure which should follow velocity loop tuning 1 Disable the drive 2 Choose Manual_Tune Velocity Step from the Tuning window 3 Enter the desired step Velocity rpm of the internal square wave generator 4 Enter the desired Time to complete one cycle of the square wave of the internal step velocity 5 Select the desired Motor Direction Forward Only Reverse Only or Bi Directional 6 Select the Oscilloscope 7 Enable the drive 8 Choose Start The motor should start moving and the oscilloscope will display the commanded velocity and the motor velocity 9 While monitoring the motor velocity waveform increase P gain until the desired rise time is achieved 10 While monitoring the motor velocity waveform increase I gain until an acc
105. 0 8 H 6300 F 6300 10 0 8 10 0 8 H 8350 25 0 4 16 0 6 H 8500 25 0 4 16 0 6 N Series 1 5 16 1 5 16 Y Series 1 5 16 1 5 16 a Recommendations are based on motor ratings only If the drive in the system cannot deliver rated power to the motor then smaller wire sizes may be required for connection to the drive Motor Overload Protection The drive utilizes solid state motor overload protection which operates e within 8 minutes at 200 overload e within 20 seconds at 600 overload Publication 1398 5 0 October 1998 7 6 Power Connections Publication 1398 5 0 October 1998 Emergency Stop Wiring An overlapping contactor may be inserted between the motor and the drive for emergency stop purposes The contactor must not simply break the motor current it also must switch a three phase resistive load in parallel with the motor windings The three resistors provide dynamic braking In addition they prevent continuous arcing at the main contacts when breaking DC currents such as when the motor stalls Simply breaking the motor current can result in high voltages due to motor inductance which will cause prolonged arcing in the contactor In extreme cases the prolonged arcing could result in the contactor catching fire An overlapping contactor provides the required timing by engaging the braking contactors before the drive contactors disengage Figure 7 3 depicts a contactor installation with resistive loads Fo
106. 00 ft Humidity 5 to 95 non condensing Ambient operating temperature range and airflow clearances are 0 to 55 Celsius 32 to 131 Fahrenheit 50 8 mm 2 inches above and below unit for airflow 4 Bolt the unit to the cabinet using the mounting slots in the drive Mounting dimensions are shown in Figure 5 1 The recommended size of mounting hardware is M5 Metric 1 4 20 equivalent or 10 MS bolts Publication 1398 5 0 October 1998 Installation 5 3 A2 Figure 5 1 1398 DDM Mounting Dimensions sheet 1 of 2 B af CLEARANCE HOLES FOR MOUNTING SCREWS A KEY mm in 1398 DDM 010 010X 1398 DDM 020 020X 1398 DDM 030 030X 360 6 14 2 332 7 13 1 349 3 13 75 6 4 0 25 27 9 1 35 6 4 101 6 124 5 8 9 1 104 1 8 0 A a 26 7 25 4 25 4 226 8 17 0 1 4 4 0 4 1 1 1 5 0 5 0 0 3 7 m EXHAUST T 1398 DDM 075 1398 DDM 075X 360 6 14 2 332 7 13 1 349 3 13 75 69 0 27 279 1 1 356 1 4 1016 4 0 1245 5 3 89 0 35 151 7 5 97 50 5 1 99 254 1 00 254 1 00 224 5 8 84 17 0 0 67 AIR INTAKE Publication 1398 5 0 October 1998 5 4 Installation Figure 5 1 1398 DDM Mounting Dimensions sheet 2 of 2 1398 DDM 150 and 1398 DDM 150X mm
107. 01 1380 B 18 J2 to N Series Encoder Cable P N 9101 1468 B 19 No Connector to N Series Encoder Cable P N 9101 1469 B 20 2000 or 3000 F or H Series Power Cable P N 9101 1381 B 21 4000 F or H Series Power Cable P N 9101 1382 B 22 6100 or 6200 or H Series Power Cable P N 9101 1383 2 6300 H Series Power Cable P N 9101 1399 B 23 8000 H Series Power Cable P N 9101 1384 B 23 Y Series Power Cable P N 9101 1385 B 24 Publication 1398 5 0 October 1998 Intro 10 List of Figures Appendix C Appendix D Appendix E Appendix F Appendix G Publication 1398 5 0 October 1998 N Series Power Cable P N 9101 1467 B 25 F or H Series Motors to ULTRA 200 Series Drive B 26 F or H Series Motors to ULTRA 200 Series Drive using P2 Terminal Strip sem s s B 27 Y Series Motors to ULTRA 200 Series Drive B 28 Y Series Motors to ULTRA 200 Series Drive using P2 Terminal 5 B 29 TouchPad Instructions TouchPad Connection and 5 C 2 TouchPad Version Number Display C 2 TouchPad Command Tree sheet10f2 C 4 Creating Custom Motor Files Allen Bradley Motor Naming Convention D 3 Required Back EMF and Hall Signal Phasing for Clockwise Rotation D 4 Ph
108. 010 7 6 25 9101 1468 025 15 50 9101 1468 050 ULTRA 200 Series drives only 23 75 9101 1468 075 ULTRA 200 Series drives only 30 100 9101 1468 100 Y Series Motor to customer supplied connector i e no 3 10 9101 1373 010 connector 7 6 25 9101 1373 025 15 50 9101 1373 050 ULTRA 200 Series drives only 23 75 9101 1373 075 ULTRA 200 Series drives only 30 100 9101 1373 100 J2 to Y Series Motor 3 10 9101 1375 010 7 6 25 9101 1375 025 15 50 9101 1375 050 ULTRA 200 Series drives only 23 75 9101 1375 075 J2 to customer supplied connector 3 10 9101 1380 010 i e no connector 7 6 25 9101 1380 025 15 50 9101 1380 050 ULTRA 200 Series drives only 23 75 9101 1380 075 ULTRA 200 Series drives only 30 100 9101 1380 100 Publication 1398 5 0 October 1998 Options and Accessories A 5 Motor Power Cables Diagrams and schematics for cables listed below are shown in Appendix B Interface Cables beginning on page B 21 Description m ft Part Number Drive to 2000 or 3000 Motors F or H Series 3 10 9101 1381 010 7 6 25 9101 1381 025 15 50 9101 1381 050 ULTRA 200 Series drives only 23 75 9101 1381 075 ULTRA 200 Series drives only 30 100 9101 1381 100 Drive to 4000 Motors F or H Series 3 10 9101 1382 010 7 6 25 9101 1382 025 15 50 9101 1382 050 ULTRA 200 Series drives only 23 75 9101 1382 075 ULTRA 200 Series drives only 30 100 9101 1382 100 Drive to 6100 or 6
109. 045 H 3007 N L 1046 H 3016 N L 1047 H 4030 P L 1048 H 4030 M L 1049 H 4050 P L 1050 H 4075 R L 1051 H 6100 Q L 1052 H 6200 Q L 1053 H 6300 Q L 1054 H 8350 S L 1055 H 8500 S L 1283 F 4050 Q M 1295 F 4030 Q M 1296 F 4075 R M 1297 F 6100 R M 1298 F 6200 R M 1299 F 6300 R M 1300 H 2005 K M 1301 H 3007 N M 1302 H 3016 N M 1303 4030 1304 H 4030 M M 1305 H 4050 P M 1306 H 4075 R M 1307 H 6100 Q M 1308 H 6200 Q M 1309 H 6300 Q M 1310 H 8350 S M 1311 H 8500 S M 1539 F 4050 Q N 1551 F 4030 Q N 1552 F 4075 R N 1553 F 6100 R N 1554 F 6200 R N 1555 F 6300 R N 1556 H 2005 K N 1557 H 3007 N N 1558 H 3016 N N 1559 4030 1560 H 4030 M N 1561 4050 1562 H 4075 R N 1563 H 6100 Q N 1564 H 6200 Q N 1565 H 6300 Q N 1566 H 8350 S N 1567 H 8500 S N TouchPad Options Table C 4 Option Selections for the TouchPad DRVPARM TUNING Parameter Options Parameter Options AccelEn Enable Disable SWEnable Enable Disable SlewEnab Enable Disable OverRd Enable Disable STATUS CTLPANEL Parameter Options Parameter Options SWEnable Enable Disable SWEnable Enable Disable EncAlign Normal Align Start Normal CtlPanel RmvOfst to Rmv Publication 1398 5 0 October 1998 TouchPad Lists TouchPad Instructions C 13 Table C 5 Drive Communications Parameter List for the TouchPad Display Parameter 00 7 Data Bits 1 Stop Bit Ev
110. 1 The following steps generalize these procedures When autotuning is selected the drive rotates the motor shaft for a short time interval typically a few seconds Motor movement should not exceed 30 seconds ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation Tuning 9 5 Choose the Tuning command icon from the Drive window Choose Auto Tune from the Tuning window This activates the Auto Tune Command and Motor Direction boxes within the Tun ing window Then enter or select appropriate values for Distance in the Auto Tune Command box appropriate values for Step Current in the Auto Tune Com mand box and an appropriate motor rotation in the Motor Direction box either BiDirectional if the motor will be powered in both the forward and reverse directions Forward Only if the machinery is designed to operate only in the forward direction Reverse Only if the motor will be powered only in the reverse direction Use the default settings if you are uncertain about what values to enter The default settings are set to values appropriate to the drive and motor combination selected during drive initialization 3 5 6 7 8 Enable the drive Choose Start from the Tuning window The drive rotates the motor shaft and then motion will cease The calculated gains are displayed and the drive is disabled
111. 11 Example of Custom Motor File Creation D 14 Manufacturers D 14 Parameter 5 D 15 Custom Motor File D 16 Troubleshooting Custom Motor Files D 16 Electromagnetic Compatibility Guidelines for Machine Design HFitering 2 2 AC Line Filter E 3 Grounding kk Q Bus RR Ree W dnx PUR ee SSeS E 5 Shielding and 5 E 6 Dynamic Braking Resistor Selection Dynamic Braking 5 1 Sample 5 F 3 Specifications PONOT Ge Q G 5 Power Dissipation jane a su guna n ae ace G 7 Index Index 1 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 List of Figures Product Parts Explained Intro 21 Safety Selecting Other System Components ULTRA Master Installation Unpacking Inspecting and Storing Connection 4 4 Installation 1398 DDM Mounting Dimensions sheet 1 of 2 5 3 MDF AC Line Filter Mounting Diagrams 5 8 MIF Single Phase AC Line Filter Mounting Diagram 5 10 Power Wiring Diagrams sheet 1 of 3 5 11 Interfaces Digital Input
112. 13 Publication 1398 5 0 October 1998 Interfaces 6 13 Figure 6 14 Drive Output Connected to Active Low Input using a Switch Relay OUTPUT INPUT Drive 24VDC 24VDC 3 3K 2 ZS Solid State was Relay ZN E J wv Vv 24VCOM 24VCOM Figure 6 15 Drive Output Connected to Active Low Input using Opto Isolator OUTPUT Drive 24VDC 24VDC mas K E dE cl V 2 24VCOM 24VCOM Figure 6 16 Drive Output Connected to Active High Sinking Input OUTPUT INPUT Drive 24VDC e S ASK K Zs J1 6 or 41 13 24VCOM 5 24VCOM 2 Publication 1398 5 0 October 1998 6 14 Interfaces Analog Inputs Two types of analog input circuits are available on the J1 connector e The current limiting inputs support 0 to 10 Volt signals e The command input supports 0 to 10 Volt signals Positive Current Limit I LIMIT and Negative Current Limit I LIMIT Figure 6 17 Positive and Negative Current Limit Circuits J1 Drive 15 Volts 10K I LIMIT eS gt W or i LIMIT ANA 20K 01uF NC The I LIMIT and I LIMIT are current limit inputs to the drive They have a range of 0 to 10 Volts where 10 Volts corresponds t
113. 1Ohm b If the box is not checked the resistance should be very high gt 1 MOhm A load is necessary to test the transistor outputs listed below A 1 kOhm resistor may be connected from the transistor output J1 42 J1 43 J1 44 or J1 45 to the 24 VCOM J1 6 C Digital Output 1 then measure the voltage between J1 42 and 11 13 If the box is checked the voltmeter should read approximately 24 VDC b If the box is not checked the voltmeter should read approximately 0 VDC D Digital Output 2 then measure the voltage between J1 43 and J1 13 a If the box is checked the voltmeter should read approximately 24 VDC b If the box is not checked the voltmeter should read approximately 0 VDC E Digital Output 3 then measure the voltage between J1 44 and J1 13 a If the box is checked the voltmeter should read approximately 24 VDC b If the box is not checked the voltmeter should read approximately 0 VDC F Digital Output 4 then measure the voltage between J1 45 and 11 13 a If the box is checked the voltmeter should read approximately 24 VDC b If the box is not checked the voltmeter should read approximately 0 VDC 4 After the test has been completed you may select Close to exit Output Diagnostics window If you determine that a digital output is defective return the unit for repair Publication 1398 5 0 October 1998 11 14 Maintenance and Troubleshooting Publica
114. 2 Instructions Intro 16 Readme File 3 4 Requirements 3 1 Starting and Quitting 3 3 Version Level 3 3 Space Requirements 5 1 Specifications G 1 ABS Input G 1 Address Switch G 1 Agency Approvals G 1 Altitude G 1 Analog Inputs G 2 Outputs G 2 Auxiliary Encoder Signal Inputs G 2 Index 5 Auxiliary Power Current G 5 Frequency G 5 Voltage G 5 Bus Capacitance G 5 Voltage G 5 COMMAND G 2 Command Source G 3 Current Limit G 2 Regulation Bandwidth G 2 Resolution G 2 Data Collection G 3 Retention G 2 Dielectric Withstanding Voltage G 1 Digital Inputs ENABLE G 2 Selectable G 2 Digital Outputs BRAKE G 2 READY G 2 Selectable G 2 EEPROM G 2 EPROM G 2 Hall Inputs G 1 Hi Pot Testing G 1 Humidity G 1 Low Pass Filter G 3 Main Power Current G 5 Frequency G 5 Voltage G 5 Microcontroller Type G 2 Motor Encoder Interface G 1 Input 6 1 Power 1 Output G 2 Operating Temperature G 1 Output Current Continuous peak G 5 Peak G 5 Position Regulation G 3 Power Output Continuous G 6 Peak G 6 Power Ratings G 5 Power Supply 5 Volt G 2 Power Up Faults G 3 PWM Carrier Frequency G 2 RAM G 2 Run Time Faults 0 4 Selectable Digital Inputs G 4 Selectable Digital Outputs G 4 Serial Ports G 1 Publication 1398 5 0 October 1998 Index 6 Publication 1398 5 0 October 1998 Serial Protocol G 3 Shock G 1 Shunt Power Continuous G 5 Peak G 5 Speed Control Command G 4 Speed Regulation Bandwidth G 3 Resolution G 3 Rip
115. 2 Step Direction 8 17 Preset Controller 8 6 Registration Indexing 8 33 Excess Error see Troubleshooting Excessive Average Current see Trou bleshooting External Shunt Regulator 7 14 External Testing 6 44 F Firmware 3 4 Displaying Revision Level 3 4 Hexadecimal Files 3 4 Upgrading 3 4 Fuses A 2 Inrush Current 7 10 Replacement 11 1 G Gains D gain defined 9 6 Effect on Tuning 9 6 I gain defined 9 6 Kd gain defined 9 7 Kff gain defined 9 7 Ki gain defined 9 7 Kp gain defined 9 7 P gain defined 9 6 Position Loop 9 7 Velocity Loop 9 6 Gear Ratios Custom Motors D 15 Selecting via TouchPad C 8 Graphical Symbols Intro 20 Gravitational Effects Tuning 9 4 Grounding Types Single Point E 5 Guidelines Electromagnetic Compatibility E 1 Manual Tune 9 6 H HallInputs G 1 Hardware Requirements 3 1 Hi Pot Testing G 1 Humidity G 1 I LIMIT see Current I O Connections Analog Command Signal 6 15 Inputs 6 14 Outputs 6 16 6 44 Auxiliary Encoder Inputs 6 19 Circuit Examples 6 7 Dedicated Relay Outputs 6 9 Digital Inputs 6 4 Outputs 6 9 Drive 5 5 European Union Directives 5 6 61 J2 6 27 J3 6 31 14 and J5 6 34 Motor Encoder Signal 6 17 Output Circuit Examples 6 11 Power 6 3 Selectable Outputs 6 9 Wiring 5 6 see also Troubleshooting Connectors Auxiliary Port 6 31 Controller 6 1 Encoder 6 27 Interface Cable Examples 6 21 6 26 J2 6 27 6 30 J3 6 31 14 and J5 6 34 T O Power see Power I
116. 2 0339X3 LON 304 STVNIWNH31 OML ANY N33M138 N3HM 5 38 AVN S3SVHd 1995 3lVH3d3S H3MOd N Z1 L1 YALAY FINGOW SNLWLS OLLSONOVIG NIVL3H OL STVNIWYAL 27 LY 340 GANYNL SI Aldd NS HOLON NIVW 3 13 G3H3MOd 539915 FINGON NOLLO3S 91907 993 OL GSN 38 AVN va sng _ S31ON SISSVHO SIXV 43d INO W31SAS H3WHO4JSNVHL HO4 1NIOd SNIGNNOYS NONNOO Nn 3 l8 v VAY ZH 09 05 SI 39VLIOA INdNI G3HIS3Q OV N3HM LON VNOLL4O 3SVHd 5 1 HO NOLIVTOSI 4 uuyaonv 3ONVH 3HIM 318V1d300V 7 1 Ov 2 IL ee s H3ddOO 2 54 wwy39nVv9 3BIWH3MOd YOLOANNOO Y3MOd HOLOW LINDHIO HO 1O3NNOOSIQ 03514 V A N H 4 seues Jo siolouu suoddns 9 ALON sors wws z OMW vL WWO E OMY ZL 20202 uus YOM 9 Lossy unus 9L NIN 394400 9 54 3ZIS LOVLNOO MHOLO3NNOO 3u ero H3MOd HOLOW X0 0 Waq 8eer 10 0 0 INQQ 86 L 0 86 10 020 INQQ 86 XOLO WGq 86 10 86
117. 200 Motors F or H Series for 1398 DDM 3 10 9101 1383 010 030 or 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X 7 6 25 9101 1383 025 15 50 9101 1383 050 ULTRA 200 Series drives only 23 75 9101 1383 075 ULTRA 200 Series drives only 30 100 9101 1383 100 Drive to 8000 Motors F or H Series for 3 10 9101 1384 010 1398 DDM 150 or 1398 DDM 150X 7 6 25 9101 1384 025 15 50 9101 1384 050 ULTRA 200 Series drives only 23 75 9101 1384 075 ULTRA 200 Series drives only 30 100 9101 1384 100 Drive to 6300 Motors F or H Series for 3 10 9101 1399 010 1398 DDM 150 or 1398 DDM 150X 7 6 25 9101 1399 025 15 50 9101 1399 050 ULTRA 200 Series drives only 23 75 9101 1399 075 ULTRA 200 Series drives only 30 100 9101 1399 100 Drive to N Series Motors 3 10 9101 1467 010 7 6 25 9101 1467 025 15 50 9101 1467 050 ULTRA 200 Series drives only 23 75 9101 1467 075 ULTRA 200 Series drives only 30 100 9101 1467 100 Drive to Y Series Motors 3 10 9101 1385 010 7 6 25 9101 1385 025 15 50 9101 1385 050 ULTRA 200 Series drives only 23 75 9101 1385 075 ULTRA 200 Series drives only 30 100 9101 1385 100 Publication 1398 5 0 October 1998 A 6 Options and Accessories Connector Kits Connector kits provide the ability to construct custom length cables Kits are available for all ULTRA 200 Series connectors Each kits consists of the appropriate 3M connector with the corresponding plastic backshell and in
118. 26 and J1 20 to enable the drive 2 Close any of the switches for INPUT1 INPUT2 or INPUTS to run the drive at the programmed preset speed or torque Publication 1398 5 0 October 1998 8 12 Application and Configuration Examples Position Follower Master Encoder Publication 1398 5 0 October 1998 The ULTRA 200 Series can be electronically geared to a master incremental encoder generating quadrature encoder signals by making the hardware connections and performing the software setup and tuning described below The connection diagram depicts the minimum hardware necessary Interfacing the drive to an external controller requires similar circuitry from the controller to J1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional TouchPad also may be used Hardware Setup Make the connections described below and shown in Figure 8 3 The appendix Options and Accessories on page 1 lists the interconnect cables available from the factory 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series A simple 3 wire cable is depicted in the figure below 2 Connect a Motor Feedback cable from the motor to the J2 connec tor on the drive 3 Connect a Power cable from the motor to TB1 terminals S T and on the drive 4 Connect the Master Encoder to the drive as shown in the diagram 5 Connect a jumper wire with a s
119. 30 Offset Publication 1398 5 0 October 1998 Hall Offset The Hall offset specifies the offset of the Hall feedback signals relative to the Allen Bradley standard The drive uses the Hall offset to determine the commutation angle at startup Hall offset is specified as a value in the range from 0 to 359 electrical degrees R S ST T R a Allen Bradley Hall Location 09 Offset Creating Custom Motor Files D 9 The Hall signals as well as the line to line back EMF voltages must sequence according to the Allen Bradley standard refer to Figure D 2 and the Motor Phasing on page D 3 The Hall offset value is the value the drive uses to correct for Hall signals that are shifted from the line to line back EMF Figure D 5 a shows the Allen Bradley standard for orientation of the Hall signals to the line to line back EMF voltages Figure D 5 b shows an example of a 60 Hall offset from the standard location Figure D 5 Hall Offsets 0 60 120 160 5 0 60 120 180 240 300 360 b Non Standard Hall Location 60 Offset Startup Commutation The startup commutation list box specifies the type of commutation to be used at startup The choices are e 6 Step ABS Index e 8 Step ABS Index e Hall Index and e Hall Hall The different types of startup are identified by their initial and final commutation angle measurement Fo
120. 3750 E x 4 0959 The following table shows the relationship between drive addresses whether set by hardware or software It also lists the communications settings whether mandatory default settings or software selectable Table 6 25 Drive Addressing Address Range Communications Hardware Software 0 N A Factory Default 9600 baud rate 8 Data 1 Stop Bit No Parity 1 A N A Software Selected Settings include 1200 2400 4800 9600 and 19200 baud rates 8 Data Bits 1 Stop Bit Even Odd or No Parity B E N A Reserved F 1 32 Software Selected 1 Hardware rotary address switch and software address and communications settings changes are not immediate they are logged but do not become active until after the drive is RESET Interfaces 6 37 Addressing Examples Setting the rotary switch to position 0 forces the drive to communicate using the factory default settings refer to Table 6 25 The drive ignores any software address assigned to it However the drive may be assigned a unique name Note This setting ensures that communications with the drive can be established at any time Setting the rotary switch to position assigns the drive to physical address 1 The communications parameters may be modified but software addressing is not enabled Setting the rotary switch to position F as shown in Figure 6 38 forces the drive to read its address from EEPROM
121. 45 FOLLOWER END 2 6 x 0 45 RETRACTABLE TASTENS DREGTY To BOM CONNECTOR WHITE BLACK A 2 BLACK H 2 WHITE RED ray 4 RED 5 4 7 14 VIOLET i 9 9 WHITE BLUE 54 10 0 BLUE T n 6 WHITE GREEN ia T 8 GREEN 5 9 we 1 PIN 1 THIS END H NC we 3 5 NC we 5 6 NC NC 6 18 NC NIC 7 PIN 14 THS END 4 15 Nic we 9 16 Nc 10 17 NIC 18 we 12 19 we Nc 13 20 20 21 2 22 NIC NC 22 23 Ne 23 wc NC 25 26 DRAIN NC 26 DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 BOTH B 5 FOLLOWER END Publication 1398 5 0 October 1998 B 6 Cable Diagrams Schematics and Examples Figure B 4 J3 to No Connector Interface Cable P N 9101 1368 E feet amp MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE 2 6 x 0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR 1 BLACK X 5 WHITE BLACK 2 e WHITE RED GREEN WHITE GREEN ORANGE 3 7 A WHITE ORANGE 0 9 t BLUE PIN 1 THIS END a A Ay 10 WHITE BLUE 11 YELLOW pern X F1 z 12 WHITE
122. 6 44 on page 6 45 for an intercon nect diagram 5 Choose the Drive Signals command icon from ULTRA Master 6 Choose Set Up if the Drive Signals Set Up window is not already active 7 Choose Current Input Limit as the analog signal Publication 1398 5 0 October 1998 11 16 Maintenance and Troubleshooting Publication 1398 5 0 October 1998 8 Choose OK to close the Set Up window and activate the Drive Signals window Slowly adjust the potentiometer while viewing the Drive Signals window The Current Input Limit value should update as the potentiometer is adjusted Testing Negative Current Limit 1 Verify the accuracy of the potentiometer with an ohmmeter before installing Disable the drive by opening the connections between the ENABLE input and 24VDC Disconnect the connections to J1 29 and J1 28 Connect the 10K potentiometer between J1 29 and J1 28 Refer to J1 Controller on page 6 1 for a diagram showing the location of the pins and Figure 6 44 on page 6 45 for an intercon nect diagram Choose the Drive Signals command icon from ULTRA Master Choose Set Up if the Drive Signals Set Up window is not already active Choose Current Input Limit as the analog signal Choose OK to close the Set Up window and activate the Drive Signals window Slowly adjust the potentiometer while viewing the Drive Signals window The Current Input Limit value should update as the po
123. 7 STTOA OE S1 OA 5 E 834402 20 UU 390v9 NT Tl SWH SdWv WWIXVM INSHSHIDO3E INSHUnO NIW 339909 2 52 F TW 834402 2 5 U0 39 C UU 390v9 v9 3715 12 1 02 WH3L 39VINVAG 5 12 S1N343H INGOW 80123 02 9NI1vW 80104 WA 83804 30108 0 817554 53818 H3MOd 4010 XSZO 86 10 S Z20 INQQ 86 1 Publication 1398 5 0 October 1998 5 13 Installation ue mx 133HS 325 avos 500 XXX 7691 1016 10 81 b9 LF SNOILOVH4 ON 1HVd S3 19NV I S319NV NOSONVESTOL ONIMIM H3MOd yid 20 ANY S13114 Ur S3HONINI SNOISN3AIG 31 25 LON OQ SIXV INO H3ITIdAV HO4 LNIOd NOWNOO SHOLOW HOIO3NNOO HOLOW SNILVIN HOLO3NNOO H3MOd HOLOW 31naow 1 001 OL DNIGHODOV 93159796 38 1 63215 3603 GSGNSWWOOSY 353 MOS AV130 INIL 1N3W313 1 1 901 LMANI NIYIN 3HL VOL 30 ANSYUND LHOHS V NOIIVZITVILINIU3MOd 310N esey OOM OV SHOA 02 001 SWE sduv 097 IAG SLNAWSHINOFY LNSYYND FINGO
124. 8 5 0 October 1998 D 8 Creating Custom Motor Files RS K st TR INDEX Feedback Parameters Linecount The encoder linecount or size specifies the number of encoder lines per mechanical revolution of the motor and is required in units of lines mechanical revolution The linecount value can be in the range from 100 to 15000 lines rev Note that the linecount value is in units of lines rev rather than counts rev The number of lines rev will be 1 4th of the number of counts rev Index Offset The index offset specifies the offset of the encoder index signal from the Allen Bradley standard and is required in units of electrical degrees If the startup commutation type specifies that the index be used for the final commutation angle measurement then the drive uses the index offset to determine the commutation angle when the index is first located the rising edge The index offset value can be in the range from 0 to 359 degrees For custom motor files this parameter is not required Set it to 0 since only the Hall signals are needed for most custom motor files Figure D 4 a shows the Allen Bradley standard index location and Figure D 4 b shows an example of a 30 index offset Figure D 4 Index Offsets RS ST INDEX 0 60 120 180 240 300 360 0 60 120 180 240 300 360 a Allen Bradley Index Location 0 Offset b Non Standard Index Location
125. 8 9 If the settings are different correct the Port Settings to allow communications with the drive Factory default communications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions Select Read Drive Parameters from the Communications menu Verify the Drive Name and Address are correct for the drive that is being addressed Choose OK to load the drive parameters Note A motor must be selected for the parameters to load 10 11 12 13 14 15 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Motor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select the Operation Mode parameter for the drive Velocity Mode Settings Torque Mode Settings Preset Velocities as the Opera Preset Torques as the Opera tion Mode tion Mode Choose Close from the Drive Setup window Choose the Drive Parameters command icon from the Drive window and then select the Preset tab Enter the approp
126. 8 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 030 or 1398 DDM 030X Publication 1398 5 0 October 1998 Part Number Part Number 1398 1 001 9101 1516 9101 1517 9101 1518 9101 1387 9101 1388 9101 1575 9101 1389 9101 1391 9101 1392 9101 1079 Publications Interface Cables Serial Interface Cables Description Manuals TouchPad Card Installation Manual Options and Accessories Publication Number 1398 5 5 1398 5 0 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 030 or 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Installation Manual 1398 5 2 1398 DDM 005 or 1398 DDM 005X 1398 DDM 009 or 1398 DDM 009X 1398 DDM 019 or 1398 DDM 019X Diagrams and schematics for cables listed below are shown in Appendix B Interface Cables beginning on page B 3 Description J1 to customer supplied connector no connector J3 to customer supplied connector no connector ULTRA 200 Series drives only J3 to J3 Master Follower ULTRA 200 Series drives only m ft 3 10 7 6 25 15 50 23 75 3 10 7 6 25 15 50 23 75 0 6 2 Part Number 9101 1370 010 9101 1370 025 9101 1370 050 9101 1370 075 9101 1368 010 9101 1368 025 9101 1368 050 9101 1368 075 9101 1463 002 Diagrams and schematics for cables listed below are shown in Appendix B Interface Cables beginning on page B 11 De
127. 8 DDM 030X require single phase input power The 1398 DDM 075 and 1398 DDM 075X may use either single or three phase input power but the 1398 DDM 150 and 1398 DDM 150X require three phase input power ULTRA 200 Series Power Ratings on page G 5 lists the output power characteristics of the ULTRA 200 Series drives The AC input supplies power to the motor and the drive logic as the default factory setting An auxiliary power source may provide input power to the drive I O independent of the motor power Alternatively the drive may be powered by an external DC power source Publication 1398 5 0 October 1998 7 8 Power Connections Terminals 7 8 and 9 are the single phase AC input power connections for the 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 and 1398 DDM 030X Terminals 7 8 9 and 10 are the three phase AC input power connections for the three phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 and 1398 DDM 150X Terminals 7 8 and 10 are the AC input power connections when the 1398 DDM 075 and 1398 DDM 075X are powered from a single phase input ATTENTION The user is responsible for conforming with all applicable local national and international codes Wiring practices grounding disconnects and overcurrent protection are of particular importance Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION High voltage may be present on the ter min
128. DDM 020 and FN 350 20 MIF 23 or MDF 18 1398 DDM 020X 1398 DDM 030 and FN 350 30 MIF 32 or MDF 36 1398 DDM 030X 1398 DDM 075 and FN 351 36 MIF 330 or MDF 336 1398 DDM 075X 1398 DDM 150 and MDF 350 1398 DDM 150X Allen Bradley AC Line Filters An AC line filter is not required on the auxiliary line input when it is used Refer to Options and Accessories on page 2 for part numbers Note The ordering of an Allen Bradley part number will result in Roxburgh line filter being received ATTENTION Large leakage currents exist in AC line filters They 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 prior to handling the equipment Failure to observe this precaution could result in severe bodily injury Mounting dimensions for single and three phase AC line filters available from Allen Bradley are illustrated in Figure 5 2 and Figure 5 3 with corresponding numbers in Table 5 2 and Table 5 3 Wiring diagrams for Allen Bradley AC line filters follow in Figure 5 4 Publication 1398 5 0 October 1998 5 8 Installation Figure 5 2 MDF AC Line Filter Mounting Diagrams SCALE 24 5 1 o MDF Three phase Publication 1398 5 0
129. Description Internal Connections BX and or DIR and DIR or CCW Step Down and CCW Step Down J3 16 J3 17 Auxiliary Channel B and B Differential quadrature or TTL level encoder input The signals are selectable as BX and or DIR and DIR or CCW Step Down and CCW Step Down For encoder information refer to Quadrature Interface Specifications on page 6 20 and Figure 6 23 6 24 6 25 6 26 6 27 6 28 and 6 29 For stepper information refer to Step Direc tion and CW CCW Step Up Step Down Interface Specifications on page 6 24 and Figure 6 30 6 31 6 32 and 6 33 J1 16 J1 17 J3 18 J3 19 Differential quadrature or TTL level encoder input The signals are selectable For encoder information refer to Quadrature Interface Specifications on page 6 20 and Figure 6 23 6 24 6 25 6 26 6 27 6 28 and 6 29 J1 18 J1 19 ENABLE J3 20 Enables and disables the drive Refer to Digital Input Specifications on page 6 6 and Figure 6 1 J1 20 FAULT RESET J3 21 General purpose input selectable to one of several drive functions Refer to Digital Input Specifications on page 6 6 and Figure 6 1 J1 21 COMMAND COMMAND 13 22 J3 23 Analog command signal is a differential type signal that drives the servo controller Separate scale and offset parameters are use
130. E PINK 18 19 WHITEIPINK 19 20 5 WHITEIBLACKIRED 26 ot x REDIBLACK 22 gt WEITE BLACKIQRANGE 22 ts 1 THIS END 23 4 ORANGEIBLACIC 23 24 2i 25 YELLOWIBLACK 5 22 27 5 27 28 GREENIBLACK 5 18 29 Waman anqa uE 25 30 BLUEIBLAGK 2 x YELLOWIED 22 32 32 33 8 33 51 x PIN 26 THIS END 35 GRAYIBROWN 4 35 j vELOWIBRDWA 22 37 GRAYIGREEN 5 38 YELLOWIGREEN EH 39 GRAYIDRANGE 39 40 veuowionance 40 4 GRAYMHITE re YELLOWAWHITE 4 BLUERED 43 5 dd BLUE ORANGE K GREEN ORANGE_ 46 BLUEYYELLOW 1 mi 47 GREENYELLOW 48 BLUE WHITE L4 49 X GREEN WHITE 5 50 DRAIN M _ 0 DENOTES TWISTED PAIR Cable Diagrams Schematics and Examples B 9 Figure B 7 J2 to 25 pin Terminal Block Kit Diagram P N 9101 1392 0000000000000 gt 000000000000 eee 0 156 DIA IHRU 2 Mounting bracket 0002 7068 shown and cable 9101 1371 003 next page supplied with kit NOTES The terminal block and cable provide a one to one transfer of the signals from the con nector to the respective pin s on the terminal block The cabling examples beginning on page B 26 depict the use of this kit to pass a
131. EIE E S A SIR 8 31 Operations 22555545 He S omae ep IP ee So 8 32 Registration Indexing 8 33 Hardware Setups 8 34 Connection Diagram 8 35 CONT PUTAON TTL 8 35 TUME ibo Rp a ee Unos 8 37 Operation s a u oie ede 8 38 Absolute Indexing 8 39 Hardware Setup 8 39 Connection Diagram 8 40 Configuration e s u p ee eR S 8 41 PUMP au Gin SS eae Oe She aes 8 43 225222 552424 5522 9555 Ged es 8 44 Modifying User 8 45 Changing the Display Units 8 45 Tuning TuningGuidelines 9 1 General Tuning 9 1 High Inertia 45 9 1 Mechanical Resonance 9 2 Backlash aa ak ole E UIROS OK S oed 9 3 Auto Tune 9 4 Auto TUNNE EG SHS 9 4 Manual Tune Mode dda Sau m aa 9 6 dde eS A Sa SOP 9 6 PUGS z aco ne lee Soe net ete E SELLE ed 9 7 Manual 9 8 Velocity Loop Tuning Examples 9 10 Status Display Operating Messages
132. IWNHZIN 02 1 HO NINIS 319NIS 803 5 05 51 1 30 IN3ON3d3ONI 38 59 81 300801 H3A3N 5318 2 Q30131H5 NON 83 04 80104 JHL 31VNIHH3L w NIA Juv 51715 JAIXO 3H1 NY SYH 113N9yN08109313 340803 30131 5 3 10N 00 OVA 022 001 JAIUG 5 35VHd 330Hl lya IN3HN02 VZ G31W1SNI NE 7 xnv z1 02510 v NZ 40 011235 21901 4333 Ol 0951 38 SI NICd 804 1 104 SNTGNNOXS NOHAO2 N3HM 03411038 4 0341530 01191051 432388 1109919 40 1 VAE ti 30 90 39 9 SONVH JAIM 318 14322 JAH 1 11910 23 02510 03504 N Z V ALON 311004 W190 _ 10934 7 201 01 9 108022 23135 38 3 Q3QN3WWO0938 34 53504 AY T yn 303 956 IHL 804 VOS HSNUNT 30 0101 34 5170 5044 916915 2 1402 0 9MV 21 0508 5 N ET 1 AUVIT 85044 9947 51104 2
133. If a Gear Ratio of 3 1 is entered the motor is moved 3 encoder pulses for every incoming step pulse Choose Close to exit the Drive Parameters window Select the Configuration command icon from the Drive Win dow Select an appropriate digital input from the pull down lists avail able as Digital Input Assignments in the I O Configuration win dow For example Follower Enable as Input 1 Not Assigned as Inputs 2 through 4 Not Assigned as Outputs 1 through 4 Choose Close to exit the I O Configuration window Tuning Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 2 3 Choose the Tuning command icon from the Drive window Select AutoTune from the Tuning mode group Select the appropriate values for the following Auto Tune com mands Distance and Step Current Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only Application and Configuration Examples 8 21 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the d
134. Indexing Connection Diagram Close to ENABLE Drive Close to RESET Fault Close to Start INDEX Close for Registration Sensor DRIVE J4 XMT 2 RCV Encoder RGV 3 XMT COM 5 COM Phase 1 Phase 2 J1 Phase T 3 26 I O PWR Motor Gnd 4 20 ENABLE 21 FAULT RESET 32 INPUT1 100 240 VAC ie 50 50 Hz 2 33 INPUT2 Single Phase Power Source or 100 240 VAC 50 50 Hz Three Phase Power Source Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F or P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display codes 2 Start ULTRA Master on the PC 3 Choose Cancel from the Drive Select dialog box 4 Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings Publication 1398 5 0 October 1998 8 36 Application and Configuration Examples Publication 1398 5 0 October 1998 5 8 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are diffe
135. LUE LABEL BRADY z 0 4 40 12 0 25 012 0 8 0 12 1 24012 5 25 0 12 7 25 10 25 Publication 1398 5 0 October 1998 B 26 Cable Diagrams Schematics and Examples Cabling Examples Figure 26 F or H Series Motors to ULTRA 200 Series Drive Enclosure Cabinet F or H Series Motor Motor Power Connector Encoder Connector 9101 1366 XXX 9101 1391 92 To 28 Control Interface 96 20 Screw Terminal Strip Clamp exposed motor cable shield to the chassis ground terminal ot Motor Power Cable Notes This wiring method should be used to run cables through a bulkhead or enclosure without removing the connectors Cable 9101 1366 has connectors on both ends The connectors are molded and potted to the cable and may not be disassembled Adaptor Kit 9101 1391 includes the 3 foot cable screw terminal strip and mounting bracket The cable has a 50 pin Mini D ribbon connector at the drive end and a 50 pin D connector at the terminal strip end Motor Power Cables Use ULTRA Series cables for applications requiring the CE mark The shield on
136. M 075X are rated for either single phase or three phase power inputs When connected to a single phase input the user must change the current limits of the drive The following drive parameters must be set e Positive Current Limit 50 A peak e Negative Current Limit 50 A peak e Average Current 15 A continuous An explanation of how to set these values is contained in ULTRA Master on line help ATTENTION DC bus capacitors may retain hazardous voltages for several minutes after input power has been removed but will normally discharge in several seconds Measure the DC bus voltage to verify it has reached a safe level each time power is removed before working on the drive or wait for the time indicated in the warning on the front of the drive Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION Motor power connectors are for assembly purposes only They should not be connected or discon nected while the drive is powered ATTENTION Failure to set the current limits for single phase operation of the 1398 DDM 075 or 1398 DDM 075X can result in drive malfunction and potential damage Power Connections 7 3 Motor Power Cabling Terminals 1 through 4 connect the drive to the windings of the motor gt Note Proper phasing of these outputs relative to the motor terminals is critical Double check the connections after wiring the motor Table 7 1 lists the drive termin
137. MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE r BLACK 1 _ Hi WHITE BLACK b 2 RED I 3 WHITERED Hi 4 ER 2 GREEN 5 1 WHITE GREEN h i 1 ORANGE 7 WHITE ORANGE 8 BLUE 9 X WHITE BLUE 4 0 YELLOW X WHITE YELLOW X 2 BROWN 3 WHITE BROWN 25 MOLET 14 WHITEIOLET 5 GRAY x WHITE GRAY K 7 PINK 8 A WHITE PINK I 9 WHITE BLACK RED 20 RED BLACK B 21 __WHITE BLACK ORANGE 22 ORANGE BLACK 5 23 S SHTEIBLACKNELLOW 24 YELLOW BLACK 25 a WHITE BLACKIGREEN 27 GREEN BLACK 28 22 WHITE BLACK BLUE 29 ALUE BLACK H 30 GREEN RED 31 X YELLOWIRED 32 GRAYJBLUE 33 X YELLOWIBLUE 34 GRAY BROWN 35 YELLOW BROWN 4 35 GRAY GREEN 37 5 YELLOW GREEN 38 GRAYIORANGE 39 Xx YELLOW ORANGE X 40 GRAYAWHITE 41 X YELLOWAWHITE x 42 BIUE RED 43 A GREENRED 4 44 BLUE ORANGE i 45 GREEN ORANGE x 46 BLUE YELLOW X GREENNELLOW x 0 i 48 BLUEAVHITE 49 _ 4 X GREENWHITE 50 DRAIN Publication 1398 5 0 October 1998 PIN 26 THIS END DENOTES TWISTED PAIR CONNECTOR BACKSHELL SHIELDED 360 PIN 1 THIS END PIN 14 THIS END Figure Cable Diagrams Schematics and Examples J3 to J3 Interface Cable P N 9101 1463 E e foot 50 5 25
138. Mask ROM Checksum Error 83 Personality EEPROM Incompatibility OO 84 Service EEPROM Incompatibility Publication 1398 5 0 October 1998 10 6 Status Display Publication 1398 5 0 October 1998 Maintenance Chapter 11 Maintenance and Troubleshooting The ULTRA 200 Series drive is designed to function with minimum maintenance Periodic Maintenance Normally the only maintenance required is removal of superficial dust and dirt from the drive and a quick check of cable insulation and connections Cleaning To clean the drive use an OSHA approved nozzle that provides compressed air under low pressure lt 20 kPa 30 psi to blow the exterior surface and the vents clean Cable Inspection Inspect the connections particularly the power connections to ensure their tightness e All power connections should be torqued to 1 4 Nm 12 Ib in e D shell signal connectors can be inspected for proper seating e Visually inspect all cables for abrasion ATTENTION DC bus capacitors may retain hazardous voltages for several minutes after input power has been removed but will normally discharge in several seconds Measure the DC bus voltage to verify it has reached a safe level each time power is removed before working on the drive or wait for the time indicated in the warning on the front of the drive Failure to observe this precaution could result in severe bodily injury or l
139. Master Publication 1398 5 0 October 1998 At startup ULTRA Master examines the contents of MOTORDIR subdirectory to determine the list of motors it will display If a custom motor file is to appear it must be copied into the MOTORDIR directory before ULTRA Master is started Each motor file is a binary file that contains e the motor parameter set atable ID number and e text string Because they are binary files only ULTRA Master can be used for editing and generation i e you cannot edit motor files using a text editor Motor Parameter Set The motor parameter set configures the ULTRA 200 Series drive to control a specific motor Motor parameters provide information about the electrical properties ratings and construction of the motor Subsequent sections of this appendix explain these properties with meaningful depth For now it is sufficient to know that accurate and complete definition of the motor s properties is necessary to achieve good performance Table ID The table ID number tells ULTRA Master whether the motor file represents a standard motor or a custom motor e Standard motor table IDs occupy the range 0 to 65534 e custom motor table ID is 65535 also known as 1 Standard motor parameter sets are stored in the drive as well as in the motor file Thus ULTRA Master needs to transmit only the table ID to select the motor model from the drive s personality EEPROM For custom m
140. N SYSTEM a VCR06R18 4S MOLDING ADAPTER ALUMINUM BLACK OVERMOLDING PVC BLACK DRAWING 9101 1381 l il 20418 10418 903440010 Q Ad Qf 20 ervel 25 z N 18 GLUE SHRINK 2 MARKED WITH 1 2418 PART AND REV MANUFACTURERS PART REV AND DATE CODE 525418 7 25 14 4 18 B 18 Publication 1398 5 0 October 1998 B 22 Figure B 20 Cable Diagrams Schematics and Examples 4 50 APPROX 200 94 CONNECTOR VAN SYSIEM VCR06R20 4S MOLDING ADAPTER ALUMINUM BLACK 4000 F or H Series Power Cable P N 9101 1382 WIRING DIAGRAM pum FERRULE INSULATED ALTECH 2207 0 wm wie L4 n ER 0 389 0 010 p 95 I 7 GLUE SHRINK MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE OVERMOLDING PVC BLACK Figure B 21 4418 p 848 5 25 18 7 25 1 4 6100 or 6200 F or H Series Power Cable P N 9101 1383 5 25 APPROX CONNECTOR N VAN SYSTEM MOLDING ADAPTER ALUMINUM BLACK OVERMOLDING PVC BLACK Publication 1398 5 0 October 1998 00 614 0 020
141. NS 1 amp 2 OF TB2 5 FOR EXTERNAL SHUNT RESISTOR 0 050 REMOVE JUMPER INSTALLED BETWEEN PINS 1 8 2 OF TB2 gt FO 10 M5 27 INSTALL WIRING AS SHOWN MTG HOLES 3 N 860 T oN 36 OF 14 AWG WIRE IS SUPPLIED WITH EXTERNAL SHUNT RESISTOR 54 025 0184 CUT TO LENGTH AS REQUIRED k 3N 6 32 STUD NUT AND WASHER SUPPLIED FOR CUSTOMER GROUNDING J N LITTLEFUSE PART NUMBER 4 5 LAN 0 0 EXTERNAL SHUNT RESISTOR 5 20 132 1 EXTERNAL SHUNT RESISTOR p ON AA 2 Xv 0 MIN 863 J aR 5 E EXHAUST 1 i p n 9 Sa CONNECTION DIAGRAM INCHES A mm AIR INTAKE Publication 1398 5 0 October 1998 Analog Control Chapter 8 Application and Configuration Examples This section explains how to install and verify the ULTRA 200 Series drive for various modes of operation The procedures verify the installation by e Showing how the power and logic wiring is connected e Selecting the Operation Mode setup for the drive e Tuning the drive for a particular motor type and size e Verifying the basic functionality of the drive and motor combinat
142. NT J1 29 AOUT1 J1 30 AOUT2 41 31 INPUT1 LIMIT INPUTS ANALOG OUTPUTS 15V 10KQ 20KQ PROGRAMMABLE CURRENT MONITOR L J1 32 INPUT2 DIGITAL J1 33 INPUTS 5KQ MAX 91 34 TYPICAL DIGITAL INPUT 1 OF 4 1 35 J1 36 41 37 21 38 J1 39 J1 40 41 41 OUTPUT1 PROGRAMMABLE gt 5KQ 6 45 MOTOR ENCODER OUTPUT AUXILIARY ENCODER INPUT ANALOG COMMAND FORWARD 1 CURRENT LIMIT TYPICAL DIGITAL INPUT 1 OF 4 INPUTS 1 4 D 41 42 OUTPUT2 DIGITAL z J1 43 OUTPUT3 OUTPUTS 11 44 OUTPUT4 Y MOTOR BRAKE v J1 45 J1 46 J1 47 J1 48 PROGRAMMABLE TYPI 5V 2 HU 5V CAL DIGITAL OUTPUT 1 OF 4 IOPWR J1 49 J1 50 BRAKE BRAKE 24VDC OUTPUTS 1 4 Publication 1398 5 0 October 1998 6 46 Interfaces Publication 1398 5 0 October 1998 TB1 DC Bus and AC Power Power Connections Chapter 7 Refer to Figure 5 4 on page 5 11 for power wiring connection diagrams for the drives
143. OTOR ENCODER 15 B CONTROLLER Models 1398 DDM 075 and 1398 DDM 075X page 10 1 11 6 page 6 44 page 6 36 page 6 34 page 6 34 page 6 31 page 6 27 page 6 1 Preface Intro 23 Product Parts Explained sheet 3 of 3 A V x DNE page 10 1 11 6 E page 6 44 6 36 page 6 34 WARNING HIGH VOLTAGE B page 7 6 POWER i page 6 34 page 7 3 page 6 31 page 7 6 lt page fo 5 12 E S page 6 27 page 7 10 4 i L2 N AUX m ES z gt page 6 1 1 CGO A Li 7 Tt Models 1398 DDM 150 and 1398 DDM 150X Publication 1398 5 0 October 1998 Intro 24 Preface Publication 1398 5 0 October 1998 Installing and Using the ULTRA 200 Series Chapter 1 Safety Read the complete manual before attempting to install or operate the ULTRA 200 Series drive By reading the manual you will become familiar with practices and procedures that allow you to operate the ULTRA 200 Series drive safely and effectively Potential Hazards The equipment described in this
144. October 1998 Installation 5 9 Table 5 2 MDF AC Line Filter Dimensions DIMENSION SINGLE PHASE THREE PHASE THREE PHASE THREE PHASE 36 A 50 36A 50A 70 174 6 85 230 9 06 230 9 06 238 9 37 1 104 2 4 09 2 110 3 4 33 3 110 3 4 33 3 150 3 5 91 3 2 80 2 3 15 2 120 3 4 72 3 120 3 4 72 3 120 2 4 72 2 20 0 79 120 4 74 147 5 79 147 5 79 186 7 32 1 101 2 3 98 2 128 2 5 04 2 128 2 5 04 2 167 2 6 57 2 2 86 3 39 113 4 45 113 4 45 152 5 98 B3 60 2 2 36 2 25 0 98 25 0 98 40 1 57 B4 _ _ 25 2 0 98 2 25 2 0 98 2 40 2 1 57 2 B5 25 2 0 98 2 25 2 0 98 2 40 2 1 57 2 C 77 3 03 77 3 03 77 3 03 114 4 49 C1 55 2 17 55 2 17 55 2 17 85 3 35 C2 20 0 79 14 0 55 14 0 55 14 0 55 C3 22 4 0 87 4 22 6 0 87 6 22 6 0 87 6 29 6 1 14 6 D1 12 0 47 12 0 47 12 0 47 12 0 47 D2 6 0 24 6 0 24 6 0 24 6 0 24 D3 12 0 47 12 0 47 12 0 47 12 0 47 Connectors 5 7 M6 7 8 6 and 6 earth NOTE Line filters are manufactured to millimeter dimensions inches are approximate conversions Publication 1398 5 0 October 1998
145. P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display codes Start ULTRA Master on the PC Choose Cancel from the Drive Select dialog box Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings Publication 1398 5 0 October 1998 8 30 Application and Configuration Examples Publication 1398 5 0 October 1998 5 8 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are different correct the Port Settings to allow communications with the drive Factory default communications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions Select Read Drive Parameters from the Communications menu Verify the Drive Name and Address are correct for the drive that is being addressed Choose OK to load the drive parameters Note A motor must be selected for the parameters to load 10 11 12 13 14 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Motor Model selection parameter active The motor ma
146. P N amp REV PVC BLACK MFG P N amp REV amp DATE CODE MOLDING ADAPTER ALUMINUM BLACK COBALT PLATED WIRING DIAGRAM x BLACK 28 AWG 28 X RED 28 AWG 5 WHITE RED 28 AWG GREEN 28 AWG WHITE GREEN 28 AWG X ORANGE 28 AWG WHITE ORANGE 28 X NC 20 AWG K GRAY 16 AWG 20 AWG Y 20 AWG X X L WHITE GRAY 16AWG 20AWG 1 KPSE05E14 19S A71 CONNECTOR M FACE VIEW BLUE 28 AWG WHITE BLUE 28AWG X BROWN 28 AWG Uu i X WHITEIBROWN 28 AWG X VIOLET 28 AWG 5 X WHITEVIOLET28AWG X DRAIN T NC i P NC DENOTES TWISTED PAIR V CONNECTOR BACKSHELL SHIELDED 360 Publication 1398 5 0 October 1998 B 21 Cable Diagrams Schematics and Examples Motor Power Cables ATTENTION Shielded power cables must be grounded at a minimum of one point for safety Failure to ground a shielded power cable will result in potentially lethal volt ages on the shield and anything connected to it Figure B 19 2000 or 3000 F or H Series Power Cable P N 9101 1381 4 25 APPROX 188 m 94 FERRULE INSULATED AUECH 22050 2 LABEL BRADY i 6 BROWN CONNECTOR VA
147. PhaseR 1 5 2 J1 14 STEP Step Dir L 15 STEP Motor Gnd 4 Generator 16 DIR TB4 L1 ico 100 240 VAC Close to ENABLE Drive 20 ENABLE LOIN 50 60 Hz Single Phase Close to Faut 21 FAULT 8 Power Source 26 24V or Close to Turn ON 25 32 INPUT1 TBI L1 100 240 VAC LaN 50 60 Hz L3 Three Phase Gnd Power Source Note 1 Refer to Figure 6 30 and 6 31 for additional details on the Control Interface Cable Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify e green DC BUS LED is ON e seven segment display shows an operational status A F or P Analog Follower or Preset mode of operation Refer to Operating Messages on page 10 1 for an explanation of the display codes Publication 1398 5 0 October 1998 8 Application and Configuration Examples 8 19 Start ULTRA Master on the PC Choose Cancel from the Drive Select dialog box Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are different correct the Port Settings to allow communications with the drive Factory default communications Port Setti
148. Publication 1398 5 0 October 1998 The following is an example of a custom motor A 50 1 gear is included inside this motor The example illustrates how to configure a custom motor Manufacturer s Data The following specifications were taken from the manufacturer s data sheet e Reduction Ratio 1 50 e Rated Current 1 4 Amp e Maximum Current 3 8 Amp e Maximum Speed 80 RPM e Torque Constant 270 in lb Amp e BEMF 1 1 Volt RPM per phase e Motor Resistance 3 7Q per phase e Motor Inductance 5 0mH per phase e Thermal Time Constant 30 minutes e Moment of Inertia 5 1 in Ib sec e Encoder Linecount 1500 lines rev e No Integral Thermostat A check with the manufacturer yielded that the motor has 8 poles and that the line to line back EMF and Hall signals are as shown in Figure D 7 below The figure indicates that no lead swapping is necessary but the Hall offset is 120 Figure D 7 Back EMF and Hall Signals Clockwise Rotation Creating Custom Motor Files D 15 Parameter Conversions The 1 50 gearing makes this motor an unusual case The motor file must be generated as if the motor and gear are two separate devices The inertia torque speed etc must be computed based on the motor side of the gearing rather than the load side The maximum speed of the motor before gearing is computed as rev rev 80 50 4000 a m
149. RA 200 Series Drives Appendix A Options and Accessories ULTRA 200 Series drives conformance to the European Union Directives is contingent on e Installation of AC line filters between the power source and the drive and e Use of Allen Bradley cables to connect F H N or Y motors to a 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X drive Diagrams and schematics for all Allen Bradley cables are shown in Appendix B Cable Diagrams Schematics and Examples Model Description 1398 DDM 010 1000 Watt Universal Drive single phase 100 240 VAC 50 60 Hz 1398 DDM 010X 1000 Waitt Universal Indexing Drive single phase 100 240 VAC 50 60 Hz 1398 DDM 020 2000 Watt Universal Drive single phase 100 240 VAC 50 60 Hz 1398 DDM 020X 2000 Watt Universal Indexing Drive single phase 100 240 VAC 50 60 Hz 1398 DDM 030 3000 Watt Universal Drive single phase 100 240 VAC 50 60 Hz 1398 DDM 030X 3000 Watt Universal Indexing Drive single phase 100 240 VAC 50 60 Hz 1398 DDM 075 7500 Watt Universal Drive single or three phase 100 240 VAC 50 60 Hz 1398 DDM 075X 7500 Watt Universal Indexing Drive single or three phase 100 240 VAC 9 50 60 Hz 1398 DDM 150 15000 Watt Universal Drive three phase 100 240 VAC 9 50 60 Hz 1398 DDM 150X 15000 Watt Universal Indexing Drive three phase 100 240 VAC 9 50 60 Hz Publication 1398 5 0
150. Start up Error 7 2432 73 Sub Processor Checksum Error 7 4 74 Personality EEPROM Write Error 27 29 75 Service EEPROM Write Error E 76 Software Clock Error E 77 Sub Processor Communication Checksum Error E 4 8 78 Sine Table Generation Error Publication 1398 5 0 October 1998 Table 10 2 Status Display 10 5 Power Up Error Codes continued Status Display Error Code Fault Description Seer ree eee a 79 n Personality Data Out of Range where n suberror parameter 1 Serial baud rate selection 2 Serial stop bits parity selection 3 Position Loop Kp 4 Position Loop Ki 5 Position Loop Kff 6 Position Loop Kd 7 Gear ratio 8 Encoder Output Divider 9 Velocity Loop Update Period 10 Velocity Loop P Gain 11 Velocity Loop Gain 12 Velocity Loop D Gain 13 Reserved 14 Analog Command Velocity Offset 15 Analog Command Torque Offset 16 User D A Variable Selection 17 Command Source 18 Drive Mode Torque Velocity 19 Tuning Direction 20 Motor Encoder User Alignment Offset 21 Encoder Size 22 Motor Torque Constant 23 Motor Inertia 24 Motor Back EMF 25 Motor Resistance per Phase 26 Motor Inductance per Phase 27 Motor Commutation Type 28 Motor Encoder Hall Offset 29 Motor Encoder Index Offset 30 Motor Pole Count 80 1 Service Data Out of Range Drive Type 81 Motor Block Checksum Error 82
151. TL Output 14 PEE __ 4 4 twisted 45V 5 Supply Return lt TTL Output lt twisted pair ChB gt i eS 4xx TTL Output Ch 5 Volts 5V Connect only if J1 sources Encoder power 3 5VDC Supply 250 mA Encoder Case Drive Chassis Figure 6 28 Single Ended Encoder Interface via Open Collector Transistor with 5 VDC to 12 VDC Pull up not recommended ENCODER J1 Drive 5 12 Volts f f AN 14 ChA 4 twisted pair 4 5V x 2 ECOM Supply Return 57 x lt twisted pair 5 12 Volts 16 BX ChB d BC 5 12 Volts 18 IX Ch R V i 2 I Encoder Case Drive Chassis Publication 1398 5 0 October 1998 6 24 Interfaces Figure 6 29 Single Ended Encoder Interface via Open Collector Transistor with 24 VDC Pull up not recommended ENCODER J1 Drive 24VDC ChA IN751 twisted pair A 2 Supply Return v twisted pair nm 16 BX ChB 4 m 9 Bx gt 5 1 VI IN751 24VDC D 5 D gt 5 1 VI IN751 Encoder Case v Drive Chassis Table6 21 Step Direction and CW CCW Step Up Step Down Interface Specifications Specification Description Minimum Maxi
152. The current revision level of drive firmware excluding the TouchPad firmware is displayed in the Drive Information window of ULTRA Master The current revision level of TouchPad firmware is displayed as part of the TouchPad initialization when a TouchPad is connected to the drive The types of files and their functions are e Firmware Main Operating firmware for the drive e Boot Block Drive Initialization firmware for the drive Unpacking the Drive Inspection Procedure Chapter 4 Unpacking Inspecting and Storing This chapter describes four steps which should ensure that the drive functions correctly The steps include e Unpacking the ULTRA 200 Series drive e Inspecting the drive for shipping damage e Testing the basic functionality of the drive e Guidelines for storing the drive 1 Remove the ULTRA 200 Series drive from the shipping carton and remove all packing materials from the unit The materials and carton may be retained for storage or shipment of the drive 2 Check all items against the packing list A label located on the side of the unit identifies model number serial number manufacturing date code To protect your investment and ensure your rights under warranty we recommend the following steps be performed upon receipt of the unit e Inspect the unit for any physical damage that may have been sustained during shipment e Perform the drive checkout test to verify the functionality of
153. Troubleshooting Guide Problem or Symptom Error Code Possible Cause s Action Solution Status display not lit No AC power Verify power 115 230VAC single phase or 230 VAC three phase is applied to the drive Blown power fuse s Check for open circuits in the AC line fuses DC BUS LED not lit No Bus power Verify AC power is applied to the drive Check for open circuit break ers in AC line Blown power fuse s Check fuses Motor jumps when first Motor encoder wiring error Check motor encoder wiring enabled See Figure 6 36 on page 30 to verify connection of encoder power sense sig nals Incorrect motor chosen in Select the proper motor in personality module ULTRA Master Digital I O not working cor 24V power supply discon Verify P5 P6 jumper set rectly nected tings are correct 24V Fuse Blown 01 F1 Blown The fuse on the isolated 24 VDC power supply has tripped Check replace fuse F1 if necessary Check for shorts on I O or 24VDC output Publication 1398 5 0 October 1998 Table 11 1 Maintenance and Troubleshooting Troubleshooting Guide continued 11 7 Problem or Symptom Error Code Possible Cause s Action Solution 5V Fuse Blown 02 F2 Blown The fuse on the encoder power output for the 5 VDC power supply has tripped Check replace fuse F2 if necessary Check for shorts on Encoder output signals or 5V output Check that J4 pin 9 or J5 pin 9 is not connected to a
154. ULTRA Master software supports the addressing range to 32 which is stored in EEPROM Each drive may be assigned a unique name of up to 32 characters in length a name is often easier to remember than the address of a drive ULTRA Master software automatically associates a drive name with the correct drive address Publication 1398 5 0 October 1998 6 38 Interfaces Publication 1398 5 0 October 1998 RS 232 Connections The physical address is set using the 16 position rotary switch on the front panel Note Do not connect any device to J4 6 J5 6 J4 9 or J5 9 except an Allen Bradley TouchPad Figure 6 39 RS 232 Connection Diagrams USER Drive PC RS 232 CABLE 9 Pin 9 Pin 9 Male Connector to 9 Pin Female Connector pi RS 232 Female Male _J4 J5 U RCV 2 2 2 XMT XM 3 3 COM U COM K Drive Chassis PC pin outs may vary by manufacturer USER Drive PC RS 232 CABLE 25 Pin 252 9 Male Connector to 25 Pin Female Connector pin RS 232 Female Male J4 or J5 2 2 2 XMT 3 3 3 com F 7 5 5 d Drive Chassis PC pin outs may vary by manufacturer Single Axis RS 232 Set Up A single ULTRA 200 Series drive may be selected using RS 232 communications After cabling is attached to the unit and the drive a
155. VDC power to user electr nics 1 5VDC 5 Volts Supply 5V 250 mA Publication 1398 5 0 October 1998 Drive Chassis J1 Terminal Strip Breakout Board A 50 terminal strip kit is available for extending the signals from the J1 connector The kit includes a 1 meter 3 foot interface cable a 50 pin terminal strip and mounting hardware Refer to Options and Accessories on page A 1 Cabling Examples on page B 26 depicts the use of this kit to pass a cable through a bulkhead J2 Encoder Pin Signal Description Pin Signal Description 1 EPWR Encoder 11 Motor Encoder Power Input Channel 1 2 ECOM Encoder 12 1 Motor Encoder Common Input Channel 3 EPWR Encoder 13 HALL A Hall Effect A Power 4 ECOM Encoder 14 HALL B Hall Effect B Common 5 SENSE Encoder 15 HALL C Hall Effect Power Sense 6 SENSE Encoder 16 ABS Absolute Power Position Sense 7 A Motor Encoder 17 Reserved Input Channel A 8 A Motor Encoder 18 Reserved Input Channel A 9 Motor Encoder 19 TS Thermal Input Switch Channel B 10 B Motor Encoder 20 TS Thermal Input Switch Channel B Interfaces pin 20 pin 11 em 6 27 pin 10 pin 1 J2 is a 20 pin female mi
156. W INYA NI 8101 H3AO 300801 H3A3N N3LH LLH3AO LON SM3HOS 1308 9nNS 5 5318 0 31 39733 NIVH1S 5 38 13 0VH8 SIHL LOVEE OL LI NIdNV19 AB 318VO H3MOd IHL 3IVNINH31 Q3AH3580 38 SNOILVINDAY W907 40 SLNAWSYINOAY aH SAMA G3G3N3WWOO3ti WAWININ 53215 3HIW 31815504 SV 3AIHQ 01 35070 Sv 38 uva SNE NOWNOO 318ISSOd SV LHOHS SV 193 38 SINGOW IHL NIAMLIA HANIA 7 NY SVH 1 XNY IHL TWAOWAY HaMOd NOdN AWIL 39HVHOSIG 39V3V31 SHALT INIT OV NOLLAVO 3AI193HIG ALIISVIVdNOO O1LANDVWOULOS T3 NV3dOun3 133W 01 38V ALIISVIVdWOO OlL13NOVWOH10313 SINON NIAOHdWI GASN 38 OL HO1ON HALT 3N10V 304006 OV H3H1O HO H3WHO4SNVHI G3H3MOd 38 8 8 LINW4 V HO 1N3S3Hd SI H3MOd SI H3MOd NIVW N3HM G3N3dO 38 LSAW LONI 318VN3 V XlddfiS OV OL A1103HIO SNOLLO3NNOO 31VHVd3S JV SNOLLOSNNOO H3MOd FINGON LON OG 9 8 OVA 062 SWH OVA 092 001 WV
157. Wire size mm AWG 2 5 14 2 5 14 2 5 14 2 5 14 6 0 10 Figure 7 4 External Shunt Wiring Examples 1X Shunt Resistance up to 200 Watts TB2 1 2 Rt TB2 3 NOTES 1 A single resistor of equivalent total resistance may replace multiple resistors 2 Dissipation uses approximately 50 of total resistance value 4X Shunt Resistance up to 1000 Watts 2 1 2 1 lt R2 2 R4 TB2 3 300 Ohm 500 Watts is factory available 9X Shunt Resistance up to 2400 Watts TB2 1 d 2 R1 lt 2 gt R3 gt Rat 2 R5 2 gt R7 2 R8 gt TB2 3 Publication 1398 5 0 October 1998 7 14 Power Connections External Shunt Connection The following procedure outlines the installation of an external shunt resistor 1 Remove jumper between TB1 1 and TB 1 2 the internal shunt connection The jumper is supplied with the drive 2 Wire an external shunt resistor between TB1 1 and TB1 3 the external shunt connections Use wire of the size recommended in Minimum Ratings for Customer Supplied External Shunt Resis tor on page 7 13 3 Torque all terminals to 11 0 Ib in Note A fan may increase the dissipation capability of the shunt resistor Figure 7 5 External Shunt Mounting Diagram NOTES 1 FOR INTERNAL SHUNT RESISTOR 5 JUMPER INSTALLED BETWEEN PI
158. YELLOW BROWN qox J B WHITE BROWN PIN 14 THIS END 14 VIOLET 15 Q WHITE VIOLET 16 GRAY Y 17 WHITE CRAY 18 PINK WHITE PINK 19 20 A WHIIEJBIACK RED A 2 RED BLACK 22 WHITE BLACK ORANGE 23 ORANGE BLACK 24 A WHITE BLACKIYELLOW y 25 YELLOWY BLACK Q DENOTES TWISTED PAIR DRAIN 0 CONNECTOR BACKSHELL SHIELDED 360 Publication 1398 5 0 October 1998 Cable Diagrams Schematics and Examples B 7 Figure B 5 J1 to 50 pin Terminal Block Kit Diagram P N 9101 1391 and 9101 1560 1 E 1 gt J 0 156 THRU 2 1 38 Y E REF j 25 Mounting bracket 0002 7069 shown and cable 9101 1369 003 supplied with 9101 1391 kit Mounting bracket 0002 7069 shown and cable 9101 1369 010 supplied with 9101 1560 kit NOTES The terminal block and cable provide a one to one transfer of the signals from the connect
159. able inputs are e Drive Mode Select e Integrator Inhibit e Follower Enable e Forward Enable e Reverse Enable e Preset Select A e Preset Select B e Preset Select C e Operation Mode Override e Start Index e Define Home e Start Homing e Remove COMMAND Offset Interfaces 6 5 Refer to the I O Configuration section of the ULTRA Master manual for information on choosing the input type for each channel Table 6 3 General and Dedicated Inputs Digital Input Pin Function Description Internal Number Connections ENABLE J1 20 Enables and disables the drive Motor torque cannot be J3 20 applied unless the ENABLE input is active FAULT 11 21 General purpose input selectable to one of several drive 13 21 RESET functions Refer to Table 6 4 for I O configuration INPUT 1 J1 32 INPUT 2 J1 33 INPUT 3 J1 34 INPUT 4 J1 35 Table 6 4 INPUT1 INPUT2 INPUT3 INPUT4 and FAULT RESET Functions Function Description Drive Mode Select Active state configures the drive for Torque Mode Inactive state selects the personality EEPROM setting as the command source Integrator Inhibit Active state zeros the Velocity Loop Error Integrator Follower Enable Active state allows the position loop to track the AUXILIARY POSITION LOOP signal when in the Follower mode Forward Enable Active state allows forward commands in velocity mode only If this input is inactive or not connected
160. ace Intro 17 Description Provides information on making motor power DC bus and AC Power connections Describes the hardware and software set up necessary to install the drive as one of the following types Analog Control in velocity or torque mode Preset Controller in velocity or torque mode Position Follower Master Encoder in velocity mode Position Follower Step Direction in velocity mode Position Follower Step Up Step Down in velocity mode Incremental Indexing Registration Indexing Absolute Indexing Modifying User Units Provides instructions on how to tune a drive and motor combination using the autotuning or manual tuning features in ULTRA Master Discusses the operator indicators available on the front panel Operat ing or Error Messages are explained Describes the minimal maintenance necessary with the ULTRA 200 Series drives and provides a comprehensive troubleshooting chart of potential problems and their solutions Lists the optional equipment available for the ULTRA 200 Series drives Provides schematics and cabling examples Describes how to program a ULTRA 200 Series drive using the optional TouchPad device Tables reference the various motor types that are programmed to work with the ULTRA 200 Series drive A TouchPad Command Tree card for the current firmware version is bound into the manual Describes how to create a custom motor file for use with an ULTRA 200 Series drive Describes c
161. achieve a reasonable bandwidth and servo response based on the system inertia and friction Auto tune may be used when a significant amount of compliance or backlash exists for example belt systems in the mechanical load but precise tuning requires the load be fully coupled to the motor Instability problems occur when the load is not fully coupled to the motor Note The autotune algorithm will not provide satisfactory results in systems with significant gravitational effects Auto Tuning A PC running ULTRA Master is required to perform tuning on a ULTRA 200 Series drive The optional TouchPad does not support tuning Before auto tuning is invoked three autotuning parameters must be set e Distance sets the rotation limit of the motor This is the maximum distance the motor is allowed to move during any one test Note a test in the bi directional mode includes two different tests e Step Current sets the amount of current given to the motor during the test If this is set too low a system may not move enough to gather sufficient data if it is set too high the test will be too short and very jerky e Motor Direction Forward Only Reverse Only Bi directional sets the rotational direction for the test The bi directional test does the same test in both directions with the forward rotation first Auto tune procedures are explained for each drive configuration in Application and Configuration Examples starting on page 8
162. ailable from the factory 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series A simple 3 wire cable is depicted in the figure below Connect a Motor Feedback cable from the motor to the J2 connec tor on the ULTRA 200 Series Connect a Power cable from the motor to terminals R S T and on the drive Connect the Stepper Indexer to the drive as shown in the diagram Connect a jumper wire with a toggle switch between the follow ing pins J1 20 ENABLE and J1 26 I O PWR e J1 32 INPUTI and J1 26 PWR e 11 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches Connect the drive to a 100 240 VAC 50 50 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Application and Configuration Examples 8 23 Connection Diagram Close to ENABLE Drive Close to RESET Fault Close to Turn ON Figure 8 5 Step Up Step Down Controller Connecti
163. all State Sublntr Unused Interrupt sub processor Unused Interrupt main processor ExsAvgl Excessive Average Current OvSpeed Motor Overspeed ExsFErr Excessive Following Error MtrEnc Motor Encoder State Error MstrEnc Auxiliary Encoder State Error MtrThrm Motor Thermal Protection IPMThrm IPM Thermal Protection EnNoMtr No Motor Selected while enabling drive MtrType Motor Selection not in Table Publication 1398 5 0 October 1998 TouchPad Instructions C 17 Table C 17 Drive Status List for TouchPad continued Display Parameter PersWrt Personality Write Error ServWrt Service Write Error CPUComm CPU Communications Error MtrOvt Motor Overtemperature IPMFalt IPM Fault ExsVErr Excess Velocity Error Comutat Commutation Angle Error Not Homd Axis Not Homed NOTE The Drive Status display is read only DrvEnab and DrvRgy indicate that the drive is functional The other displays indicate an error condition Table C 18 Input Flags Parameter List for TouchPad Display Parameter FItRst Fault Reset Input Flag ENABLE Drive Enable Input Flag Inputi Input 1 Input Flag Input2 Input 2 Input Flag Input3 Input 3 Input Flag Input4 Input 4 Input Flag Table C 19 Output Flags Parameter List for TouchPad Display Parameter READY Ready Output Flag BRAKE Brake Output Flag Outpt1 Output 1 Flag Outpt2 Output 2 Flag Outpt3 Output 3 Flag Outpt4 Output 4
164. all terminal connections to 11 0 Ib in Table 7 9 Internal Shunt Power Ratings for Drive Models Drive Model 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010 020 030 075 150 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010X 020X 030X 075X 150X Continuous Shunt Power Watts 50 50 50 50 180 Peak Shunt Power kWatts 4 5 4 5 4 5 10 0 19 0 If the application requires a higher continuous power dissipation the ULTRA 200 Series provides easy access to an external shunt connection Connecting an external resistor requires disabling of the internal shunt resistor Figure 7 4 depicts the use of one or more shunt resistors to provide 1 X 4X or 9X resistance 200 Watts to 2 4 kWatts Table 7 10 Maximum External Shunt Power Ratings for Drive Models Drive Model 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010 020 030 075 150 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010X 020X 030X 075X 150X Continuous Shunt Power kWatts 2 4 2 4 2 4 4 0 8 0 Peak Shunt Power kWatts 6 0 6 0 6 0 10 0 19 0 Publication 1398 5 0 October 1998 Power Connections 7 13 Table 7 11 Minimum Ratings for Customer Supplied External Shunt Resistor Drive Model 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010 020 030 075 150 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010X 020X 030X 075X 150X Minimum Resistance 10 Ohms 30 30 30 16 5 9
165. als and typical motor connections Table 7 2 lists the minimum wire size for making power wiring connections Table 7 1 1 Motor Power Terminals Motor Phase Signal Description Terminal R R phase from drive TB1 1 51 S phase from drive TB1 2 T T phase from drive TB1 3 1 Ground for the motor case TB1 4 NOTE Torque all terminal connections to 1 25 Nm 11 0 Ib in 1 The I Series and V Series motors require swapping of the R and S motor power leads when connecting to the drive Refer to Appendix A Options and Accessories for a list of available Allen Bradley cables Shield Termination of Power Cables ATTENTION Shielded power cables must be grounded at a minimum of one point for safety Failure to ground a shielded power cable will result in potentially lethal volt ages on the shield and anything connected to it Allen Bradley motor power cables are shielded The power cable is designed to be terminated at the drive during installation A small portion of the cable jacket is stripped which exposes the shield wires The exposed area must be clamped at the left front of the drive chassis using the clamp provided near the bottom It is critical for EMC performance that the shield wires be clamped against the area of the chassis which is not painted This section of the chassis is labeled with the chassis ground symbol Figure 7 1 Motor Power EMC Shield Connection Cable Jacket
166. als of the ULTRA 200 Series drive Ensure that the drive is connected to a safety earth ground ATTENTION Do not tin solder the exposed leads on cables Solder contracts over time and may loosen the connection Table 7 4 TB1 AC Power Terminals Signal Description Terminal 1398 DDM 010 and 1398 DDM 075 and 1398 DDM 010X 1398 DDM 075X 1398 DDM 020 and 1398 DDM 150 and 1398 DDM 020X 1398 DDM 150X 1398 DDM 030 and 1398 DDM 030X L1 100 240 Volts AC Line 1 input TB1 7 TB1 7 power L2 N 100 240 Volts AC Line 2 input TB1 8 TB1 8 power Neutral on single phase drive 1398 DDM 010 020 030 075 and 1398 DDM 150 L3 240 Volts AC Line 3 input power not used TB1 9 Available only on three phase drives 1398 DDM 075 and 1398 DDM 150 Safety earth ground TB1 9 TB1 10 NOTE Torque all terminal connections to 1 25 Nm 11 0 Ib in Publication 1398 5 0 October 1998 Power Connections 7 9 The inputs to the main logic and motor supply and the auxiliary logic supply only power sources are separated This permits independent powering of the control power and the motor power This dual power sourcing is useful for troubleshooting and diagnostics Table 7 5 AC Input Power Sizing Requirements Model Current Requirements Input Inrush Fuse Wire Transformer 2 rms Amps peak Amps Amps AWG kVA 1398 DDM 010 10 50 10 14 2 1398 DDM 010X 1398 DDM 020
167. and Configuration Examples Publication 1398 5 0 October 1998 8 Open the switch between J1 26 and J1 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Operation The drive is now configured as either a Position Follower Step Up Step Down The servo parameters have been setup with the unloaded motor e The motor position is controlled by the step indexer The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 26 and J1 20 to enable the drive 2 Close the toggle switch between J1 26 and J1 32 to enable fol lowing Incremental Indexing Application and Configuration Examples 8 27 gt Note This feature is available only on drives capable of indexing 1398 DDM 010X 1398 DDM 020X 1398 DDM 030X 1398 DDM 075X and 1398 DDM 150X The ULTRA 200 Series drive can be set up as a incremental indexer by making the hardware connections and performing the software setup and tuning described below A connection diagram depicts the minimum hardware necessary Interfacing the drive to an external controller requires similar circuitry from the controller to J1 refer to Controller on page 6 1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional
168. anual Units rpm V or Amps Publication 1398 5 0 October 1998 C 6 TouchPad Instructions Supplemental Instructions Publication 1398 5 0 October 1998 Motor Selection Enter a Motor Identification number to load the correct motor parameters into the drive Table C 2 and Table C 3 list the motors available in the motor table directory Displays Selection of a motor defines default operating parameters for the drive and motor combination Text A drive name longer than eight characters may require scrolling with the Left and Right arrow keys Drive names may be up to 32 characters in length Flashing characters in the Modify mode display are the characters that are active e Change the cursor position and resolution using the gt and keys For example If the Drv Name in the Modify mode displays InFeed with the F flashing pressing the gt key causes the first e to flash e Press the 7 or keys to increment or decrement a character by scrolling through the list of valid ASCII characters For example If the Drv Name in the Modify mode displays InFfed with the lowercase f is flashing pressing the key causes the flashing character to decrement to e Numeric Flashing characters in the Modify mode display are the numbers that are active e Change the cursor position and resolution using the
169. ardware necessary Interfacing the drive to an external controller requires similar circuitry from the controller to J1 refer to Controller on page 6 1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional TouchPad also may be used Note This feature is available only on drives capable of indexing 1398 DDM 010X 1398 DDM 020X 1398 DDM 030X 1398 DDM 075X and 1398 DDM 150X The following example depicts a simple move from a home position Figure 8 10 Absolute Indexing Examples Defined Velocity Velocity Defined Deceleration Defined Acceleration Outputs In Motion Hardware Setup Make the connections described below and shown in the Figure 8 11 The appendix Options and Accessories on page A 1 lists the interconnect cables available from the factory 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series A simple 3 wire cable is depicted in the figure below 2 Connect a Motor Feedback cable from the motor to the J2 connec tor on the ULTRA 200 Series 3 Connect a Power cable from the motor to TB terminals R S T and on the drive Publication 1398 5 0 October 1998 8 40 Application and Configuration Examples 4 Connect a jumper wire with a toggle switch between the follow ing pins J1 20 ENABLE and J1 26 PWR J1 32 INPUT1 and J1 26
170. asing of the Encoder Signals for Clockwise Rotation D 4 Index OffsetS eae wey evaded se Lhe eae D 8 Fall BE RAR dem a D 9 Motor Thermal Protection Software Method D 13 Back EMF and Hall Signals Clockwise Rotation D 14 Electromagnetic Compatibility Guidelines for Machine Design Source Victim Model E 2 Single Point Ground Types E 5 Dynamic Braking Resistor Selection Specifications Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 List of Tables Safety Selecting Other System Components ULTRA Master Installation Unpacking Inspecting and Storing Installation Qualified AC Line Filters 5 7 MDF AC Line Filter 5 9 MIF AC Line Filter Dimensions 5 10 Interfaces 24 Volt Power Supply 5 6 3 5 Volt Power Supply Specifications 6 4 General and Dedicated Inputs 6 5 INPUT1 INPUT2 INPUT3 INPUT4 and FAULT RESET 6 5 Digital Input 6 6 READY Output Specifications 6 9 BRAKE Output 6 10 General and Dedicated Outputs 6 10 OUTPUT1 OUTPUT2 OUTPUT3 and OUTPUT4 Functions 6
171. aware of safety considerations For example ATTENTION This symbol identifies information about practices or 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 the hazard e recognize the consequences Note This symbol identifies information that is critical for successful application and understanding of the product Mathcad is a registered trademark of MathSoft Inc Microsoft MS DOS and Windows are trademarks of Microsoft Corporation UL and cUL are registered trademarks of Underwriters Laboratories Chapter 1 Chapter 2 Table of Contents Table of Contents Intro 1 List of Figures Intro 7 List of Tables Intro 11 Preface Intro 15 About This Manual Intro 16 Additional Instructions and Manuals Intro 17 Host Commands and ULTRA Master Intro 17 TouchPad Intro 18 Symbols and Conventions Intro 19 Typographical and Wording Conventions Intro 19 Graphical Symbols and Warning Classifications Intro 20 Pictorial Index 2 2 22 2 2 460 4 Intro 21 Safety Installing and Using the ULTRA 200 1 1 Potential 1 1 Safety Guidelines eer Ss 1 3 Selecting Other System Components ULTRA 200 Series Overview
172. ble B 4 9 230 to J1 Connector 9 230 8520 ASM 4 Drive Connections Pin Signal J1 Pin Signal 11 CHA HI 7 Mtr Output Chnl A 10 CHB HI 9 Mtr Output Chnl B 39 CHZ HI 11 Mtr Output Chnl Index 41 CHA LO 8 Mtr Output Chnl A 40 CHB LO 10 Mtr Output Chnl B 9 CHZ LO 12 Mtr Output Chnl Index NOTE A B 845 encoders are usually wired with the A signal into the A signal on the Allen Bradley drive Publication 1398 5 0 October 1998 B 32 Cable Diagrams Schematics and Examples Publication 1398 5 0 October 1998 0089 979 912 1 uoddng jeoiuuoer yrrr Z88 b lb 1 0002 28 vv 1 1 1 VSN 70265 IM 19945 puooes YINOS 021 sjeuenbpeoH UOREWOINY FFOMAYION Wo OL H A 991 peduonol p ljipouu Jajawesed 1sp eui sioejes e uo uonejedo jo uonejedo sjejue Jajawesed e uo jo suinjed 1X N 1se1 9polN 1X9N euin eui Shay uloq 55914 ejeurejed umog pue 141 10 Bumes si 0 19 e siu JON Ek
173. ble to noise which may cause intermittent or continuous errors To improve noise immunity terminate cable shields at both ends of the cable Connect shields to the backshell of the connector with a complete circumferential 360 termination The cable connector should then connect to chassis ground not signal ground Figure 6 22 Auxiliary Encoder Input Circuit J1 Drive 5VDC 5K 1K AX T 220pF 5VDC um gt 10K 1K 26LS33 W 220pF 10K 5VCOM Publication 1398 5 0 October 1998 6 20 Interfaces Table 6 19 Auxiliary Encoder Step and Diection CW amp CCW Step Up amp Down Signals Auxiliary Encoder Input Pin Description Internal Number Connections AX and AX or J1 14 Auxiliary Channels A and A Differ J3 14 Step and Step or J1 15 ential quadrature or TTL level encoder J3 15 CW Step Up and input The signal input and resolution are CW Step Up selectable Refer to ULTRA Master Drive Setup BX and BX or J1 16 Auxiliary Channels B Differ J3 16 DIR and DIR or J1 17 ential quadrature or TTL level encoder J3 17 CCW Step Down and inputs The signal input and resolution are CCW Step Down selectable Refer to ULTRA Master Drive Setup IX and IX J1 18 Auxiliary Input Channels 1 and Dif J3 18 J1 19
174. blication 1398 5 0 October 1998 1 2 Safety Publication 1398 5 0 October 1998 Your Responsibilities As the user or person installing this drive you are responsible for determining the suitability of the product for the intended application Rockwell Automation is neither responsible nor liable for indirect or consequential damage resulting from the inappropriate use of this product A qualified person is someone who is familiar with all safety notes and established safety practices with the installation operation and maintenance of this equipment and the hazards involved For more detailed definitions refer to IEC 364 It is recommended that anyone who operates or maintains electrical or mechanical equipment should have a basic knowledge of First Aid As a minimum they should know where the First Aid equipment is kept and the identity of the official First Aiders Safety Guidelines Safety 1 3 Electrical shock and fire hazards are avoided by using normal installation procedures for electrical power equipment in an industrial environment Installation must be undertaken by suitably qualified personnel Note that this amplifier must be installed in an industrial cabinet such that access is restricted to suitable qualified personnel Mechanical hazards are associated with potentially uncontrolled movement of the motor shaft If this imposes a risk in the machine then appropriate precautions must be made to electrically di
175. by step approach to building a servo system using a ULTRA 200 Series drive The manual is divided into chapters that cover specific phases of the system design process from ordering components that will complement the performance of the ULTRA 200 Series drive to receiving installing and verifying the drive s functionality Chapters and appendices in the manual include e Safety e Selecting Other System Components e ULTRA Master Installation e Unpacking Inspecting and Storing e Installation e Interfaces e Power Connections e Application and Configuration Examples e Tuning e Status Display e Maintenance and Troubleshooting e Options and Accessories e Cable Diagrams Schematics and Examples TouchPad Instructions e Creating Custom Motor Files e Electromagnetic Compatibility Guidelines for Machine Design e Dynamic Braking Resistor Selection e Specifications The intent of the manual is to assemble a high performance servo system in a methodical manner By making correct decisions and taking appropriate actions a servo system that performs as designed can be assured Publication 1398 5 0 October 1998 Intro 16 Preface About This Manual Title Safety Selecting Other System Components This manual provides instructions on how to setup and connect the ULTRA 200 Series drive to a controlling device and a motor A ULTRA 200 Series drive may operate in one of several different functional modes The har
176. ce Digital Input 4 see Table see Table see Table Enc Out I pM Falt Rst Encoder Output i Fault Reset Input see Table Analog Presets Follower Analog Position Indexing see Table Y f Y bit Out CmdScale Preset FolRatio CmdScale Mode see Table Command Scale Presets 0108 Gear Ratio Command Scale Index Mode 0 to 8 DigOut2 rpm V Amps V rpm or Amps Numeric Counts Volt Selection Digi Output 2 CmdOfset A SlewEnab CmdoOfset Dist see Table Command Offset Slew Enable Command Offset IO Distance 0 to 8 DigOut3 mV Selection mV H counts Di giti Output 3 A SlewRate A Vel see Table Presets 4 Slew Rate IO Velocity 0 to 8 DigOut4 rpm sec m 09 Velocity Mode Anal Digita Output 4 761000 MastrRot nalog WE Count see Table y Master Rotation Position Batch Count 0 to 8 BrkDelOn or reverse counts AccelEn noma Brake Delay Active Acceleration Enable Y W Dwal msec Selection 5 wes ist BrkDelOff 5 AccelLim WA xx Brake ned Inactive 5 cceleration Limit IO Accel msec rpm sec PosErTim Ere 0108 AOutiCfg z DecelLim Position Error Time ELVIS Anal Out 1 Config o Deceleration Limit msec Li Decel see Table 2 rpm sec PosErLim IO Deceleration 0 to 8 AOutiScl Position Error Limit rpm sec Anal Out 1 Scale counts RegDs 5 Velocity Mode InPosTim gt o ERTO o In Position Time Waaa Anal Out 1 Offset msec mV InPosWin
177. configure the drive to control a custom motor Selecting Other System Components 2 7 European Union Requirements ULTRA 200 Series drives conform to the following European Union Directives Machinery Directive 89 392 EEC Article 4 2 and Annex II sub B Low Voltage Directive 72 23 EEC 93 68 EEC Electromagnetic Compatibility Directive 89 336 EEC 92 3 1 EEC 93 68 EEC Compliance with the EEC Directives is contingent on Installation of AC line filters between the power source and the drive and Use of Allen Bradley cables to connect motors See European Union EMC Directives on page 5 6 Appendix A Options and Accessories lists the mentioned equipment and Allen Bradley part number Allen Bradley motors available for use with ULTRA 200 Series drives include all F Series motors H Series motors Y Series motors N Series motors Publication 1398 5 0 October 1998 2 8 Selecting Other System Components Publication 1398 5 0 October 1998 Hardware and Software Requirements Chapter 3 ULTRA Master Installation Installation of ULTRA Master on a PC is covered in this chapter which Lists the minimum PC hardware and software necessary to run ULTRA Master Provides step by step instructions on how to load ULTRA Master Shows you how to start and quit ULTRA Master and introduces the Drive Window the main command window for ULTRA Master Instructs you on how to access on line hel
178. creen The About ULTRA Master window includes additional data about system resources typically displayed in Windows Help The ULTRA Master Start Up Screen When ULTRA Master starts for the first time its default instructions are e Display the Help menu Quick Start e Present the Drive Select window The Drive Select window offers Drive 0 which is the default drive address assigned at the factory The default ULTRA Master Start up screen is shown below The comments point out many of the Windows controls that are available in ULTRA Master Pop up menus accesses File Communications Window Help PC based commands Tool bar buttons provide quick access to common commands and windows Step 1 Choose OK in the Online Help explains tasks For Help press F1 Drive Select dialog box The Drive Sam 2 and commands box is displayed autometically when Ultra T Master is started to specify Hypertext links to specific which drive to setup It items in online Help presents the factory default Status bar reveals current menu selection and status Buttons perform typical Windows functions such as information sizing or scrolling opening or closing windows gt Note ULTRA Master displays the Help menu Quick Start when it is first accessed To disable this automatic display deselect the menu item Show Quick Start from the Help menu Setup automatically creates the ULTRA Master program group and
179. d for the input depending on whether the signal is a position velocity or torque com mand Refer to Analog Command Input on page 6 15 and Figure 6 18 J1 22 J1 23 w READY READY J3 24 J3 25 Contact closure indicates the drive is ready to follow commands Refer to READY Output Specifications on page 6 9 and Figure 6 8 J1 24 J1 25 Publication 1398 5 0 October 1998 6 34 Interfaces J4 and J5 Serial Port Publication 1398 5 0 October 1998 Pin Signal Description Use 1 RCV Receive RS 485 four wire 2 RCV Receive RS 232 pin5 3 XMT Transmit RS 232 idi M 4 XMT Transmit RS 485 four wire 5 COM 5 VDC Com mon MR pin 1 6 Reserved 7 ROV Receive RS 485 four wire 8 XMT Transmit RS 485 four wire 9 Reserved a Do not connect any device to J4 6 J5 6 J4 9 or J5 9 except an Allen Bradley TouchPad J4 and J5 are 9 pin female D shell AMP 205204 4 pins AMP 66506 3 connectors Each connector is a serial interface that allows communication with another ULTRA 200 Series drive a PC a terminal a host computer a controller or an optional TouchPad The signals on J4 and J5 are internally connected which allows daisy chain connection of several drives The shell of the connector is grounded to the chassis for shield
180. ddress is assigned configuration of i e communications with the unit may proceed The following steps outline how to select the communications options 1 Set the rotary switch to zero 0 which forces default communica tions with the drive 2 Connect an RS 232 cable between the computer and a serial con nector on the drive J4 or J5 Interfaces 6 39 3 Verify the computer can communicate with the drive by perform ing the following Switch drive power to ON e Start ULTRA Master on the attached PC Choose CANCEL from the Drive Select window Select Communications from the menu Select PC Set Up from the pull down menu Verify the port settings and if necessary change them then choose OK Select Communications from the menu Select Read Drive Parameters from the pull down menu Choose OK in the Drive Select window 4 Verify that ULTRA Master reads the drive parameters If not refer to Troubleshooting on page 11 6 The cable diagrams provide wiring examples for both 9 pin and 25 pin serial ports from an IBM compatible personal computer to the drive RS 232 pin outs vary between computer manufacturers Check the hardware reference manual of your machine to ensure correct signal connections between the computer and the drive Publication 1398 5 0 October 1998 6 40 Interfaces Four Wire RS 485 Connections The ULTRA 200 Series drives use a variation of the RS 485 standard known as four wir
181. der Case connect only if J1 sources Encoder power Dava Chassis Publication 1398 5 0 October 1998 6 22 Interfaces Figure 6 25 Complementary Encoder Interface via Standard TTL Logic ENCODER J1 Drive 74xx A 14 LoS lt twisted pair p 15 16 BX ChB lt twisted pair g 17 BX 74 18 1 Chl i lt twisted pair p 19 2 5V 4 ECOM Supply lt wisted pair gt Return 5 Volts 5V I J 1 5VDC Supply 5V 250 mA For horizontal dashed lines connect only if J1 sources Encoder power Encoder Case Drive Chassis Figure 6 26 Single Ended Encoder Interface via Open Collector Transistor without Pull up not recommended ENCODER J1 Drive 14 ChA lt lt twisted pair 4 5V V A 2 ECOM Supply Return 4 twisted pair gt gt 16 U U ee ChB I 5 Volts 3 5V Connect only if J1 sources Encoder power 1 5VDC Supply 5V 250 mA L Encoder Case Drive Chassis Publication 1398 5 0 October 1998 Interfaces 6 23 Figure 6 27 Single Ended Encoder Interface via Standard TTL Signals not recommended ENCODER J1 Drive 74xx T
182. dog error needs to be investigated to determine the source of the problem A personality EEPROM error results when a personality module is not installed or is improperly installed in the drive Installation of the personality EEPROM will fix this error Table 10 2 lists the Power Up Error Codes Publication 1398 5 0 October 1998 10 4 Status Display Table 10 2 Power Up Error Codes Status Display Error Code Fault Description 5 51 Program Memory Boot Block Error 5 2 52 Program Memory Main Block Error 58 53 Uninitialized Personality EEPROM Error E 5 4 54 Personality EEPROM Read Error 55 Personality EEPROM Data Corruption E 5 6 56 Main Processor Watchdog Error E25 57 Sub Processor Watchdog Error E 5228 58 Main Processor RAM Error BD 9 59 Sub Processor RAM Error E 6 0 60 Uninitialized Service EEPROM Error E 6 3 61 Service EEPROM Read Error E 6 2 62 Service EEPROM Data Corruption Error E 6 3 63 Main Processor A D Converter Error E 6 4 64 Sub Processor A D Converter Error 6 5 65 ANALOG1 Output Error E 6 6 66 Gate Array Error E6207 67 ANALOG2 Output Error 6 8 68 Inter Processor Communication Error E 6 9 69 Sub Processor Initialization Error E750 70 Sub Processor SRAM Error Ed 71 Sub Processor Code Loading Error E 2 72 Sub Processor
183. drive that is being addressed Choose OK to load the drive parameters Note A motor must be selected for the parameters to load 10 11 12 13 14 15 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Motor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select Follower Master Encoder as the Operation Mode for the drive Choose Close from the Drive Setup window Choose the Drive Parameter command icon from the Drive win dow then select the Follower tab Enter an appropriate Gear Ratio as the Follower Input The default Gear Ratio is 1 1 motor encoder pulses master pulses If a Gear Ratio of 3 1 is entered the motor is moved 3 encoder pulses for every incoming master pulse Application and Configuration Examples 8 15 16 Choose Close to exit the Drive Parameters window 17 Verify the Status indicator is green 18 Select the Configuration command icon from the Drive Win dow 19 Select an appropriate digital input from the pull down lists avail able as Digital Input Assignments in the I O Configuration win dow For example Follower Enable as
184. dware connections necessary to run the drive are explained and basic software instructions are provided for common set up procedures For detailed explanation of software instructions refer to the comprehensive on line instructions available in the ULTRA Master software This manual explains how to install your ULTRA 200 Series drive using ULTRA Master software with a personal computer If you are using a TouchPad device abbreviated command titles are displayed but the setup steps remain the same This manual is organized into chapters and appendixes The topics covered in each chapter and section are briefly described Typographical conventions warning and cautions specific to the drive and complementary manuals are also described Description Lists general safety requirements that must be followed when installing or servicing the drive Reviews the major features of the ULTRA 200 Series drives and identi fies motors and signal types that are compatible ULTRA Master Installation Explains how to install access and exit ULTRA Master Unpacking Inspecting and Lists what should be included with your ULTRA 200 Series drive and Storing Installation Interfaces Publication 1398 5 0 October 1998 instructs you on how to perform a basic functional test before installing or storing the drive Instructs you on how to physically install your ULTRA 200 Series drive Provides comprehensive information about the signals available on
185. e Design E 5 Grounding High frequency HF grounding is different from safety grounding A long wire is sufficient for a safety ground but is completely ineffective as an HF ground due to the wire inductance As a rule of thumb a wire has an inductance of 20 nH in regardless of diameter At low frequencies it acts as a constant impedance at intermediate frequencies as an inductor and at high frequencies as an antenna The use of ground straps is a better alternative to wires However the length to width ratio must be 5 1 or better yet 3 1 to remain a good high frequency connection The ground system s primary purpose is to function as a return current path It is commonly thought of as an equipotential circuit reference point but different locations in a ground system may be at different potentials This is due to the return current flowing through the ground systems finite impedance In a sense ground systems are the sewer systems of electronics and as such are sometimes neglected The primary objective of a high frequency ground system is to provide a well defined path for HF currents and to minimize the loop area of the HF current paths It is also important to separate HF grounds from sensitive circuit grounds Single Point Ground Types shows single point grounds for both series daisy chain and parallel separate connections A single point parallel connected ground system is recommended Figure E 2 Single Point Ground Ty
186. e EMI standards for industrial equipment include the EN61000 4 series IEC 1000 4 and IEC801 EN55011 LISDR11 ANSI C62 and C63 and MIL STD 461 Also in industrial environments you should use encoders with differential driver outputs rather than single ended outputs and digital inputs outputs with electrical isolation such as those provided with optocouplers Publication 1398 5 0 October 1998 E 2 Electromagnetic Compatibility Guidelines for Machine Design Filtering Publication 1398 5 0 October 1998 Figure E 1 EMI Source Victim Model CONDUCTED EMI EMI EMI SOURCE VICTIM RADIATED EMI EMI VICTIM The EMI model provides only three options for eliminating the EMC problem e reduce the EMI at the source e increase the victim s immunity to EMI harden the victim or e reduce or eliminate the coupling mechanism In the case of servo drives reducing the EMI source requires slowing power semiconductor switching speeds However this adversely affects drive performance with respect to heat dissipation and speed torque regulation Hardening the victim equipment may not be possible or practical The final and often the most realistic solution is to reduce the coupling mechanism between the source and victim This can be achieved by filtering shielding and grounding As mentioned above high frequency energy can be coupled between circuits via radiation or conduction The AC
187. e 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 type interface 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 6 40 5 485 5 422 Communication Comparison Four Wire RS 485 Differential 4 Wires 2 Signal Pairs 1 to 32 Transmitters 1 to 32 Receivers V AV AV RS 422 Differential 4 Wires 2 Signal Pairs 1 Transmitter 1 to 10 Receivers RS 485 Standard Differential 2 Wires 1 Signal Pair 1 to 32 Transmitters 1 to 32 Receivers NOTE Not applicable to ULTRA 200 Series drives Publication 1398 5 0 October 1998 Interfaces 6 41 Multiple Axes Four Wire RS 485 Communications Note Do not connect any device to J4 6 J4 9 J5 6 or J5 9 except an Allen Bradley TouchPad 1 Set the rotary address switch on
188. e adjusted until the desired rise time is achieved with no overshoot Refer to Figure 9 3 10 Increase Ki very slowly until the signal begins to overshoot 11 Increase Kd very slowly to remove the overshoot caused by KI 12 In general you may leave the Kff gain set to 100 13 Choose Stop 14 Disable the drive 15 Choose Normal Drive Operation 16 Choose Close Publication 1398 5 0 October 1998 9 10 Tuning Publication 1398 5 0 October 1998 17 Enable the drive The position loop has been tuned The drive may be operated as a master encoder step direction or step up down configuration Velocity Loop Tuning Examples Figure 9 3 Signal Nomenclature A VELOCITY Overshoot Following Error or Steady State Error p gt 4 Rise Time 4 Settle Time TIME Transient State gt a Steady State gt Tuning 9 11 Figure 9 4 Underdamped Signal Unnamed Oseillc File Communications Window Help Input Command Velocty E Seale E w Use B for Horizontal For Help press F1 On Line 02 25 UNDERDAMPED Motor Velocity consistently overshoots the Velocity Command To correct Decrease P gain Decrease I gain Figure 9 5 Overdamped Signal Unnamed Oscilloscope File Communications Window Hi in ei Channel A sede s v 7 Channel we
189. e user to select and change parameters activate commands and monitor drive variables The TouchPad also allows the user to display drive status and diagnostic information and to control functions such as distances speeds and other alphanumeric data 1 Power down the drive ATTENTION Ignoring this step may result in damage to the drive 2 Plug the TouchPad into the serial port on the ULTRA 200 Series drive by latching the tab into the drive and then mating the con nector as shown 3 Power up the drive Installing the TouchPad defaults the drive to the following settings The personality module settings stored in the drive are not affected by the installation or removal of the TouchPad 4 Verify the Ver displayed is correct at power up The version number designates the type of drive and its firmware level Figure C 2 explains this display If you are referring to the TouchPad Command Tree card verify the version number display and the Drive Type and Firmware Version of the card are the same Publication 1398 5 0 October 1998 C 2 TouchPad Instructions Figure C 1 TouchPad Connection and Pinouts 1 Insert tab Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Address 0 19200 Baud Figure C 2 TouchPad Versio
190. e velocity loop bandwidth increase the P gain setting decrease the I gain setting or increase the low pass filter band width This provides a faster rise time and increases drive response 3 increase stiffness increase the I gain setting It rejects load dis turbance and compensates for system friction 4 To reduce velocity loop overshoot increase P gain or D gain or decrease I gain 5 reduce mechanical resonance use a stiffer mechanical cou pling or select a nega tive D gain value Alternatively decrease the low pass filter value and the velocity loop update rate 6 Ifthe motor oscillates decrease either individually or together the P gain e gain low pass filter bandwidth High Inertia Loads Proper compensation of load inertia may not be simply a matter of increasing the P gain and I gain settings Problems are often encountered when tuning systems with a high load to motor inertia ratio Publication 1398 5 0 October 1998 9 2 Tuning Publication 1398 5 0 October 1998 Mechanical Resonance Mechanical resonance between the motor and the load occurs when the motor and load are oscillating with the same frequency but opposite phase when the motor is moving clockwise the load is moving counter clockwise The amplitude of the motor and load oscillations is such that the total momentum of the oscillating system is zero In the case of a high load to motor inertia ratio this means tha
191. ectable Encoder Input 4 Channel A 16 BX Auxiliary 36 Reserved Encoder Channel B 17 BX Auxiliary 37 Reserved Encoder Channel B 18 IX Auxiliary 38 Reserved Encoder Channel 19 Auxiliary 39 Reserved Encoder Channel 20 ENABLE Drive Enable 40 Reserved Interfaces 6 3 Digital 1 0 Power ULTRA 200 Series drives provide 24VDC and 5VDC to power external devices within the following specifications 24 Volt I O Power One isolated 24 Volt power supply is accessible from the connector e The allowable load is lt 500 mA e The pin outs are 24VDC J1 5 26 13 5 13 26 24VCOM J1 6 J1 13 13 6 13 13 This supply is intended for powering the digital I O circuitry The 24 VCOM is a floating ground It must be grounded during installation to meet the European Low Voltage Directive LVD The 24 Volt power supply is internally fused by F1 a 1 Amp fast acting fuse Refer to Fuse and Jumper Locations on page 11 4 for the location of F1 Note Ifan external 24VDC power source will power the I O remove jumpers P5 and P6 Refer to Fuse and Jumper Locations on page 11 4 for the location of the jumpers Table 6 1 24 Volt Power Supply Specifications Parameter Description Minimum Maximum Output Voltage Voltage difference between 24VDC and VDC 24VCOM 21 6 26 4 Output Current Current flow mA 0 500 5 Volt Power One 5 Volt power supply is accessible from
192. ed into a Fault History record stored in EEPROM Run Time fault handling executes every 1 millisecond 1 kHz rate Thus the maximum time interval between an error occurring and the fault action is 1 millisecond The following errors are only available when the drive is in a specific configuration e Auxiliary Encoder State and Excessive Following errors require the drive to be in the position follower mode e Illegal Hall State error requires the motor to be configured as having a hall switch input signal Run Time Error Codes Maintaining and Troubleshooting the ULTRA 200 Series lists the error codes and possible actions or solutions to take when resolving the error condition Table 10 1 Run Time Error Codes Status Display Error Code Fault Description E 0 1 01 24 VDC Fuse blown 20 2 02 5 VDC Fuse blown 0 3 03 Encoder Power Fuse blown 0 2 4 04 Motor Overtemperature Thermostat E 0 5 05 IPM Fault Overtemperature Overcurrent Short Circuit E 0 6 06 Channel IM Line Break E 0 7 07 Channel BM Line Break E 0 8 08 Channel AM Line Break E 0 9 09 Bus Undervoltage 1 2 0 10 Bus Overvoltage E 1 1 11 Illegal Hall State 1 2 12 Unused interrupt sub processor E 1 3 3 13 Unused interrupt main processor E 1 4 14 Reserved E15 15 Reserved E fu 16 Reserved 17 Excessive Average Current
193. en Parity 01 7 Data Bits 1 Stop Bit Odd Parity 02 8 Data Bits 1 Stop Bit No Parity 03 8 Data Bits 1 Stop Bit Even Parity 04 8 Data Bits 1 Stop Bit Odd Parity Table C 6 Baud Rate Parameter List for TouchPad Display Parameter 00 1200 Baud 01 2400 Baud 02 4800 Baud 03 9600 Baud 04 19200 Baud Table C 7 Encoder Output Parameter List for TouchPad Display Parameter by 1 Divide Encoder counts by 1 2 Divide Encoder counts by 2 by4 Divide Encoder counts by 4 by8 Divide Encoder counts by 8 Table C 8 IO Mode Parameter List for TouchPad Display Parameter Inc Incremental Indexing Abs Absolute Indexing Reg Registration Indexing a Parameters available only if the drive supports Indexing Publication 1398 5 0 October 1998 C 14 TouchPad Instructions Table C 9 Index Pointer Parameter List for TouchPad Display Parameter 00 Index 0 01 Index 1 02 Index 2 03 Index 3 04 Index 4 05 Index 5 06 Index 6 07 Index 7 08 RAM Index a Parameters available only if the drive supports Indexing Table C 10 Index Termination Parameter List for TouchPad Display Parameter Stop Stop NxtlNow Start another Index immmediately NxtIWt Start another Index at next Start Index transition a Parameters available only if the drive supports Indexing Table C 11 Home Type Parameter List for TouchPad Display Parameter Sns Mrk Home t
194. ence Complete An active state indicates all batches of the indexing sequence are finished Registered An active state indicates the indexing move has been adjusted after sensing the registration sensor At Home An active state indicates the drive is at the home position Axis Homed An active state indicates the drive has been homed Table 6 10 Transistor Output Specifications Parameter Description Minimum Maximum ON state Voltage Voltage difference between the 24 VDC 0 VDC 1 5 VDC supply and the output when the transistor is ON ON state current Current flow when the transistor is ON 0 50 OFF state Voltage Voltage difference between the 24 VDC 0 Volts 50 Volts supply and the output when the transistor is OFF OFF state current Leakage current from the output when the 0 1 mA 0 1 mA transistor is OFF Output Interface Circuit Examples Figure 6 10 Drive Output Connected to Opto Isolator J1 Drive 24 Y 24VCOM Publication 1398 5 0 October 1998 6 12 Interfaces Figure 611 Drive Output Connected to an LED Indicator J1 Drive 24VDC jay 24VCOM Figure 6 12 Drive Output Connected to a Resistive Load J1 Drive 24VDC zx 4 1K Pin 6 Pin 13 24VCOM x Figure 6 13 Drive Output Connected to a Switch Relay J1 Drive Pwr 25 Pin 6 Pin
195. eptable amount of overshoot is reached 11 Apply filtering by selecting Filters and then select Filter Enable 12 While monitoring the motor velocity waveform decrease the fil ter Bandwidth until the overshoot begins to increase in many applications the filter is not necessary 13 Choose Stop Tuning 9 9 14 Disable the drive 15 Choose Normal Drive Operation 16 Choose Close 17 Enable the drive The drive s velocity loop is tuned Tuning the Position Loop Specify the step period and step position values and then input a square wave to the position loop Adjust the gain controls parameters Kp Kd Kff Ki and Ki Zone Filters to tune the system Note Tune the velocity loop before attempting to tune the position loop The bandwidth of the velocity loop must be set before position loop tuning is attempted 1 Disable the drive 2 Choose Manual Tune Position Step from the tuning window 3 Enter an appropriate Distance count step position for the inter nal square wave 4 Enter an appropriate time to complete one cycle of the square wave for the internal step position 5 Select the desired Motor Direction BiDirectional Forward Only or Reverse Only 6 Select the Oscilloscope 7 Enable the drive 8 Choose Start The motor will move and the oscilloscope will dis play the Position Motor Feedback signal 9 Increase the Kp gain while monitoring the signal on the scope The Kp gain should b
196. er ANALOG 1 A1 Selectable analog output with 12 bit resolution J1 30 Displays any firmware variable with selectable scale and offset ANALOG 2 A2 Selectable analog output with 8 bit resolution J1 31 Displays any firmware variable with selectable scale and offset COMMON COM Analog Common return J1 28 Publication 1398 5 0 October 1998 Table 6 16 on page 6 17 lists the output specifications for the signals Interface Connections Interfaces Shown here are typical components and connections for a ULTRA 200 Series drive Figure 6 44 1398 DDM Interface Connection Diagram J5 1 J5 2 RCV RCV XMT RECEIVE TRANSMIT J5 3 45 4 VXMT PERSONAL COMPUTER R BRUSHLESS MOTOR J5 5 J5 6 J5 7 J5 8 J5 9 J4 1 J4 9 93 1 18 26 RESERVED RCV XMT RESERVED gt J4PINS 1 9 CONNECT TO gt J J5PINS 1 9 J3 PINS 1 26 CONNECT TO J1 PINS 1 26 CS 1AFAST EPWR J2 1 ECOM Gnd J2 2 EPWR Y 42 3 42 4 SENSE J2 5 J2 6 SENSE 42 7 J2 8 J2 9 J2 10 POSITION CONTROLLER INTERFACE FROM BRAKE 21 49 and 41 50 IL ENCODER J2 11 J2 12 J2 13 J2 14
197. erves certain multiple keystroke combinations to activate Windows commands Publication 1398 5 0 October 1998 Intro 20 Preface Publication 1398 5 0 October 1998 Graphical Symbols and Warning Classifications This manual uses the following graphical symbols and warning classifications The use of a symbol and signal word is based on an estimation of the likelihood of exposure to the hazardous situation and what could happen as a result of exposure to the hazard Example Description Chassis terminal not a protective ground Protective conductor terminal Earth ground Symbol plus ATTENTION These notices provide information intended to prevent potential personal injury and equipment damage Pictorial Index individual parts are discussed Product Parts Explained sheet 1 of 3 7 11 7 6 7 3 lt 7 6 amp page 7 7 Auf page 7 10 Preface Intro 21 Shown here are face views of the product with pointers to where X ES i sms 10 1 11 6 E 2 i pe page 6 44 3
198. escribed in the following sections e TBI DC Bus and AC Power on page 7 1 defines the power connections e TB2 Shunt Regulator on page 7 11 defines the internal and external shunt connections Figure 6 44 on page 6 45 shows these inputs and outputs on a general level Specific operational set ups are depicted in Figure 8 1 through Figure 8 12 pages 8 2 through 8 45 respectively These figures cover position velocity and torque mode controls for e Analog Controllers e Preset Controllers e Position Followers or e Indexing controllers available only on 1398 DDM 010X 1398 DDM 020X 1398 DDM 030X 1398 DDM 075X and 1398 DDM 150X Publication 1398 5 0 October 1998 5 6 Installation Publication 1398 5 0 October 1998 Wiring Wiring sizes and practices as well as grounding and shielding techniques are described in the sections listed below Refer to the Power Wiring Diagrams on page 5 11 for graphic depictions and recommended wire gaging The descriptions represent common wiring practices and should prove satisfactory in the majority of applications Note Cables listed in Appendix A Options and Accessories are not rated for continuous flexing Minimum wire gages for power cables are listed in e Motor Power Contact and Wire Sizing Recommendations on page 7 5 e AC Input Power Sizing Requirements on page 7 9 e Auxiliary Power Sizing Requirements on page 7 10 Elec
199. eset 3 0 1 1 Preset 3 or Index 3 is selected Preset 4 1 0 0 Preset 4 or Index 4 is selected Preset 5 1 0 1 Preset 5 or Index 5 is selected Preset 6 1 1 0 Preset 6 or Index 6 is selected Preset 7 1 1 1 Preset 7 or Index 7 is selected Start Index A change from inactive to active starts an indexing move Define Home A change from inactive to active defines the home position for absolute index ing Sensor This selection is available only on selectable INPUT 2 and a change from inactive to active is sensed as a registration or home sensor NOTE During the homing routine with an indexing drive an inactive to active state transition will be registered as the home sensor even if selectable Input 2 is not configured as registration sensor This allows Input 2 to have a dual fea ture role Remove COMMAND Achange from inactive to active sets the offset of the analog COMMAND input Offset to achieve a zero command Fault Reset A change from inactive to active will clear any faults and re enable the drive if any faults were pending Start Homing A change from inactive to active will start the homing procedure a Active state indicates current flow through the input optocoupler b Inactive state indicates no current flow The specifications for these inputs are as follows Table 6 5 Digital Input Specifications Parameter Description Minimum Maximum ON state Voltage Voltage applied to the input to guarantee an
200. esolution is J3 8 selectable BOUT J1 9 Motor Output Channels B and B Differential J3 9 BOUT J1 10 TTL levels from line driver Signal resolution is J3 10 selectable IOUT J1 11 Motor Output Channels I and Differential J3 11 IOUT J1 12 TTL levels from line driver Output pulse occurs J3 12 once per motor shaft revolution Table 6 18 Motor Encoder Output Specifications Specification Description Minimum Maximum Differential Output Voltage measured between the and Volts pins with 100 Ohm 2 0 Output Current Current flowing out of the or pin mA 20 20 Publication 1398 5 0 October 1998 Interfaces 6 19 Auxiliary Encoder Inputs Figure 6 21 Auxiliary Encoder Input Types A B STEP DIR Cw CCW The ULTRA 200 Series drive may be electronically geared by a remote signal Electronic gearing may be driven by any of the following three signals master incremental encoder that generates quadrature encoder signals e Step and direction signals such as those created by indexers for step motors e CW Step Up CCW Step Down signals typically used with stepper indexers Note The use of differential signals is strongly recommended Single ended signals are suscepti
201. etc The formula assuming the torque constant has already been converted to N m A peak is given by maximum torque in N m leak 1 1 K Thermal Time Constant The thermal time constant check box indicates if a valid thermal time constant exists for the motor If this check box is not selected the motor thermal protection software is disabled Enabling of the motor thermal protection software is recommended even if the thermal time constant is not known This software feature significantly reduces the chance of damage to the motor even when the motor has an integral thermostat The thermal time constant value also known as the cool down time constant identifies how fast the motor winding temperature dissipates heat The value is entered in seconds The thermal time constant value can be in the range from 1 to 65535 seconds Creating Custom Motor Files D 13 The thermal time constant of the motor is measured by stabilizing the motor temperature at its rated condition disabling the drive and measuring the time for the hottest part of the motor winding to drop 63 of the difference from ambient Allen Bradley as well as many other motor manufacturers specifies this parameter for motors although it may not be published in catalogs or data sheets If the thermal time constant of a motor is unknown or unavailable an estimated value is preferable to disabling the motor thermal protection software A reasonable substitute is
202. eters If not refer to the troubleshooting section 6 Repeat the preceding two steps for each additional drive Publication 1398 5 0 October 1998 6 42 HOST COMPUTER RS 485 INTERFACE RCV Interfaces RCV XMT XMT kA Pin outs may vary by manufacturer Four wire RS 485 connections are shown below The cable diagram provides a wiring example of a daisy chain connection in a typical installation A multi drop cable Figure 6 42 may also be used Note RS 485 pin outs vary between manufacturers Check the hard ware reference manual to ensure correct signal connections between the host computer and the drive Figure 6 41 Four Wire RS 485 Daisy Chain Connection Diagram 3 7 4 8 7 4 8 1 7 4 8 1 7 4 8 3 7 4 8 RCV RCV XMT RCV RCV XMT XMT RCV RCV XMT RCV XMT XMT RCV RCV XMT XMT J4 J4 J5 J4 J5 Drive 1 Drive 2 Drive n Publication 1398 5 0 October 1998 Multiple axes systems may be controlled by a computer 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 A daisy chain wiring configuration may also be used as shown in Figure 6 41 Interfaces 6 43 F
203. eunwN 40413 A yuq JUBUND 80 8 ured 1510 AOW ESHO OWOH tur Hal A SJO 5 Ux 9941 peduo noL 8 ueg OUeuinN eui JOU QL dn uled 0504 LIOH 01 21 UOISISA 8 04 udi B OUOLNN juaung peeds ured py eoegjeooy I uimp ds urec puopodoid oueunN MOpUIM peedsie Q paeds 0197 dy Y 5 uympdso Au 10 9 9 A soz no FU geo A UOHISOd sioanoy 1501 i 10 Seed JOSEY xepul aeos Ino euy JOSE teuy A nov 5449594 ure ala uogeuiuue x pu 9590 g eos sunos esed qunog JOU sod 5 BYUOD z 1no euy 995 MOUIM 40504 uj pe juoxepul 5Idi3sod uep UIMSOq UI S suu yne soy uid sod ured SO 1 NO euy zx eui uonisog ul 15 5 SIOLInOV 5 apoyw iI20 9A 4 313804 8 euoruodoi 80101910 Ol POW A 4019595 50105 g UPS 12001 vsuun Sjunoa Sjqeu3 aremyos JO gt eos ro
204. euy suq yur 1043 uonisod Y 9149 3 15 A DSHnOV gouomeo qol IL 9 A A suno s po Duiun _ 998 998 1 osu z uonisod 1 euy 7 043 urqe eg T 71 19509 oespudi 3 lt pur sod Y 8 0 0 uoneJojeooy O uogesaeooy 910100 0010995 8099 1 Urqjeoo 5 I20 A ejqeu3 Aejaq exeig pace m v Y 452 504 891019 I came slunoo 10 d A 995 1 A Y Y Y ug 909 sod 1010 uno 85183130 Puuou Y enbi qaAnNSod Ageunr 0 0 9 uonisoq 1952 Kk _ E 1399W L 1 4 ED UNOS JOHNSEN apo ISOI A xeput LEIS J0413 d y 1ndinO erbia as ud j XPURAS deis uolisoq 915 Ajooje eun 8 0 aey weis sjasaig 890 poN I90 A udi dest EUA lt i Au 1010285 Au Jesxepul Y 8 0 0 1 5 ejgeu3 Jesyo
205. fy the phasing of the back EMF and Hall feedback signals or an application engineer may have access to an internal document listing the information As a last resort the motor can be rotated in the lab to check the phasing If the phasing is not correct the respective leads must be physically swapped to correct the sequencing A custom motor file cannot be created until the sequencing is correct because the offset of the Hall signals from the Allen Bradley standard must be defined and swapping wires affects the offset value Encoder Sequencing Separate from the phasing of the commutation and motor power signals the encoder A quad B signals must sequence properly The A channel must lead the B channel for CW motion when viewed looking at the motor shaft from the load Figure D 3 depicts this encoder signal sequencing If the encoder phasing is not as shown in Figure D 3 the encoder leads must be swapped Figure D 3 Phasing of the Encoder Signals for Clockwise Rotation Creating Custom Motor Files D 5 Motor Parameter Definitions The parameters to configure in a custom motor file are defined below ULTRA Master arranges motor parameters in an index card format The groupings are e General e Feedback e Current Loop e Electrical and e Ratings General Parameters Motor Model The motor model field is a text display from which a motor is selected If the motor model te
206. g faults The figure below shows the jumper including normally open toggle switches 6 Connect the drive to a 100 240 VAC 50 60 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Connection Diagram Figure 8 1 Analog Controller Connection Diagram Eu JA DRIVE a XMT Motor 2 RCV Encoder RCV 3 XMT COM 1 A PhaseR 1 J1 PhaseS 2 26 424V Phase 3 ENABLE Dri ON Close to rive 20 ENABLE Motor Gnd 4 Close to RESET Fault 21 FAULT RESET 1 B 100 240 VAC 50 60 Hz 23 CMND Single Phase Power Source 1 or L1 100 240 VAC L2 N 50 60 Hz L3 Three Phase l tis Power Source Publication 1398 5 0 October 1998 Application and Configuration Examples 8 3 Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F or P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display code
207. hat results in cabinet heating The following table lists power dissipation values for the ULTRA 200 Series drives Calculate the cabinet cooling requirements using the power dissipation information and formulas below Current as of 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM Rated Continuous 010 020 030 075 150 Current 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010X 020X 030X 075X 150X 100 75 W 100 W 150W 300 W 500 W NOTE These values do not include internal or external shunt regulator power regenerated power Refer to TB2 Shunt Regulator on page 7 11 for shunt regulator dissipation values Maximum power losses are shown to help size a NEMA 12 or equivalent enclosure and to ensure the required ventilation Typical power losses are about one half maximum power losses When sizing an enclosure with no active method of heat dissipation the following equation approximates the size of enclosure necessary Tp 4 08 Q A 1 1 2 27 Q A 0 61 where Tr Temperature difference between inside air and outside ambient F Temperature difference between inside air and outside ambient C Q Heat generated in enclosure watts A Enclosure surface area in ft 2dw 2dh 2wh 144 d Depth in inches h Height in inches w Width in inches Publication 1398 5 0 October 1998 G 8 Specifications Publication 1398 5 0 October 1998
208. ication 1398 5 0 October 1998 Index 4 Publication 1398 5 0 October 1998 Procedure Position Loop 9 9 Velocity Loop 9 8 Velocity Loop Examples 9 10 Mechanical Installation 5 1 Mechanical Resonance Possible Causes 9 2 Tuning Guidelines 9 2 Microcontroller Type G 2 Modifying User Units see User Units Motor Cabling 7 3 1 2 Custom 2 6 D 1 Default Parameters G 7 Identification Table C 10 C 11 Information Missing 11 10 Overload Protection G 2 Overspeed 11 9 Overtemperature 11 7 Phase Connections 7 3 Thermal Protection 11 10 see also Troubleshooting Motor Encoder Error 11 9 Interface G 1 Input G 1 Power G 1 Output G 2 see also Troubleshooting Mounting Requirements 5 1 N Negative Current see Current Operating Temperature G 1 Options A 1 Output Current Continuous peak G 5 Peak G 5 P Part Numbers AC Line Filters 2 Cables B 3 Connector Kits A 6 Drives Encoder Cables A 4 B 14 Fuses A 2 Interface Cables A 3 Manuals A 3 Mating Connectors A 6 Motor Cables A 5 Motor Power Cables B 21 Serial Interface Cables A 3 B 13 Shunt Resistor 2 Terminal Strip 2 TouchPad A 2 PC Display Units Dialog 8 45 P gain defined 9 6 Position Follower Master Encoder 8 12 Step Up Down 8 22 Step Direction 8 17 Position Regulation G 3 Positive Current see Current Power AC Cabling 7 7 Sizing 7 9 Terminals 7 1 7 8 Auxiliary 7 10 G 5 Sizing 7 10 Terminals 7 10 Connections 7 3
209. id function type encountered in the TouchPad data table The TouchPad data table is incorrect for the drive Checksum Error The checksum of the command is in error Information is corrupted CmdNoEnb Error The command is not enabled DataDisp Warning The parameter is a live data display and cannot be modified DrvEnabl Warning The parameter cannot be changed while the drive is enabled Fault Fault Drive fault detected InviData Warning Invalid data was entered for the parameter InvidFn Error Illegal function code received by drive The TouchPad data table is incorrect for the drive InvidRsp Error Invalid Response received from drive Received code did not match transmitted code Lower Lim Warning The lower limit of the parameter has been reached NoMemory Error TouchPad memory has been exhausted NoRetSel Warning Mode Enter key incorrectly pressed OverRng Error Value from drive is too large to display RAMWrite Error An error was detected while writing the drive s parameter memory ReadOnly Warning The parameter is Read Only and cannot be modified Timeout Error The communications port timed out UnxpChar Error The communications port received an unexpected character UpperLim Warning The upper limit of the parameter has been reached Publication 1398 5 0 October 1998 C 10 Motor Table TouchPad Instructions
210. igure 6 42 5 232 to RS 485 Multi Drop Connection Diagram PC 12 VDC K Return RS 232 RS 232 to Interface RS 485 Adapter m RCV L RCV lt RCV 7 XMT eS mE xa NOE Pin outs may vary by manufacturer 1 7 4 8 1 7 4 8 1 7 4 8 RCV RCV XMT XMT RCV RCV XMT XMT RCV RCV XMT XMT J4 J4 J4 Drive 1 Drive 2 Drive n NOTE This example uses a 2 channel RS 232 to RS 485 adapter manufactured by B amp B Electronics 815 433 5100 Publication 1398 5 0 October 1998 6 44 Interfaces A1 A2 and COM Analog Outputs Analog outputs may be monitored with external equipment such as an oscilloscope on the external output pins Al ANALOG 1 A2 ANALOG 2 and COM COMMON These output signals are parallel connections to the analog command signals available on connector J1 Refer to Analog Outputs on page 6 16 Figure 6 43 ANALOG 1 and ANALOG 2 Output Circuits 1 or A2 Drive ANALOG OUTPUT A 12 bit digital to analog converter DAC generates ANALOG 1 ANALOG 2 is a filtered PWM signal with 8 bit resolution and a carrier frequency of 32 8 kHz Both outputs are scaled to a range of 10 to 10 Volts Table 6 26 Analog outputs ANALOG 1 and ANALOG 2 Analog Output Pin Description Pin Number Numb
211. ilter An effective filter achieves this by using capacitors and inductors to mismatch the source impedance AC line and the load impedance drive at high frequencies AC Line Filter Selection Selection of the proper filter is only the first step in reducing conducted emissions Correct filter installation is crucial to achieving both EMI attenuation and to ensure safety All of the following guidelines should be met for effective filter use 1 The filter should be mounted to a grounded conductive surface 2 The filter must be mounted close to the drive input terminals If the distance exceeds 1 foot then a strap should be used to connect the drive and filter rather than a wire 3 The wires connecting the AC source to the filter should be shielded from or at least separated from the wires or strap con necting the drive to the filter If the connections are not segregated from each other then the EMI on the drive side of the filter can couple over to the source side of the filter thereby reducing or eliminating the filter effectiveness The coupling mechanism can be radiation or stray capacitance between the wires The best method of achieving this is to mount the filter where the AC power enters the enclosure AC Line Filter Installation shows a good installation and a poor installation When multiple power cables enter an enclosure an unfiltered line can contaminate a filtered line external to the enclosure Therefore
212. in 360 7 14 20 331 5 13 05 349 0 13 74 6 86 33 02 36 32 26 92 196 09 12 95 203 20 31 70 69 80 139 7 31 70 139 70 224 50 AIR INTAKF AIR INTAKE AIR INTAKE Publication 1398 5 0 October 1998 Interface Connections Installation 5 5 Input output and power cables connect to the front panel of a ULTRA 200 Series drive no internal connections are necessary ATTENTION The user is responsible for conforming with all applicable local national and international codes Wiring practices grounding disconnects and overcurrent protection are of particular importance Failure to observe this precaution could result in severe bodily injury or loss of life Connections are fully described in the following sections Controller on page 6 1 defines the controller connections e J2 Encoder on page 6 27 defines the motor encoder connections e J3 Auxiliary Port on page 6 31 defines the auxiliary controller connections e J4 and J5 Serial Port on page 6 34 defines the RS 232 RS 485 serial port connections Power Connections are fully d
213. in The torque constant of the motor before gearing is computed as else Jl L Joe Amp J 8 85075 in Ib 50 Amp The back EMF constant of the motor before gearing is computed as 4 4 Volts 1000 RPM 2 1 44 Volts RPM 1 50 KRPM Note that the back EMF was specified as a per phase value and is doubled to obtain a line to line value The motor inertia before gearing is computed as 2 5 112985 oor ae 2 26 Kg cm The resistance and inductances are also specified as per phase values and are computed as Ohms Phase Huic 37 J 2 27 4 Ohms mH L 2 5 0 2 10 0 mH EL 519 2 The thermal constant is specified in minutes and is computed as thermal time constant 30 6052 1800 sec Publication 1398 5 0 October 1998 D 16 Creating Custom Motor Files Custom Motor File The custom motor file parameters are as follows GENERAL CURRENT LOOP Motor Model A_CUSTOM Current Feedforward 0 degrees Table ID 1 Motor File CUSTOM21 MTR ELECTRICAL Motor Type Synchronous Resistance 7 4 Ohms Number of Poles 8 Inductance 10 0 mH Kt 0 61 N m Amp Jm 2 26 kg cm2 RATINGS Ke 44 0 Volts KRPM Continuous Torque 1 4 Amps Peak Torque 3 8 Amps Thermal Time Constant Checked 1800 sec FEEDBACK Integral Thermostat Unchecked Linecount
214. ini D Ribbon 28 30 AWG Insulation Displacement Plastic Backshell Squeeze Latch 20 pin Mini D Ribbon 28 30 AWG Insulation Displacement Metal Backshell Squeeze Latch 20 pin Mini D Ribbon 24 30 AWG Solder Cup Plastic Backshell Squeeze Latch J3 AMP 2 175677 4 10126 6000EC 3M 10126 3000VE AMP 176793 4 3M 10326 A200 00 3M 10326 52F0 008 26 pin Mini D Ribbon 28 30 AWG Insulation Displacement Plastic Backshell Squeeze Latch 26 pin Mini D Ribbon 28 30 AWG Insulation Displacement Metal Backshell Squeeze Latch 26 pin Mini D Ribbon 24 30 AWG Solder Cup Plastic Backshell Squeeze Latch 1 For use with MDR Hand Press Tool Kit 3M part number 3829 Publication 1398 5 0 October 1998 Appendix B Cable Diagrams Schematics and Examples Factory supplied cables allow ULTRA 200 Series drives to conform to the European Union Directives when connecting the drive to motors controllers or computers The following diagrams provide information on the cables available from the factory Refer to Appendix A Options and Accessories for ordering information The information below applies to all factory supplied cables Wire Insulation Type Polyvinyl Chloride Conductor size 0 08 mm 28 AWG tinned copper except as noted below 0 25 mm 24 AWG on 9101 1372 9101 1374 and 9101 1379 1 5 mm 16 AWG on 9101 1190 9101 1381 9101 1385 and 9101 1467 2 5 mm 14 AWG o
215. ion How to modify the units of measurement for ULTRA Master displays is explained on page 8 45 The ULTRA 200 Series drive can be set up as an analog drive in either the Velocity or Torque mode by making the hardware connections and performing the software setup and tuning described below The connection diagram depicts the minimum hardware necessary Interfacing the drive to an external controller requires similar circuitry from the controller to J1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional TouchPad also may be used Hardware Setup Make the connections described below and shown in the figure 1 Connect a 10VDC power source between J1 22 and 71 23 ANALOG CMND to provide the analog speed or torque command 2 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the drive A simple 3 wire cable is depicted in the figure below 3 Connect a Motor Feedback cable from the motor to the J2 connec tor on the drive 4 Connect a Power cable from the motor to TBI terminals S and on the drive Publication 1398 5 0 October 1998 8 2 Application and Configuration Examples 5 Connect a jumper wire with a toggle switch between the follow ing pins J1 20 ENABLE and J1 26 I O PWR 11 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resettin
216. ion This appendix provides equations to assist in sizing resistors for dynamic braking A properly sized resistive load may be required to dynamically brake the system by dissipating the energy stored in a motor The section Emergency Stop Wiring on page 7 6 depicts the necessary circuitry Winding inductance is ignored in this analysis which allows the load on the motor winding to be considered as purely resistive when dynamic braking occurs This simplifies the evaluation to a scalar analysis instead of a vector analysis For simplicity friction damping and load torque also are ignored in the equations Equations for the magnitutde of instanteous velocity and per phase current energy and power are derived by solving the differential equation governing the motor velocity The equations are shown below Table F 1 Dynamic Braking Resistor Parameters Parameter Description Parameter Description i t Phase Current RL Line Neutral Dynamic Braking Resis tance E t Per Phase Energy Peak Line to Line Back EMF Jm Motor Inertia Peak Line to Line Torque Constant JL Load Inertia Initial Angular Velocity P t Per Phase Power w Angular Velocity R Motor Line to Line Resis t Time tance olt where R 2R Ju J ee en 1 KpKy f 0866 28 1 2 2t E t 5001 Jy oe di Publication 1398 5 0 October 1998 F 2 Dynamic Braking Resistor Selection Pub
217. isconnect the cable from your PC b Jumper Pins 2 and 3 on the communication port of the PC c Type any character on the keyboard 1 If the character echoes back the communication port is OK and the cable or the connectors are defective Replace the communication cable assembly 2 If the character did not echo back the communication port is defective Replace the communication port Testing Digital Outputs This test verifies the functionality of the selectable outputs Test equipment requirements are e A PC running ULTRA Master e A multimeter It assumes there are no error codes displayed and the 24V power supply is connected correctly Disconnect the outputs from any external hardware while performing this test 1 Disable the drive by opening the switch connecting J1 26 and J1 20 2 From the Drive Window select the Output Diagnostics com mand icon 3 Verify each of the digital Outputs in the Output Diagnostics win dow registers the following values when it is selected or dese lected A Drive Ready box then measure the resistance between J1 24 and J1 25 a If the box is checked the resistance should read approximately 1 Ohm b If the box is not checked the resistance should read very high 1 MOhm Maintenance and Troubleshooting 11 13 B Brake Enable box then measure the resistance between J1 49 and J1 50 a If the box is checked the resistance should read approximately
218. issipate the heat gener ated by the ULTRA 200 Series drives Refer to Power Dissi pation on page G 7 for the amount of heat generated by ULTRA 200 Series drives and enclosure sizing equations Minimum unobstructed surrounding space for cooling air intake and fan exhaust e Above 5 cm 2 in e Below 5 cm 2 in e Sides 1 25 cm 0 5 in Front 7 5 cm 3 0 in for cable clearance ATTENTION 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 Position the drive in a vertical position on a flat solid surface that meets the mounting hardware should meet the following weight vibration and shock altitude and humidity airflow clearance and temperature requirements Unit weights are e 1398 DDM 010 and 1398 DDM 010X 5 80 Kg 13 78 Ibs e 1398 DDM 020 and 1398 DDM 020X 6 36 Kg 14 02 lbs e 1398 DDM 030 and 1398 DDM 030X 6 48 Kg 14 28 lbs e 1398 DDM 075 1398 DDM 075X 9 67 Kg 21 32 lbs 1398 DDM 150 and 1398 DDM 150X 14 06 Kg 31 00 Ibs Publication 1398 5 0 October 1998 5 2 Installation Vibration and shock altitude and humidity limits are Vibration 2g at 10 to 2000 Hz Shock 15g 11 msec half sine Altitude 1500 meters 5000 feet Derate power performance 3 for each 300 m above 1500 m 1000 ft above 50
219. itch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive 7 Choose Normal Drive Operation from the Tuning window 8 Open the switch between J1 26 and J1 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Operation The drive is now configured as a Registration Indexing controller e The servo parameters have been setup with the unloaded motor e Motion is commanded through the inputs The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 26 and J1 20 to enable the drive 2 Close the toggle switch between J1 26 and J1 32 to start Index 0 3 Close the toggle switch between J1 26 and J1 33 to simulate reg istration Absolute Indexing Application and Configuration Examples 8 39 The ULTRA 200 Series drive can be set up as a absolute indexer by making the hardware connections and performing the software setup and tuning described below A connection diagram depicts the minimum h
220. ith the position following mode Kd gain Differential gain of the position loop Provides position loop damping and reduces overshoot caused by Kp or Ki gain Kff gain Feedforward gain of the position loop Kff gain reduces following error However a high value of Kff gain can result in posi tion overshoot A reduction in following error allows the system to more closely approximate gear driven systems Ki gain Integral gain of the position loop Ki gain decreases the time period for the error to decay A non zero value of Ki allows integration in the position loop which eliminates the steady state following error However a non zero value for Ki may introduce over shoot and ringing which cause system instability oscillation Note Ki gain is used in conjunction with the Ki Zone value Ki Zone is the area around the commanded position where Ki gain is active Filters The velocity regulator has one low pass filter The filter bandwidth range is from 1 Hz to 992 Hz The filter serves two purposes e Adjust the frequency range to remove filter the noise produced by encoder resolution e Reduce the amount of the mechanical resonance in the mechanical system e g belt systems Similar results may often be achieved by reducing the update rate of the velocity loop Publication 1398 5 0 October 1998 9 8 Tuning Publication 1398 5 0 October 1998 Manual Tuning Manual tuning may be
221. its are not recommended and may result in system malfunction To improve noise immunity a cable shield should terminate at both ends of the cable Shields should connect to the backshell of the connectors with termination around the full circumference 360 The connectors should attach to chassis ground not signal common Figure 6 23 External Encoder Interface via TTL Differential Line Drivers ENCODER J1 Drive f Q 14 AX ChA gt 4 twisted pair 15 gt O 16 BX ChB L lt twisted pair 17 DOn 18 1 Ch gt 2 lt twisted par A 19 X gt 2 5V 4 ECOM Suppl Bam 4 twisted pair p 5 Volts 3 5V g i 5VDC Supply 250 mA For horizontal dashed lines i ncederiGsc connect only if J1 sources Encoder power Dive Chassis Figure 6 24 Complementary Encoder Interface via 7406 Line Drivers with Pull up Resistors ENCODER 91 Drive 5 Volts xm O Cha AE SX lt Wistedpair X 15 5 Volts U U 7406 16 BX ChB le amp z lt Iwisted pair 17 BX 5 Volts 7406 18 Ix Chl lt misted pair p 19 IX 45V ECOM Suppl Bem v twisted pair p 5 Volts 3 45V JE 1 5VDG Supply For horizontal dashed lines SV 250 Enco
222. l 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1398 5 0 October 1998 PN 0013 1042 002 Rev A Copyright 1997 Allen Bradley Company Inc Printed in USA
223. lect or verify the correct motor model number from the drop down Motor Model list 11 If a message advises that the drive must be reset choose Yes 12 Select the Operation Mode parameters for the drive Velocity Mode Settings Torque Mode Settings Analog Velocity Input as the Analog Torque Input as the Operation Mode Operation Mode 13 Choose Close to exit the Drive Set Up window 14 Choose the Drive Parameters icon from the Drive window and then select the Analog tab 15 Enter appropriate Scale and Offset values for the input Tuning Note Do not attempt to Tune a drive with the Command mode set for Analog Torque Input If the drive is set to Torque mode continue with the Operation section below Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 Choose the Tuning command icon from the Drive window The drive must be configured in Velocity mode for tuning to be effec tive Select AutoTune from the Tuning mode group Select the appropriate values for the following Auto Tune com mands Distance and Step Current Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only Application and Configuration Examples 8 5 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly gua
224. liary Power Auxiliary AC Terminals 10 and 11 supplies power to the logic control circuits and fault logic The main and auxiliary power must be connected in phase Table 7 6 Auxiliary Power Terminals Signal Description Terminal 1398 DDM 010 1398 DDM 075 1398 DDM 010X 1398 DDM 075X 1398 DDM 020 1398 DDM 150 1398 DDM 020X 1398 DDM 150X 1398 DDM 030 1398 DDM 030X L1 AUX Auxiliary 100 240 Volts AC Line 1 input TB1 10 TB1 11 L2 AUX IN Auxiliary 100 240 Volts AC Line 2 input or neu 1 11 1 12 tral NOTE Torque all terminal connections to 1 25 Nm 11 0 Ib in AUX power is supplied to a switching power supply This input accepts Voltages from 100 to 240 VAC rms single phase with an input frequency 47 63 Hz The auxiliary logic supply only and the main logic and motor supply power sources are separated This permits the logic power to operate independently of the motor This dual power sourcing is useful for troubleshooting and diagnostics Table 7 7 Auxiliary Power Sizing Requirements Voltage Current Requirements Input Input Inrush Wire Transformer Volts AC Amps AC Amps mm AWG VA 100 1 0 47 1 5 16 250 240 0 5 95 1 5 16 250 1 Dual element time delay slow acting fuses are required to accommodate inrush current at the auxiliary terminals during power up Local regulations must be observed when selecting fuses 2
225. lication 1398 5 0 October 1998 2 J m 25 2 P t pus Q For this type of response 98 of the energy will be dissipated in 4 time constants Therefore the average power for each dynamic braking event can be calculated as 2 11 KEKTO 3 Pave 2 0144 Equation is used in equation 2 and 3 to put the power in terms of the motor parameters and the dynamic braking resistance independent of the load inertia Dynamic Braking Resistor Selection F 3 Sample Calculations The following example uses an H4075 motor with a 10 times inertia mismatch and dynamic braking resistors sized at four times the motor winding resistance The average power of the motor is 1116 Watts for the selected paramters but it is unlikely that a resistor with this Wattage is required Pulse type currents such as this example require sufficient thermal mass to absorb the energy and to dissipate or accomodate the peak Voltage Adequate information for intermittent duty cycle and surge current applications is seldom provided by resistor manufacturers However often they will assist in resistor selection when supplied with the current profile Note The equations using the symbol are assigned in Mathcad H4075 Motor Parameters in MKS Units 0 74 R 0 9 J 0 00068 22 60 Load Inertia Dynamic Braking Resistance and Velocity in MKS Units _ 3000 2 7 Ry 4
226. llow these guidelines e The resistor values should be one to four times the winding resistance for good braking performance Refer to Appendix F Dynamic Braking Resistor Selection for resistor sizing equations e Screen and ground cables should be connected as shown e Shields should be unbraided not a drain wire soldered to the shield e Connection lengths should be minimized e Safety ground GND and shield connections are permanently connected This is essential for electrical safety e EMC guidelines require connection of the shield at the point where the contactor is inserted DC Bus Terminals 5 and 6 have voltage present when AC power is applied to the drive The DC Bus LED also illuminates when voltage is present on the terminals Power Connections 7 7 Figure 7 3 Emergency Stop Contactor Wiring Overlapping Contactor Resistor E Resistor Resistor O Enclosure wall mum Table 7 3 TB1 DC Bus Terminals Signal Description Terminal DC Bus Positive DC Bus voltage signal TB1 5 DC Bus Negative DC Bus voltage signal TB1 6 NOTE Torque all terminal connections to 1 25 Nm 11 0 Ib in AC Power Cabling The ULTRA 200 Series drives require 100 to 240 VAC rms power with an input frequency of 47 63 Hz The 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 and 139
227. lls through the list which includes Presets gt StepDir StepU D and Analog e Mode Enter key selects a parameter from the list e List selections that are undefined are indicated by s Unknown This display indicates the TouchPad data table is incompatible with the drive Lists are associated with all parameters except DISPLAY and DRVINFO Refer to page C 13 for items in each list Table C 17 Drive Status List for TouchPad on page C 16 is read only all other lists contain possible parameter selections After an option is selected the display reverts to the parameter from which the option was selected For example Selection of the EncAlign parameter under STATUS provides the options Normal and gt Align Selection of either option returns you to the EncAlign display Publication 1398 5 0 October 1998 C 8 TouchPad Instructions Publication 1398 5 0 October 1998 Ratio A FolRatio gear ratio longer than eight characters may require scrolling with the gt and keys The ratios are numeric values that increment or decrement by 1 each time the 7 or key is pressed The method of display is dependent on the length of the ratios e Ifthe ratio is eight characters or less it is displayed in full For example a Master to Follower ratio of one thousand to nine hundred is displayed as 1000 900 e Ifthe
228. lose to RESET Fault Close to Turn ON Close to Turn ON Close to Turn ON Publication 1398 5 0 October 1998 Connection Diagram Figure 8 2 Preset Controller Connection Diagram ZW Z ET DRIVE dc J4 Motor 2 RCV Encoder 3 XMT TB1 5 COM 4 PhaseR 1 J1 5 2 __ 26 24 A Phase 3 20 ENABLE Motor Gnd 4 21 FAULT RESET TBI 32 INPUT1 100 240 VAC 33 INPUT2 50 50 Hz pm Single Phase 34 INPUTS Gnd Power Source TB1 or L1 100 240 VAC ren 50 60 Hz L3 Three Phase Gnd Power Source Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F or P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display codes 2 Start ULTRA Master on the PC 3 Choose Cancel from the Drive Select dialog box 4 Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings 5 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box 8 Application and Configuration Examples
229. ltage IPM Fault Overspeed Excess Error Encoder State Change Encoder Line Break Fuse Illegal Hall State Drive Mode Select Integrator Inhibit Follower Enable Forward Enable Reverse Enable Operation Mode Override Preset Selects Start Index Define Home Remove Command Offset Start Homing Sensor In Position Within Window Zero Speed Speed Window Current Limit Up To Speed Drive Enabled Bus Charged Disabling Motion In Motion In Dwell Sequence Complete Registered At Home Axis Homed 0 to 32 767 RPM actual maximum speed depends on the motor drive combination Specifications G 5 Power Table G 1 ULTRA 200 Series Power Ratings 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010 020 030 075 150 1398 DDM 1398 DDM 1398 DDM 1398 DDM 1398 DDM 010X 020X 030X 075X 150X Auxiliary AC Input Voltage rms Volts nominal 100 to 240 100 to 240 100 to 240 100 to 240 100 to 240 Frequency Hz 47 63 47 63 47 63 47 63 47 63 Current Ams 100 Vins 1 0 1 0 1 0 1 0 1 0 Aims 240 Vims 0 5 0 5 0 5 0 5 0 5 Main AC Input Voltage rms Volts nominal 100 to 240 100 to 240 100to240 100 to 240 100 to 240 18 18 18 18 or 3 3g Frequency Hz 47 63 47 63 47 63 47 63 47 63 Current rms Amps 10 19 28 30 46 Bus Voltage Volts DC 141 339 141 339 141 339 141 339 141 339 Peak Output Current Amps 10 20 30 50 18 150 75 30
230. m the motor cable and power wiring Separate steel conduit can be used to provide shielding between the signal and power wiring Do not route signal and power wiring through common junctions or raceways 2 Signal cables from other circuits should not pass within 1 foot of the drive 3 The length or parallel runs between other circuit cables and the motor or power cable should be minimized rule of thumb is 1 foot of separation for each 30 feet of parallel run The 1 foot sepa ration can be reduced if the parallel run is less than 3 feet 4 Cable intersections should always occur at right angles to mini mize magnetic coupling 5 Do not route any cables connected to the drive directly over the drive vent openings Otherwise the cables will pick up the emis sions leaked through the vent slots 6 The encoder mounted on the brushless servo motor should be con nected to the amplifier with a cable using multiple twisted wire pairs and an overall cable shield Allen Bradley offers encoder cables in various lengths that have special terminations Following these guidelines can minimize noise problems However equipment EMC performance must meet regulatory requirements in various parts of the world specifically the European Union Ultimately it is the responsibility of the machine builder to ensure that the machine meets the appropriate requirements as installed Dynamic Braking Equations Appendix F DynamicBrakingResistorSelect
231. manual is intended for use in industrial drive systems This equipment can endanger life through rotating machinery and high voltages therefore it is essential that guards for both electrical and mechanical parts are not removed The main hazards which can be encountered in the use of this equipment are e Electric shock hazards e Electric fire hazards e Mechanical hazards e Stored energy hazards These hazards must be controlled by suitable machine design using the safety guidelines which follow There are no chemical or ionizing radiation hazards Voltage Potentials ATTENTION DC bus capacitors may retain hazardous voltages for several minutes after input power has been removed but will normally discharge in several seconds Measure the DC bus voltage to verify it has reached a safe level each time power is removed before working on the drive or wait for the time indicated in the warning on the front of the drive Failure to observe this precaution could result in severe bodily injury or loss of life Voltage potentials for the internal drive circuitry vary from 325 Volts above to 325 Volts below earth ground for a 240 Volt input Voltages can exceed 450 VDC or 240 VAC within the ULTRA 200 Series All circuits including the connections on the front panel should be considered hot when main or auxiliary power is connected and for the time specified in the warning on the front of the drive after power is removed Pu
232. may also be checked for some Allen Bradley motors where the definition of forward is opposite that of Allen Bradley i e CCW rather than CW In such a case a software inversion is preferable to the physical swapping of leads because the signals look identical when rotated CCW rather than CW For custom motors other than those mentioned above leave this box unchecked and swap the motor power and Hall feedback signals to correct the phasing Electrical Parameters Resistance The resistance value is the measured phase to phase resistance of the stator winding in Ohms The resistance is used to set the current regulator gains and is critical to current loop performance The resistance value can be in the range from 0 0039 to 255 9961Q The ratio of motor inductance to motor resistance is defined as the electrical time constant of the motor This value should always be checked to verify that it is in an acceptable range Electrical time constants less than 1mS and higher than 50mS present difficulties for current regulation and should be avoided Some manufacturers specify the resistance in Ohms phase The phase to phase resistance requested by ULTRA Master is twice the per phase value Creating Custom Motor Files D 11 Inductance The inductance value is the measured phase to phase inductance in milliHenries of the stator winding The inductance is used to set the current regulator gains and is critical to current loop perfo
233. ment drive status display e Overtemperature short circuit and overcurrent protection for the power output power time protection e Bus Overvoltage e Bus Undervoltage e Overspeed e Fault diagnostics e Fused power supply outputs e Three watchdog timers provide fail safe operation ULTRA Master Software A Windows based software interface provides start up selections Tasks are organized for efficient set up control and maintenance Context sensitive on line help provides immediate assistance e Set up is simplified by a series of logically arranged set up screens e Files can be stored and printed for on line or off line modification and on site or off site back up e Diagnostic and set up tools make system integration easy e Critical information is available with complete on line help e User defined velocity acceleration position and torque parameters e Tuning and diagnosis is aided with an on screen dual channel digital oscilloscope e On screen meters and software tools provide rapid debugging and measurement Communications One serial port with two connectors allows from 1 to 32 drives to be connected in parallel using four wire RS 485 communications The serial interface allows the user to program a drive using any PC or host computer that permits RS 232 or four wire RS 485 communications Selecting Other System Components 2 5 Autotuning Digital auto tuning allows easy setup All adjustmen
234. mmunication from ULTRA Master and verify your communication settings Verify the communication cable pin out and check cable continu ity Refer to RS 232 Connection Diagrams on page 6 38 If the communication cable is OK do the following A Disconnect the communication cable from the drive a Jumper pin 2 and 3 on the D connector of the communication cable b Close and exit from ULTRA Master Select the Terminal from the Program Manager Terminal is usually is in the Accessories group Select Settings from the Main menu a Select Terminal Emulation from the drop down menu b Choose DEC VT 100 c Choose OK to close the dialog box Select Settings from the Main menu a Select Communications from the drop down menu b Choose COMI or the number of the communication port the drive is connected to from the Connections sliding list c Set Baud Rate to 9600 d Set Data Bits to 8 e Set Stop Bits to 1 f Set Parity to NONE g Set Flow Control to XON XOFF h Choose OK to close the dialog box 5 Type any character on the keyboard The character should echo back on the screen Publication 1398 5 0 October 1998 11 12 Maintenance and Troubleshooting Publication 1398 5 0 October 1998 A If you see the character on the screen swap pins 2 and 3 close the Windows Terminal and restart ULTRA Master B If the character does not echo back on the screen do the following a D
235. motor to the DC bus When the energy transferred from the rotating inertia causes the DC bus voltage to exceed 420 VDC the shunt is enabled and the excess energy 2420 VDC is dissipated as heat ATTENTION High voltage is present on the terminals of the ULTRA 200 Series drive Remove power and dis connect the power cable before making or removing any connection Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION DC bus capacitors may retain hazardous voltages for several minutes after input power has been removed but will normally discharge in several seconds Measure the DC bus voltage to verify it has reached a safe level each time power is removed before working on the drive or wait for the time indicated in the warning on the front of the drive Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION External shunt resistors connect directly to the power bus For safety reasons an external shunt resis tor must be enclosed Publication 1398 5 0 October 1998 7 12 Power Connections ATTENTION Do not tin solder the exposed leads on cables Solder contracts over time and may loosen the connection Table 7 8 TB2 Shunt Regulator Terminals Terminal Description TB2 1 Positive DC bus TB2 2 Internal shunt regulator resistor TB2 3 Shunt regulator transistor collector NOTE Torque
236. move will not be registered 16 17 18 19 Single Move Settings Batched Move Settings Registration as Mode Registration as Mode 8000 as Distance 8000 as Distance 8000 as Registration Distance 1 as the Batch Count 3 as the Batch Count 0 as Dwell 1000 as Dwell Appropriate values for Accelera Appropriate values for Accelera tion and Deceleration tion and Deceleration Choose Close to exit the Drive Parameters window Select I O Configuration command icon from the Drive Window Select an appropriate digital input from the pull down lists avail able as Digital Input Assignments in the I O Configuration win dow For example Start Index as Input 1 Registration Sensor as Input 2 Not Assigned as Inputs 3 and 4 Not Assigned as Outputs 1 through 4 Choose Close to exit the I O Configuration window Tuning gt Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 2 Choose the Tuning command icon from the Drive window Select AutoTune from the Tuning mode group Select the appropriate values for the following Auto Tune com mands Distance and Step Current Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only Publication 1398 5 0 October 1998 8 38 Application and Configuration Examples Publication 1398 5 0 October 1998 5 Close the toggle sw
237. mum Signal frequency MHz Frequency of the input signal Pulse Width Time interval the step CW CCW signal nsec must remain in a single state for detection 500 Setup Time Time interval the direction CW CCW signal nsec must be stable before the corresponding 500 step CCW CW signal changes state The following diagram shows the relationship between STEP and DIRECTION inputs 500 nsec in either STEP c high or low state 500 nsec 14 500 4 500 nsec 4 500 nsec minimum minimum minimum minimum DIRECTION INPUT 4 4 Direction data must be steady for this time period Publication 1398 5 0 October 1998 Interfaces 6 25 Figure 6 30 External Step Direction Interface via TTL Differential Line Drivers USER J1 ELECTRONICS N Step Q 14 Step TTL Step lt isted pair p 15 Step gt Differential 2 Line Drivers N Dir Q Q 16 Dira I A Dir lt _ wisted pair 17 Dr 2 5V f 4 Supply Return gt twisted pair p 7 5 Volts Supply V 1 5VDC 5V 250 mA Encoder Case J For horizontal dashed lines c
238. n external circuit Encoder Fuse Blown 03 F3 blown Check for shorts on motor Encoder signals and cable wiring Check replace fuse F3 if necessary Bad encoder Replace encoder and or motor Motor Overtemperature 04 Motor TS J2 19 and TS J2 20 pins open Verify TS J2 19 and TS J2 20 connections for con tinuity Motor thermostat trips due to High motor ambient temper ature and or Excessive RMS torque Lower ambient tempera ture Operate within not above the continuous torque rating for the ambi ent temperature 40 C maxi mum IPM Fault 05 Motor cables shorted Verify continuity of motor power cable and connector Motor winding shorted inter nally Check for short on motor s R S T and Gnd windings Drive temperature too high Check for clogged or defec tive fan Ensure cooling is not restricted by insufficient space around the unit Operation above continu ous power rating Verify ambient temperature is not too high above 60 C Operate within the continu ous power rating Output short circuit or over current Drive has a bad IPM replace drive Channel IM line 06 Bad connections Verify continuity of the encoder cable Verify continuity of the IM and wiring signals Bad Encoder Replace the motor or the encoder Publication 1398 5 0 October 1998 11 8 Maintenance
239. n 5000 RMS symmetrical Amperes 240 Volts maximum Short Circuit Current Rating with Fuse Restrictions Suitable for use on a circuit capable of delivering not more than 200 000 RMS symmetrical Amperes 240 Volts maximum when protected by high interrupting capacity current limiting fuses Class CC G J L R T 2 The ULTRA 200 Series drives do not require an isolation transformer The recommended trans former sizes are the minimum that is adequate for most servo applications Larger transformers provide an additional safety factor The additional safety factor may occur in applications that require minimum bus voltage sag when the motor must accelerate to high speed in minimum time or in applications with high continuous power requirements 3 The ULTRA 200 Series three phase products require 240 VAC line to line power This is not available in Europe where the three phase power distribution is 400 VAC line to line 240 VAC line to neutral In Europe a transformer is required to supply the correct three phase voltage In Europe the ULTRA 200 Series single phase units may run directly off the line to neutral voltage Publication 1398 5 0 October 1998 7 10 Power Connections The inputs to the main logic and motor supply and the auxiliary logic supply only power sources are separated This permits the logic power to operate independently of the motor This dual power sourcing is useful for troubleshooting and diagnostics Auxi
240. n 8 minutes at 200 overload and within 20 seconds at 600 overload 10 kHz 5 kHz 10 kHz 5 kHz 10 kHz 5 kHz 10 kHz 5 kHz 5 kHz Digital PI with Back EMF compensation Synchronous 1 2 kHz 600 Hz 10 bit Digital PID Item Update Rate 3dB Bandwidth 45 Bandwidth Ripple Resolution Position Regulation Type Filters Low Pass Software Controls Data Collection 2 Firmware Operating Modes Command Sources Autotuning Manual Tuning User Set up Diagnostics Serial Protocol Power Up Faults Specifications G 3 Specification 5 kHz 150 Hz 50 Hz 2 RPM 1000 RPM 16 bit Digital PID with Feedforward Digital 0 1000 Hz 3 dB Bandwidth Selectable 128 samples 5 kHz Sample Rate Field Upgradeable via Flash Memory Torque or Velocity Analog Auxiliary Encoder Presets Step Direction CW CCW Indexing Position and Velocity Loop Position or Velocity Loop ULTRA Master or TouchPad Motor or Auxiliary Encoder Checks Digital Output Override Analog Output Override 7 bit ASCII Checksum Active Response EPROM Checksum EEPROM Checksum SRAM Write Read Watchdog Reset A D Conversion D A Conversion Interprocessor Communication Publication 1398 5 0 October 1998 G 4 Specifications Item Run Time Faults Selectable Digital Inputs Selectable Digital Outputs Speed Control Command Range Publication 1398 5 0 October 1998 Specification Motor Overtemperature Bus Overvo
241. n 9101 1191 and 9101 1382 6 mm 10 AWG on 9101 1192 and 9101 1383 10 mm 8 AWG on 9101 1384 and 9101 1399 16 mm 6 AWG 9101 1193 Braid Shield Coverage 85 minimum Jacket Material Thermoplastic elastomer Moldings 105 C 221 F Black PVC Minimum Bend Radius Feedback and Conirol Cables Motor Power Cables Connector mm in Cable mm in Controller J1 171 45 6 75 9101 1190 76 2 3 Encoder J2 129 54 5 10 9101 1191 76 2 3 9101 1192 120 65 4 75 9101 1193 177 8 7 9101 1381 76 2 3 9101 1382 76 2 3 9101 1383 120 65 4 75 9101 1384 152 4 6 9101 1385 88 9 3 5 9101 1399 152 4 6 9101 1467 76 2 3 Cables are manufactured to inch dimensions Millimeter dimensions are approximate conversions from inches Publication 1398 5 0 October 1998 B 2 Cable Diagrams Schematics and Examples e Alternate field wiring diagram for F H or N Series encoder cables is shown below K J WHITE GRAY 16 AWG L M NX BLUE X WHITE BLUE DENOTES TWISTED Publication 1398 5 0 October 1998 Cable Diagrams Schematics and Examples B 3 Interface Cables Figure B 1 J1 to J3 Interface Cable P N 9101 1367 PIN 1 THIS END PIN 14 THIS END E e 2 Qf 5 2 8 x0 45 RETRACTABLE MACHINED THUMBSCREW FASTENS DIRECTLY TO BOARD CONNECTOR
242. n Number Display 5 After self test is completed the TouchPad display defaults to the 2 Mate serial connectors Receive Not used Not used Transmit 4 5VDC Common TouchPad Sense Receive Transmit 5VDC 8 Data bits 1 Stop bit Drive Type 1 1398 DDM 010 or 1398 DDM 010X 1398 DDM 020 or 1398 DDM 020X 1398 DDM 030 or 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X 1398 DDM 150 or 1898 DDM 150X 2 1398 DDM 005 or 1398 DDM 005X 1398 DDM 009 or 1398 DDM 009X 1398 DDM 019 or 1898 DDM 019X irmware Level 1 00 Version 1 00 1 10 Version 1 10 2 00 Version 2 00 Indexing capable branch title DRVSETUP 6 Horizontal and vertical movement through the TouchPad Com mand Tree and parameter modification is explained below The TouchPad Command Tree sheet 1 of 2 on page C 4 illus trates the structure Publication 1398 5 0 October 1998 Pin5 Pin 9 L Pin 6 Pin 1 No Parity bit TouchPad Commands TouchPad Instructions 3 Commands are entered by pressing a single key or combination of keys Two modes of operation are available Parameter mode allows you to move through the TouchPad Command Tree to each parameter Modify mode allows you to monitor and change each parameter often while the drive is operational Key Function Mode Enter Toggles the parameter di
243. n the wrong direction but reducing the acceleration current if the motor is already accelerating in the right direction When used in this way the D gain dampens an oscillating or ringing system In the case of motor load mechanical resonance a positive D gain actually worsens the situation When a negative D gain value is used in a mechanically resonating system it may be thought of as subtracting the load acceleration the opposite sign of the motor acceleration since the system is resonating This tends to bring the motor and load back into phase with each other and therefore reduces or eliminates mechanical resonance Reducing the value of the P gain low pass filter frequency and the update frequency all have the effect of reducing the servo motor bandwidth As long as the resonating frequency is fairly high this will likely be acceptable but if the resonating frequency is low it may be necessary to modify the mechanics of the system Tuning 9 3 Figure 9 1 Velocity Loop Structure VELOCITY 1 77 gt 11 COMMAND Y MOTOR VELOCITY gt Pain 5 VELOCITY m n CONTROL VELOCITY ERROR Igain SPEED SPEED WINDOW WINDOW LP ENABLE TORQUE CURRENT COMMAND INPUT O gt OVERSPEED OVERSPEED ZERO SPEED ZERO SPEED Figure 9 2 Torque Current Co
244. nd OUTPUT4 Functions Function Description In Position An active state indicates the position window condition is satisfied and the zero speed condition is satisfied The position window and zero speed range are selectable settings Within Window An active state indicates the position window condition is satisfied The posi tion window range is a selectable setting Zero Speed An active state indicates the velocity loop zero speed signal is active The zero speed limit is a selectable setting Speed Window An active state indicates the velocity loop speed window is active The speed window range is a selectable setting Publication 1398 5 0 October 1998 Interfaces 6 11 Table 6 9 OUTPUT1 OUTPUT2 OUTPUT3 and OUTPUT4 Functions continued Function Description Current Limit An active state indicates the torque current is limited Up To Speed An active state indicates the velocity loop AT SPEED signal is active The at speed level is a selectable setting Drive Enabled An active state indicates the ENABLE signal is active and no fault is detected Bus Charged An active state indicates the DC bus is energized Disabling Fault An active state indicates a fault disabled the drive In Motion An active state indicates the indexing sequence is in the motion portion In Dwell An active state indicates the indexing sequence is in the dwell portion Sequ
245. nditioning Structure CURRENT TORQUE CURRENT LIMIT COMMAND OUTPUT AVERAGE CURRENT AVERAGE CURRENT EXCESSIVE CURRENT LOW PASS CURRENT CURRENT gt FILTER LIMIT LIMIT POSITIVE 9 DETECT CURRENT PEAK NEGATIVE PEAK DETECT CURRENT PEAK Backlash Backlash between the motor and load effectively unloads the motor over a small angle Within this small angle the increased bandwidth can result in oscillations Some backlash may be unavoidable especially with gear reduction If backlash is present the inertia match between the load and motor must be properly sized for good servo performance load inertia should roughly equal motor inertia Gearing reduces the inertia reflected to the motor by the square of the gear reduction from motor to load Therefore the gear ratio must provide the required match Publication 1398 5 0 October 1998 9 4 Tuning Auto Tune Mode Publication 1398 5 0 October 1998 The Auto Tune mode uses a self tuning algorithm that automatically adjusts the drive s velocity loop gain parameters Adjustments do not require special equipment This mode will tune a drive for constant velocity loop response across different applications The results will often provide acceptable response but in general should be considered a starting point Tuning parameters adjustments are set to
246. ng Output OUTPUT INPUT Drive 24VDC 5K 1K v 24VCOM J1 6 or J1 13 24VCOM Publication 1398 5 0 October 1998 va K Interfaces 6 9 Digital Outputs Two types of discrete output circuits are available on the J1 connector e Dedicated relay outputs e Selectable transistor based outputs Both types support 24 VDC logic interfaces Dedicated Relay Outputs BRAKE and DRIVE READY Each output is a normally open relay The brake contacts are rated for 1 Amp at 50 Volts The Drive Ready contacts are rated for 100 mA at 50 Volts If an option such as 90V brake requires more power a user provided relay may be driven by these outputs up to the specified levels Selectable Transistor Outputs OUTPUT 1 OUTPUT 2 OUTPUT 3 and OUTPUT 4 are 24 VDC optically isolated active high current sourcing single ended transistor output channels Each channel sources a maximum of 50 mA Ready and Brake Circuits Figure 6 8 READY and BRAKE Circuits J1 Drive 10 Normally Open Relay The specifications for these outputs are as follows Table 6 6 READY Output Specifications Parameter Description Maximum ON state resistance Internal resistance between J1 24 J1 25 when 1 Ohm the contacts are closed ON state current Current flow through the relay when contacts are closed 100 mA OFF state current Leakage current
247. ngs for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions Select Read Drive Parameters from the Communications menu Verify the Drive Name and Address are correct for the drive that is being addressed Choose OK to load the drive parameters Note A motor must be selected for the parameters to load 10 11 12 13 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Motor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select Eollower Step Direction as the Operation Mode for the drive Choose Close to exit the Drive Set Up window Publication 1398 5 0 October 1998 8 20 Application and Configuration Examples Publication 1398 5 0 October 1998 14 15 16 17 18 19 Choose the Drive Parameters command icon from the Drive window and then select the Follower tab Enter an appropriate Gear Ratio as the Follower Input The default Gear Ratio is 1 1 motor encoder pulses master pulses
248. ni D ribbon connector AMP 2 178238 2 It connects the motor encoder hall effect switches and the thermostat to the ULTRA 200 Series drive Contact between the connector shell and a grounded chassis provides shield termination ATTENTION Ensure that the encoder signals are con nected as shown in Figure 6 36 Incorrect connection of the encoder signals will result in improper rotor position incor rect commutation and or a runaway motor condition Allen Bradley cables are available in various lengths for connecting between J2 and an encoder Options and Accessories on page A 1 lists the cables that are available J2 Terminal Strip Breakout Board on page 6 30 details the optional signal extension kit Publication 1398 5 0 October 1998 Interfaces Figure 6 34 Motor Encoder Interface Circuit J2 Drive 1 AMC NNN 220pF I 1K 26LS33 W 220pF 7 LINE BREAK DETECT Figure 6 35 Effect Sensor Circuit J2 Drive 5V U 20 Vor n AW w 1 2 5V 7 Table 6 22 2 Motor Encoder Connector Pin Outs Motor Encoder Pin Number Description EPWR J2 1 Encoder power J2 3 Internally fused F3 is 1A fast acting ECOM J2 2 Encoder common J2 4 SENSE J2 5 Encoder power sense SENSE J2 6 NOTE The SENSE signal must be connected to the EPWR sig nal
249. nications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions Select Read Drive Parameters from the Communications menu Verify the Drive Name and Address are correct for the drive that is being addressed Choose OK to load the drive parameters Note A motor must be selected for the parameters to load 10 11 12 13 14 15 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Motor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select Follower Step Up Step Down as the Operation Mode for the drive Choose Close to exit the Drive Set Up window Choose the Drive Parameters command icon from the Drive window and then select the Follower tab Enter an appropriate Gear Ratio as the Follower Input The default Gear Ratio is 1 1 motor encoder pulses master pulses If a Gear Ratio of 3 1 is entered the motor is moved 3 encoder pulses for every incoming step pulse Application and Configura
250. ning to be effec tive 2 Select AutoTune from the Tuning mode group 3 Select the appropriate values for the following Auto Tune com mands Distance and Step Current 4 Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only Publication 1398 5 0 October 1998 Application and Configuration Examples 8 11 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive 7 Choose Normal Drive Operation from the Tuning window 8 Open the switch between J1 26 and J1 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Operation The drive is now configured as a Preset Controller in Velocity or Torque mode e The servo parameters have been setup with the unloaded motor e The motor speed or current is controlled through the digital inputs The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1
251. nnector at the drive end and a 50 pin D connector at the termi nal strip end Adaptor Kit 9101 1392 includes the 3 foot cable screw terminal strip and mounting bracket The cable has a 20 pin Mini D Ribbon connector at the drive end and a 20 pin D connector at the ter minal strip end Motor Power Cables Use ULTRA 200 Series cables if the CE Mark is required Other cables may be used if the CE Mark is not an issue In either case the shield on the motor power cable must be properly grounded at both ends the shield is grounded at the motor end when the MS connector is mated Publication 1398 5 0 October 1998 B 28 Cable Diagrams Schematics and Examples Figure B 28 Motors to ULTRA 200 Series Drive Enclosure Cabinet Encoder Connectors h 9101 1375 XXX 9101 1391 1629 To lt Control Nnterface 95 ON Screw Terminal Strip Clamp exposed motor cable shield to the chassis ground terminal 9101 1385 XXX 2 Notes Y Series Motor CPC connectors Motor Power connectors machine chassis ground
252. nsated properly for the selected motor e The servo parameters have been setup with the unloaded motor e The motor position is controlled by the master encoder input The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 26 and J1 20 to enable the drive 2 Close the switch between J1 26 and J1 32 to enable following Position Follower Step Direction Application and Configuration Examples 8 17 The ULTRA 200 Series drive can be set up as a Position Follower using Step Direction commands by making the hardware connections and performing the software setup and tuning described below This configuration allows the ULTRA 200 Series drive to electronically gear or drive a servo motor using step and direction signals that typically control a stepper drive The connection diagram depicts the minimum hardware necessary Interfacing the drive to a stepper indexer requires similar circuitry from the stepper indexer to J1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional TouchPad may also may be used Hardware Setup Make the connections described below and shown in Figure 8 4 The appendix Options and Accessories on page 1 lists the interconnect cables available from the factory 1 Connect an RS 232 cable bet
253. nts 9 2 Overcurrent 11 6 Line 11 7 Short 11 7 Thermal Protection Fault 11 10 Motor Buzz or Squeal 9 2 Information Missing 11 10 Overspeed 11 9 Overtemperature 11 7 Thermal Protection 11 10 Motor Encoder Error 11 9 RS 232 Communications 11 11 Status Display 11 6 Tuning Backlash 9 3 Gravitational Effects 9 4 Tuning Guidelines 9 1 Auto Tune 9 4 Effect of Gain Settings 9 6 General 9 1 High Inertia Loads 9 1 Mechanical Resonance 9 2 Tuning Procedure Auto Tune 9 4 Filter for Velocity Loop 9 7 Overspeed Parameter 9 5 Velocity Loop Examples 9 10 Typographical Conventions Intro 19 U Unpacking the Drive 4 1 Update Rate see Specifications User Units 8 45 V Velocity Loop Diagram 9 3 Version Level Firmware 3 4 Software 3 3 Version Level TouchPad C 1 Vibration 1 Warning Classifications Intro 20 Defined Intro 20 Weight G 1 Wire Size 7 9 7 10 Wiring I O 5 6 Wording Conventions Intro 19 Index 7 Publication 1398 5 0 October 1998 Index 8 Publication 1398 5 0 October 1998 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 Leve
254. o maximum drive current I LIMIT limits current for producing positive torque and I LIMIT limits current for producing negative torque The I LIMIT and I LIMIT are tied together for balanced current limiting The analog I LIMIT or I LIMIT signals are converted into a digital word by a 10 bit ADC analog to digital converter If the I LIMIT and I LIMIT inputs are not connected current is not limited Table 6 11 Analog Inputs 1 LIMIT and I LIMIT Analog Input Pin Description Number Positive Current Limit J1 27 Limits the peak positive current command which produces I LIMIT positive torque Negative Current Limit J1 29 Limits the peak negative current command which produces I LIMIT negative torque Table 6 12 Positive and Negative Current Limit Imput Specification Specification Description Minimum Maximum Resolution Number of units that the input voltage is 10 Bits converted to Maximum Current Short circuit between the input and 1 5mA ground Input Signal Range Allowable voltage applied to the input 0 Volts 10 Volts Publication 1398 5 0 October 1998 Interfaces 6 15 Command Input Figure 6 18 Analog COMMAND Input Circuit 01 20K J1 Drive 10K 10K COMMAND ANALOG T otuF COMMAND 10K 10K COMMAND L1 Z 20k The analog command signal to the drive has a range of 10 Volt
255. o Sensor then to Marker Marker Home to Marker Sensor Home to Sensor a Parameters available only if the drive supports Indexing Table C 12 Homing Auto Start Parameter List for TouchPad Display Parameter Disable Auto Start Homing inactive Enb Rst Auto Start Homing if not already Homed Enable Auto Start on every Enable a Parameters available only if the drive supports Indexing Publication 1398 5 0 October 1998 TouchPad Instructions C 15 Table 13 Reverse Enable for Homing Display Parameter Inactive No reversing if started on Sensor Active Reverse if started on Sensor a Parameters available only if the drive supports Indexing Table C 14 Digital Input Parameter List for TouchPad Display Parameter Not Asgn Not Assigned not used DrvMode Drive Mode Intinh Integrator Inhibit FolEnab Follower Enable FwdEnab Forward Enable RevEnab Reverse Enable CMD Ovrd Analog COMMAND Input Override PreSelA Preset Select Line A PreSelB Preset Select Line B PreSelC Preset Select Line C Start Index DefHome Define Home Registr Registration Sensor CmdOfs Remove Command Offset Home Start Homing FaltRst Fault Reset Table C 15 Digital Output Parameter List for TouchPad Display Parameter Not Asgn Not Assigned not used InPos In Position Po
256. ommon electrical noise problems and suggests methods to ensure ElectroMagnetic Compatibility Provides equations to assist in sizing resistors for dynamic braking Details the design and operational specifications for the ULTRA 200 Series drives in a tabular format Host Commands and ULTRA Master All ULTRA 200 Series drives are setup through serial Host Commands The drives may be configured directly through the Host Command language or indirectly through the ULTRA Master software ULTRA Master is a graphical user interface that provides a visual method of accessing the Host Command language through the Microsoft Windows Operating System Publication 1398 5 0 October 1998 Intro 18 Preface Publication 1398 5 0 October 1998 All documentation for both the Host Commands and ULTRA Master is on line Host Command information is available through a comprehensive on line reference manual ULTRA Master information is available through Help menus The on line documents provide in depth explanations of the Host Command language as well as the menus windows and dialog boxes that make ULTRA Master a convenient method for programming ULTRA 200 Series drives access the Host Command Reference Click on the Host Command Reference icon in the ULTRA Master program group e To access ULTRA Master Help Open ULTRA Master by clicking on the ULTRA Master icon in the ULTRA Master group and Press the F1 key TouchPad The optional
257. on Diagram DRIVE J2 J4 Motor XMT 2 RCV Encoder ny 3 XMT TB1 SOM 5 COM Phase 1 PhaseS 2 J1 Phase 3 14 CW Step 15 CW Motor Gnd 4 Indexer 16 1 17 2 100 240 VAC 50 50 Hz L2 N 2 Single Phase 21 FAULT Power Source RESET Gnd 26 24V TB1 or M 32 INPUT1 js 100 240 VAC 50 50 Hz L3 Three Phase Gnd Power Source Note 1 Refer to Figure 6 32 and 6 33 for additional details on the Control Interface Cable Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F or P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display codes Start ULTRA Master on the PC Choose Cancel from the Drive Select dialog box Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings Publication 1398 5 0 October 1998 8 24 Application and Configuration Examples Publication 1398 5 0 October 1998 5 8 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are different correct the Port Settings to allow communications with the drive Factory default commu
258. on Level 5252 ee Saw y ei Be SUR ee A ans 3 3 The ULTRA Master Start Up 5 3 3 Thereadme Fil s 3 4 Firmware 2 2 3 4 Unpacking Inspecting and Storing Unpacking the 4 1 Inspection Procedure et eee sek UY 4 1 Testing th Unit cess ER eR SR Beas 4 2 4 3 Drive Checkout Test 4 4 Storing the Unit poo eee eae SES 4 7 Installation Mechanical Installation 5 5 1 Interface Connections 5 5 hoa MER IC rcc TC 5 6 Electromagnetic Compatibility 5 6 Qualified AC Line 5 5 6 Allen Bradley AC Line 5 5 7 Interfaces Controller J cu ss etek 6 1 Digital VO ec 25222222552 9 24 6 3 Digital Inputs aes Santee Sie ee pes 6 4 Digital Outputs ee 6 9 Analog Inputs 6 14 Analog Outputs 6 16 Motor Encoder Output Signals 6 17 Auxiliary Encoder Inputs 6 19 Interface Cable Examples 6 21 Terminal Strip Breakout 6 26 J2 Bncoder 4 5 Susu m REOS 6 27 Chapter 7
259. on counts 1 Position Command Tuning Modes counts Y 1 PosError 2 Position Error SWErable P Gain lt counts Software Enable Proportional Gain 5 PosErPk IGain Fos Eiror eek Reset Fault Integral Gain 5 P SEP U to start 8 Poe Enon Peak indexCnt RstDrive D Gain 8 counts Index Count Reset Drive mese aj Differential 5 Index Num ResetPks to reset Index Number Reset Peaks l to reset Position Y Velocity or E Torque Kp Gain Proportional Gain KdGain Differential Gain 2 2 Feedforward Gain Version 12 10 KiGan 8 TouchPad Command Tree Integral Gain 8 NOTES Branch Titles sasi Path decisions are dependent counts the specified input Dashed lines Velocity indicate the possible paths and the Positi Torque I parameter selection that defines osnon TouchPad Display Drv Mode the path Y Software Title J Drive Mode AM LPFiltEn Setting Type or Units Velocity or Torque Selections in parentheses are Low Pass Enbl Shading indicates IndxCtri dependent on Drive Mode settings Selection availability only on Index Control Velocity rpm Torque Amps LPFiltBW Indexing drives or Off Selections in brackets are s Bande Selections may be made from tabulated dependent on Analog Output settings lists provided in the Installation M
260. only the output to the drive Software determines when the hall effect sensors are in an illegal state HALL C J2 15 Hall Effect C sensor logic level input Internally pulled up to 5 VDC through a 1 kOhm resistor The input signal interfaces to both a differential and single ended Hall effect sensor using either a TTL level signal or open collector signal A differential output connects only the output to the drive Software determines when the hall effect sensors are in an illegal state ABS J2 16 Absolute Position used on Allen Bradley motors for commutation J2 17 J2 18 Reserved TS TS J2 19 J2 20 Thermal Switch and Thermal Switch are thermostat inputs with an open condition indicating a motor overtemperature fault Publication 1398 5 0 October 1998 6 30 ULTRA 200 Series Motor Encoder Connections Interfaces Figure 6 36 Drive EPWR 221 ECOM 22 EPWR 23 ECOM 924 SENSE 25 SENSE 2 2 7 8 8 AM 329 BM 40 BM 42 11 IM IM HALL 5275 HALL C 3216 ABS 12 19 MEA Das J2 20 NOTES MOTOR ENCODER 5V COM A A B B Z 7 HALL HALL B HALL C ABS THERMOSTAT THERMOSTAT 1 For encoders with differential Hall outputs A A B B C and C connect only the outpu
261. onnect only i n J1 sources 5VDC power to user electronics Drive Chassis Figure 6 31 External Step Direction Interface Single Ended TTL Line Drivers not recommended USER ELECTRONICS Drive Dir 16 Dire twisted pair Dir em 45V Supply Return VY 4 twisted pair p gt Step 14 Step Sep SS 5 Volts 3 Supply bnly if J1 sources 5VDC power to user electr nics 1 5VDC 5V 250 mA Drive Chassis Figure 6 32 External CW CCW Step Up Step Down Interface via TTL Differential Line Drivers USER J1 Drive ELECTRONICS N CW 14 TTL CW lt twisted pair p 15 ICW Differential Line Drivers N CCW 16 CCW 9 lt iwisted pair gt Q 17 CCW gt 0 O 5V ECOM A lt twisted pair s 5 Volts 5V 5VDC Supply 250 mA For horizontal dashed lines connect only if d J1 sources 5VDC power to user electronics Drive Chassis Publication 1398 5 0 October 1998 6 26 Interfaces USER Figure 6 33 External CW CCW Step Up Step Down Interface via Single Ended Line Drivers not recommended ELECTRONICS Ji Drive CW 14 D n CW gt twisted pair 5V x 5 Supply 1 Return lt 4 twisted pair p 5V lt CCW 9 g 16 CC ap 3 an nly if J1 sources 5
262. ons RCV 44 1 RS 485 differential receiver input to drive 45 1 44 7 45 7 XMT 4 RS 485 differential transmitter output from drive J5 4 XMT 44 8 J5 8 COM 44 5 Common serial port interface J5 5 44 6 Reserved J5 6 RCV J4 2 RS 232 receiver input to drive J5 2 XMT J4 3 RS 232 transmitter output from drive J5 3 J4 9 Reserved J5 9 a Do not connect any device to J4 6 15 6 J4 9 or J5 9 except an Allen Bradley TouchPad Publication 1398 5 0 October 1998 6 36 Interfaces Publication 1398 5 0 October 1998 Serial Communications Overview ULTRA 200 Series drives communicate via a standard NRZ non return to zero asynchronous serial format which supports either RS 232 or four wire RS 485 The pin out arrangement on the drive serial ports provides self sensing of the communication standard To change from RS 232 to four wire RS 485 requires a simple change of the cable In multiple drive installations a unique address must be assigned to each drive either through hardware a physical address or software All physical addresses are set using the 16 position rotary switch on the front panel of the drive Software based addresses are selected by setting the rotary switch to position F as shown which forces the drive to used the address stored in the personality module EEPROM of the drive Figure 6 38 Sixteen Position Rotary Addressing Switch 4 0
263. or ID N 2302 1 F 335 N 2304 1 F 336 N 3406 2 H 81 N 3406 2 K 849 N 3412 2 H 82 N 3412 2 K 850 N 4214 2 H 83 N 4214 2 K 851 N 4220 2 H 84 N 4220 2 K 852 N 5630 2 H 85 N 5630 2 K 853 N 5637 2 H 86 N 5637 2 K 854 N 5647 2 H 87 N 5647 2 K 855 Y 1002 1 69 Y 1002 2 68 Y 1003 1 71 Y 1003 2 70 Y 2006 1 73 Y 2006 2 72 Y 2012 1 75 Y 2012 2 74 Y 3023 2 77 Table C 3 TouchPad Motor Table Identification by Motor ID ID Motor ID Motor ID Motor ID Motor 15 F 4030 Q H 16 F 4075 R H 17 F 6100 R H 18 F 6200 R H 19 F 6300 R H 20 H 2005 K H 21 H 3007 N H 22 H 3016 N H 23 H 4030 P H 24 H 4030 M H 25 H 4050 P H 26 H 4075 R H 27 H 6100 Q H 28 H 6200 Q H 29 H 6300 Q H 30 H 8350 S H 31 H 8500 S H 68 1002 2 69 Y 1002 1 70 1003 2 71 Y 1003 1 72 2006 2 73 Y 2006 1 74 2012 2 75 Y 2012 1 77 Y 3023 2 81 N 3406 2 H 82 N 3412 2 H 83 N 4214 2 H 84 N 4220 2 H 85 N 5630 2 H 86 N 5637 2 H 87 N 5647 2 H 259 F 4050 Q F 271 F 4030 Q F 272 F 4075 R F 273 F 6100 R F 274 F 6200 R F 275 F 6300 R F 276 H 2005 K F 277 H 3007 N F 278 H 3016 N F 279 H 4030 P F 280 H 4030 M F 281 H 4050 P F 282 H 4075 R F 283 H 6100 Q F 284 H 6200 Q F 285 H 6300 Q F 286 H 8350 S F 287 H 8500 S F 335 N 2302 1 F 336 N 2304 1 F
264. or to the respective pin s on the terminal block The cabling examples beginning on page B 26 depict the use of this kit to pass a cable through a restricted bulkhead Publication 1398 5 0 October 1998 B 8 Cable Diagrams Schematics and Examples 4 40 RETRACTABLE MOLDED THUVBSCREWS TFASIENS TO FEMALE SCREWLOCKS Figure B 6 J1 to 50 pin D Connector Cable P N 9101 1369 12 THREAD PROTRUSION 50 POSITION D SUB RECEPTACLE WITH FEMALE SOCKET CONTACTS FACE VIEW Publication 1398 5 0 October 1998 _ E fee E MARKED WITH PART AND REV MANUFACTURERS PART REV AND DATE CODE 3 MACHINED THUMBSCREW IFASTENS DIRECILY 10 BOARD CONNECTOR CONNECTOR BACKSHELL SHIELDED 380 BOTH ENDS n 1 9 BLACK 2 T 3 WHITE BLACK i 2 3 L4 RED 3 4 L4 5 WHITERED 4 5 4 GREEN m 6 WHITE GREEN 6 7 I T ORANGE 2 I 1 7 WHITEJORANGE 8 M I BLUE M 2 dU WHITEIBLUE 18 11 YELLOW 11 ds 5 WHITEVELLOW 12 13 BROW 13 26 i WHITEJBROWN 26 14 4 VIOLET m is WHITEVIOLET 15 16 GRAY J 16 17 WHITEIGRAY 5 18
265. oss of life Fuse Replacement The 24VDC 5VDC and Motor Encoder power lines are fused for protection All fuses are 1A fast acting fuses Refer to Appendix A Options and Accessories for the part number and Figure 11 1 for fuse locations A spare fuse F4 is included on the circuit board for convenience Publication 1398 5 0 October 1998 11 2 Maintenance and Troubleshooting Publication 1398 5 0 October 1998 EEPROM Personality Module The serial EEPROM or personality module stores all the drive setup parameters The setup parameters configure the drive to match a particular motor and operate in a particular mode of operation The personality module may be removed from a ULTRA 200 Series drive and installed in another drive By transferring the personality module from a drive to another drive the drive s personality is moved to the new drive Alternatively the data stored in the EEPROM may be transferred using ULTRA Master software to a peripheral device such as diskette or tape The only time you may need to remove the personality module is if you do not have a PC available and your drive is down EEPROM Removal Replacement To remove the EEPROM from a drive 1 Remove all power from the drive 2 Disconnect all connections to the front of the drive 3 Remove the protective cover by removing the screws attaching the right side cover to the chassis ATTENTION The circuits in the drive are
266. otection will not function properly ULTRA 200 Series Overview Chapter 2 Selecting Other System Components The Allen Bradley ULTRA 200 Series drives are part of a family of digital drives that use microcontrollers to manage the current velocity and position All system and application parameters are set in software which ensures repeatability of all functions and prevents element drift This chapter reviews the ULTRA 200 Series and associated motors command sources and interfaces Selection of complementary servo components allows you to efficiently connect other devices to your ULTRA 200 Series drive Pertinent information about each is provided to assist you in planning your servo system Drive Power Ratings Several power levels of ULTRA 200 Series drives are available All models have integral power supplies and shunt regulators and are functionally equivalent They differ only in output power and physical size e 1398 DDM 010 and 1398 DDM 010X with continuous output power of 1000 Watts using a single phase power source e 1398 DDM 020 and 1398 DDM 020X with continuous output power of 2000 Watts using a single phase power source e 1398 DDM 030 and 1398 DDM 030X with continuous output power of 3000 Watts using a single phase power source e 1398 DDM 075 and 1398 DDM 075X with continuous output power of 3000 Watts using a single phase power source e 1398 DDM 075 and 1398 DDM 075X with continuous output power of 7500 Watts
267. otor files ULTRA Master must transmit not only the custom motor s table ID but also the complete motor parameter set from the custom motor file Text String The text string allows ULTRA Master to display a meaningful name in the motor model window The text string displays one of three possible messages when a motor is loaded into the drive 4030 or equivalent if a valid motor model number is loaded e Custom if a custom motor file is loaded Unknown if an unrecognized motor file is loaded Creating Custom Motor Files D 3 The text string translates the table ID into a real motor model number for display For example the user can select the text string H 4030 P H rather than entering the table ID 23 Figure D 1 defines the text string format of Allen Bradley motors Figure D 1 Allen Bradley Motor Naming Convention Motor Part Number H 4030 P H 00 AA _ FACTORY DESIGNATED SPECIAL OPTIONS AA STANDARD FLYING LEADS IEC DIMENSIONS gt O H H H AN NEMA 56C FACTORY DESIGNATED SPECIAL OPTIONS 00 STANDARD 01 90 VDC BRAKE 02 24 VDC BRAKE OPTICAL ENCODER LINECOUNT 1000 2000 STANDARD 2500 5000 500 3000 N 1000 MOTOR WINDING DESIGNATOR FRAME SIZE SERIES DESIGNATOR COMMERCIAL MEDIUM INERTIA LOW INERTIA INDUCTION NEMA STYLE FRAME WASHDOWN LIGHT INDUSTRIAL I M H H H ow H W H H H H H I zz rmm
268. oup 3 Select the appropriate values for the following Auto Tune com mands Distance and Step Current 4 Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive 7 Choose Normal Drive Operation from the Tuning window 8 Open the switch between J1 26 and 71 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Publication 1398 5 0 October 1998 8 44 Application and Configuration Examples Publication 1398 5 0 October 1998 Operation The drive is now configured as a Absolute Indexing controller e The servo parameters have been setup with the unloaded motor e Motion is commanded through the inputs The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 20 and 71 26 to enable the drive 2 Close the toggle switch between J1 32 and
269. ower is removed several times Measure the DC bus voltage at TB1 to verify the bus capacitors are fully discharged or wait for the time indicated in the warning on the front of the drive The bus capacitors must be fully discharged for the subsequent steps to be valid If problems are encountered during this procedure refer to Fuse and Jumper Locations on page 11 4 review other appropriate sections in this manual or call your local Allen Bradley distributor ATTENTION Perform the initial power up with the motor shaft disconnected from a load and the shaft key removed Improper wiring or undiscovered shipping dam age could result in undesired motor motion Be prepared to remove power if excessive motion occurs Unpacking Inspecting and Storing 4 3 Hardware Setup Make the connections described below and shown in Figure 4 1 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series An Allen Bradley cable connects the 9 pin serial port of the ULTRA 200 Series to a 9 pin D shell connector on a serial port of the PC Allen Bradley cables are available in various lengths for connecting between J4 or J5 and a computer Appendix A Options and Accessories lists the cables A three wire cable is shown in the figure below solely for illustrative purposes 2 Connect a Motor Feedback cable from the motor to the J2 connec tor on the drive 3 Connect a jumper wi
270. p Instructions for using the features available in ULTRA Master are detailed in on line help To access the Help menu depress the F1 key The minimum personal computer PC requirements to run the software are A DOS computer with a 286 microprocessor A hard disk with 2 0 MB of free disk space 3 inch 1 44MB floppy disk drive 2 MB of RAM A Video Graphics Array VGA monitor Microsoft Windows version 3 1 A mouse is recommended Windows must be installed on your PC If Windows is not already installed refer to the appropriate Microsoft manual to install Windows on your computer Publication 1398 5 0 October 1998 3 2 ULTRA Master Installation Installing ULTRA Master To install ULTRA Master software on a hard drive 1 Make a backup copy of the ULTRA Master disk in one of the fol lowing ways Copy the ULTRA Master disk using the disk menu in the Windows File Manager If your computer has only one floppy disk drive type from the DOS command line prompt diskcopy a b and then press ENTER The software will prompt you when to insert the SOURCE ULTRA Master disk and when to insert the TAR GET blank disk 2 If Windows is not running type win at the DOS prompt gt If Windows is already running close any open applications 3 Insert the ULTRA Master disk into a 1 44MB floppy disk drive typically drive A and close the drive door 4 Choose Run from the File menu in Windows Program Manager
271. pes CIRCUIT 3 Ground Bus Bar SERIES CONNECTION PARALLEL CONNECTION A ground bus bar or plane should be used as the single point where circuits are grounded This will minimize common ground impedance noise coupling The ground bus bar GBB should be connected to the AC ground and if necessary to the enclosure All circuits or subsystems should be connected to the GBB by separate connections These connections should be as short as possible and straps should be used when possible The motor ground conductor must return to the ground terminal on the drive not the GBB Publication 1398 5 0 October 1998 E 6 Electromagnetic Compatibility Guidelines for Machine Design Shielding and Segregation Publication 1398 5 0 October 1998 The EMI radiating from the drive enclosure drops off very quickly over distance Mounting the drive in an enclosure such as an industrial cabinet further reduces the radiated emissions The primary propagation route for EMI emissions from a drive is through cabling The cables conduct the EMI to other devices and can also radiate the EMI For this reason cable segregation and shielding are important factors in reducing emissions Cable shielding can also increase the level of immunity for a drive The following suggestions are recommended for all installations especially since they are inexpensive 1 Signal cables encoder serial analog should be routed away fro
272. played by the 7 segment display whenever the drive is powered up and operational The Analog mode of operation A is the default mode of operation A sixth mode L indicates a firmware modification routine is in progress The displays and their meaning are A Analog F Follower Master Encoder Step Direction or Step Up Down H Control Panel mode controlled through the serial port L Load Firmware the in process state L loading is indicated by a flashing period P Preset or Indexing Tuning mode the Tuning mode in ULTRA Master is active Refer to Application and Configuration Examples beginning on page 8 1 for information on configuring the ULTRA 200 Series drives in any of these command modes Publication 1398 5 0 October 1998 10 2 Status Display Error Messages If there is a fault the drive provides specific error messages Faults are detected by the drive in two ways power up hardware and run time faults A power up fault usually requires servicing of the hardware while a run time fault can be cleared by resetting the drive The Status display indicates faults by flashing the letter E followed by additional digits to indicate the error The error display repeats until the drive is reset or powered down For example B 0 9 E 0 9 indicates an Bus Undervoltage fault When an error occurs the error code and the service time of the error is logg
273. ple G 3 Update Rate G 3 Status Display G 1 Storage Temperature G 1 Thermostat Inputs 6 1 Vibration G 1 Weight G 1 Speed Control Command G 4 Starting and Quitting Software 3 3 Status Display G 1 Status LED 10 1 Storage Temperature G 1 Storing the Drive 4 7 Symbols and Conventions Intro 19 T 1 7 7 AC Power Terminals 7 1 Auxiliary Power 7 10 DC Bus Terminals 7 1 7 6 Power Terminals 7 3 TB 2 7 11 Terminal Strip J1 50 pin 6 26 J2 25 pin 6 30 Terminal Strip Breakout Board 6 26 6 30 Testing the Drive 4 2 Thermostat Inputs G 1 Timing Diagram Absolute Indexing 8 39 Incremental Indexing 8 27 Registration Indexing 8 33 Torque Current Loop Diagram 9 3 TouchPad C 2 C 3 Character Selection C 6 Cursor Movements C 6 Default Settings C 1 Drive Addressing Defaults C 1 Error Display C 9 Gear Ratios C 8 Installation and Operation C 1 Instructions Intro 16 Lists Baud Rate C 13 Drive Communications C 13 Motor Table C 10 C 11 Selections C 7 Modes of Operation C 3 Motor Selection C 6 Motor Table Identification C 10 C 11 Revision Level 3 4 Text Selection C 6 Version Display 1 Transformer Isolation 7 9 7 10 Size 7 9 7 10 Troubleshooting 11 1 AM Line 11 8 Analog Outputs 11 14 Auxiliary Encoder Error 11 10 BM Line 11 8 Bus Overvoltage 11 8 Undervoltage 11 8 Digital Inputs 11 14 Outputs 11 12 Encoder Inputs 11 17 Overcurrent 11 7 Excess Error 11 9 Excessive Average Current 11 9 Fuses 11 1 Gain Adjustme
274. power wiring is one of the most important paths for both types of coupling mechanisms The AC line can conduct noise into the drive from other devices or it can conduct noise directly from the drive into other devices It can also act as an antenna and transmit or receive radiated noise between the drive and other devices Note Common mode noise is present on all conductors referenced to ground Differential mode noise is present on one conductor ref erenced to another conductor Electromagnetic Compatibility Guidelines for Machine Design E 3 One method to improve the EMC characteristics of a drive is to use an isolation AC power transformer to feed the amplifier its input power This minimizes inrush currents on power up and provides electrical isolation In addition it provides common mode filtering although the effect is limited in frequency by the interwinding capacitance Use of a Faraday shield between the windings can increase the common mode rejection bandwidth shield terminated to ground or provide differential mode shielding shield terminated to the winding One alternative to AC line filters to reduce the conducted EMI emitting from the drive This allows nearby equipment to operate undisturbed In most cases an AC line filter will not be required unless other sensitive circuits are powered off the same AC branch circuit The basic operating principle is to minimize the high frequency power transfer through the f
275. r defined Intro 20 Data Collection G 3 Retention G 2 DC Bus Connections 7 6 LED 7 6 10 1 11 6 Power 7 6 Terminals 7 1 Default Parameters Drive G 7 Motor G 7 D gain defined 9 6 Dielectric Withstanding Voltage G 1 Digital Inputs ENABLE G 2 Selectable G 2 Troubleshooting 11 14 Digital Outputs BRAKE G 2 READY G 2 Selectable G 2 Troubleshooting 11 12 Display of Status 10 1 Display User Units see User Units Publication 1398 5 0 October 1998 Index 2 Publication 1398 5 0 October 1998 Drive Addressing Serial Communications 6 36 TouchPad Defaults C 1 Default Parameters G 7 Installation Interface Connections 5 5 Mechanical Requirements 5 1 Storage 4 7 Dynamic Braking Resistors F 1 E EEPROM G 2 Electromagnetic Compatibility EMC AC Line Filters E 3 European Union Directives 5 6 Filtering E 2 Grounding E 5 Guidelines Design E 6 General 5 6 System E 1 Shielding and Segregation E 6 Electromagnetic Interference EMI E 1 EMC see Electromagnetic Compatibili ty EMI Source Victim Model 2 ENABLE see Specifications Encoder Cabling B 14 Inputs 11 17 Overcurrent 11 7 Troubleshooting 11 7 11 17 EPROM G 2 Error Codes Messages 10 2 Power Up 10 3 Run Time 10 2 European Union Directives AC Line Filters 5 7 Electromagnetic Compatibility 5 6 Example Absolute Indexing 8 39 Analog Controller 8 1 Incremental Indexing 8 27 Modifying User Units 8 45 Position Follower Master Encoder 8 12 Step Up Down 8 2
276. r P Analog Fol lower or Preset mode of operation Refer to Operating Mes sages on page 10 1 for an explanation of the display codes 2 Start ULTRA Master on the PC 3 Choose Cancel from the Drive Select dialog box 4 Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings 5 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are different correct the Port Settings to allow communications with the drive Factory default communications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions 6 Select Read Drive Parameters from the Communications menu 7 Verify the Drive Name and Address are correct for the drive that is being addressed 8 Choose OK to load the drive parameters gt Note A motor must be selected for the parameters to load Publication 1398 5 0 October 1998 8 42 Application and Configuration Examples Publication 1398 5 0 October 1998 10 11 12 13 14 15 16 17 18 19 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Mo
277. r example the 6 Step ABS Index startup uses the 6 Step ABS for the initial commutation angle measurement and the index signal for the final commutation angle measurement The Hall Hall type of startup commutation should be used unless the motor is a special version of an Allen Bradley motor The reasons for this are e The ABS signal is only available on Allen Bradley motors e Hall Hall commutation means that the location of the Index signal is unimportant Publication 1398 5 0 October 1998 D 10 Creating Custom Motor Files Publication 1398 5 0 October 1998 If the drive is set up for Hall Hall startup commutation the initial commutation angle is determined by the state of the three Hall feedback inputs 001 010 011 100 101 or 110 When the motor begins moving a transition from one Hall state to another for example 001 to 101 identifies a precise commutation angle and the measurement is completed After the final Hall measurement occurs the encoder A B inputs are used to track the commutation angle Invert Direction The invert direction check box may be used as a substitute for swapping the motor phase leads and Hall feedback signal wires This option is valid only if the motor runs backwards from the Allen Bradley standard and only if counter clockwise CCW rotation produces the same motor power and Hall feedback sequencing as rotating an Allen Bradley motor clockwise CW The invert direction check box
278. ranch of the command tree Increment Character Increases the selected character s For example 1121 2 or A I B Up amp Down Arrows Press both keys at the same time Not functional in this mode Undo Change Escape Restores a changed parameter to its original setting NOTE This command must be per formed before moving to another param eter or branch Mode Enter Next Mode Last Parameter When displaying a parameter enters the Modify mode of operation When displaying a branch title selects the last parameter modified in branch Next Mode Returns the display to the Parameter mode of operation Publication 1398 5 0 October 1998 C 4 TouchPad Instructions Figure C 3 TouchPad Command Tree sheet 1 of 2 DRVPARM m el MotorSel Drv Mode Diginp1 Motor Selection Drive Mode Digital Input 1 see Table Velocity or Torque see Table Drv Name Src Diginp2 Drive Name Command Source Digital Input 2 lt 32 characters Path Selections see Table Drv Comm OvrdMode Diglnp3 Communications Override Mode Digital Input 3 see Table Velocity or Torque see Table BaudSel OvrdSrc Diglnp4 BaudRate Override Sour
279. rded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive 7 Open the switch between J1 26 and J1 20 to disable the drive 8 Choose Normal Drive Operation from the Tuning window 9 Choose Close to exit the Tuning windows 10 Close any open windows or dialogs Operation The drive is now configured as an Analog Controller in either the velocity or torque mode e The current loop is compensated properly for the selected motor The servo parameters have been setup with an unloaded motor e The motor speed or current is commanded through the analog input The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 26 and J1 20 to enable the drive Publication 1398 5 0 October 1998 8 6 Application and Configuration Examples Preset Controller The ULTRA 200 Series drive can be set up as a preset controller in the Velocity or Torque mode by making the connections described below Three discrete digital inputs provide the programmable speed or torque control Up to eight different preset speed or torque settings can be selected by using the three digital inputs in various binary combination
280. re with a toggle switch between J1 20 ENABLE and J1 26 24VDC This provides manual control for enabling or disabling the drive Figure 4 1 shows the jumper including its normally open toggle switch 4 Connect a power cable between the external 100 240 VAC 50 60 Hz power source ATTENTION When operating the model 1398 DDM 075 or 1398 DDM 075X with single phase power the cur rent limits must be set correctly A 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X connects to the L1 L2 N and Gnd connections on TB 1 when using a single phase power source A 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X connects to the L1 L2 L3 and Gnd connections on TB 1 when using a three phase power source Publication 1398 5 0 October 1998 4 4 Unpacking Inspecting and Storing Figure 4 1 Connection Diagram Close to ENABLE drive s Close to RESET faults Publication 1398 5 0 October 1998 DRIVE r J4 J2 2 RCV Motor Encoder 3 XMT 5 COM TB1 PhaseR 1 J1 PhaseS 2 26 24V Phase T 3 20 ENABLE Motor 4 21 FAULT TB1 L1 7 100 240 VAC LOIN 8 50 60 2 Single Phase Gnd 9 10 Power Source Gnd Pin 9 for DDM 010 DDM 020 DDM
281. re with a toggle switch between the follow ing pins J1 20 ENABLE and J1 26 I O PWR e J1 32 INPUTI and J1 26 PWR J1 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches 5 Connect the drive to 100 240 VAC 50 50 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Close to ENABLE Drive Close to RESET Fault Close to Start INDEX Application and Configuration Examples 8 29 Connection Diagram Figure 8 7 Incremental Indexing Connection Diagram DRIVE J4 Mot 3 XMT COM 5 Phase 1 PhaseS 2 PhaseT 3 26 I O PWR 20 ENABLE Motor Gnd 4 os 21 FAULT RESET 32 50 50 Hz Single Phase Power Source or 100 240 VAC 50 50 Hz Three Phase Power Source Configuration Carefully check all connections before entering these parameters 1 Switch the AC Power to ON and verify green DC BUS LED is ON display shows an operational status A F or
282. red in the EEPROM personality module should be saved off line Saving the parameters off line will allow you to clone several machines with the same mechanics and provides an emergency backup of the drive data To transfer the data from the drive to a PC 1 While on line with a drive click on File in the toolbar menu 2 Select Save As the Save As window will appear 3 Enter the file name and press ENTER or choose OK to save To transfer the data from a PC to a drive 1 Close all windows in ULTRA Master 2 Choose File in the toolbar menu 3 Choose Open 4 Select the desired file name or enter the file name to be loaded and press ENTER or choose OK If you do not know the name of the file to be loaded select the correct directory from the Directories box and select the file name from the displayed list of file names The ULTRA Master Off Line Drive window appears along with the selected file name 5 Select Communications from the toolbar menu 6 Select Overwrite Drive Parameters The Drive Select window will appear Publication 1398 5 0 October 1998 11 4 Maintenance and Troubleshooting 7 Select the drive to be configured and then press ENTER or choose OK to load the parameters into the personality module Figure 11 1 Fuse and Jumper Locations SPARE Remove JUMPERS P6 and P5 FUSE to power circuitry with an external power source PERSONALITY MODULE A
283. rent correct the Port Settings to allow communications with the drive Factory default communications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions Select Read Drive Parameters from the Communications menu Verify the Drive Name and Address are correct for the drive that is being addressed Choose OK to load the drive parameters Note A motor must be selected for the parameters to load 10 11 12 13 14 If the message box appears that a motor must be selected select OK The Drive Setup window is displayed with Motor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select Indexing as the Operation Mode for the drive Choose Close to exit the Drive Set Up window Choose the Drive Parameters command icon from the Drive window and then select the Indexing tab Application and Configuration Examples 8 37 15 Enter the following values for Index 0 gt Note The Registration Distance must longer than the Deceleration Distance or the
284. rger drive and motor Velocity Error 24 Velocity error exceeded the Increase time or size of specified limit and time allowable error parameters Commutation Angle Error 25 Encoder index location is Replace encoder inconsistent Check encoder and motor power wiring RESERVED 26 Axis not Homed 27 An absolute indexing move Home the drive before was attempted without first attempting an absolute homing the axis indexing profile No Motor Selected 28 No motor was selected Select a motor before when the drive was enabled enabling the drive Motor Information Missing 29 Motor number is referencing Select a motor that is in the a motor that is not currently drive in the drive Update the motor tables in the drive contact the fac tory RESERVED 30 53 Call the factory Personality EEPROM Read 54 Personality EEPROM is Upgrade firmware Error incompatible with the drive firmware Hardware is malfunctioning Call the factory RESERVED 55 82 Call the factory Personality EEPROM 83 Personality EEPROM can Use non indexing drive Incompatibility not be used with an indexing drive Publication 1398 5 0 October 1998 Maintenance and Troubleshooting 11 11 RS 232 Communication Test This test verifies the functionality of the communications port on an MS DOS based personal computer The test uses the Terminal mode available in Microsoft Windows 1 2 Close all ULTRA Master windows Select Co
285. riate parameters for the Command mode in which the drive will operate Velocity Mode Settings Torque Mode Settings Enter the appropriate velocity Enter the appropriate current value value for each speed required for each torque required Up to eight presets 0 7 may be programmed Publication 1398 5 0 October 1998 8 10 Application and Configuration Examples 16 Choose Close to exit the Drive Parameters window 17 Select the Configuration command icon from the Drive win dow 18 Assign one of the three Preset Selects A B and C to each of the Digital Input Assignments For example the following selects three presets Input 1 to Preset Select A Input 2 to Preset Select B Input 3 to Preset Select C Input 4 to Not Assigned The presets provide up to eight binary combinations of speed or current Unassigned preset inputs should be set to Not Assigned which forces an OFF state 19 Verify all Digital Output Assignments are Not Assigned 20 Choose Close to exit the I O Configuration window Tuning gt Note Do not attempt to Tune a drive with the Command mode set for Preset Torques If the drive is set to Torque mode continue with the Operation section below gt Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 Choose the Tuning command icon from the Drive window The drive must be configured in Velocity mode for tu
286. rification 7 8 9 10 Start ULTRA Master on the PC Close any windows that are open in ULTRA Master Select PC Set Up from the Communications menu in ULTRA Master Verify the communication port settings match those of the drive then select OK Factory default drive settings are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Assignment of communications ports on PCs varies between manufacturers The COM port setting for the drive and PC must match Refer to Troubleshooting on page 11 6 if communication problems are encountered Publication 1398 5 0 October 1998 4 6 Unpacking Inspecting and Storing Publication 1398 5 0 October 1998 11 12 13 Switch AC power ON Select Read Drive Parameters from the Communications menu in ULTRA Master Select OK in the Drive Select dialog box A dialog box indicating that the PC is reading drive parameters should appear If this dialog box does not appear a message appears that advises you to check the COM settings and the communication cable If necessary refer to Troubleshooting on page 11 6 for instructions on how to perform these checks Initial Drive Operation 14 15 16 17 18 19 20 21 22 23 When the message appears that a motor must be selected choose OK The Drive Select dialog box is selected with Motor Selection active Select the appropriate motor from the
287. rive 7 Choose Normal Drive Operation from the Tuning window 8 Open the switch between J1 26 and J1 20 to disable the drive 9 Choose Close to exit the Tuning window 10 Close any open windows or dialog boxes Operation The drive is now configured as a Position Follower Step Direction The servo parameters have been setup with the unloaded motor e The motor position is controlled by the step direction inputs The firmware saves the parameters in EEPROM memory Thus the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 26 and J1 20 to enable the drive 2 Close the toggle switch between J1 26 and J1 32 to enable fol lowing Publication 1398 5 0 October 1998 8 22 Application and Configuration Examples Position Follower Step Up Step Down Publication 1398 5 0 October 1998 The ULTRA 200 Series can be set up as a Position Following using Step Up and Step Down signals typically used to control stepper drives The connection diagram depicts the minimum hardware necessary Interfacing the drive to a controller requires similar circuitry from the indexer to J1 Instructions are provided to configure the drive with ULTRA Master software Hardware Setup Make the connections described below and shown in Figure 8 5 The appendix Options and Accessories on page A 1 lists the interconnect cables av
288. rmance The inductance value can be in the range from 0 0039 to 255 9961mH The ratio of motor inductance to motor resistance is defined as the electrical time constant of the motor Always verify this value is in a reasonable range Electrical time constants less than 1mS and higher than about 50mS present difficulties in the current regulator and should be avoided Inductances less than 1mH suffer from high current ripple and are not recommended for use with the ULTRA 200 Series drives Some manufacturers specify the inductance in milliHenries phase The phase to phase inductance is twice the per phase value Rating Parameters Continuous Torque Continuous torque specifies the rated current of the motor in peak Amps Note Continuous torque is peak Amps rather than rms The drive uses the continuous torque current value in its motor thermal protection software The drive generates a fault if the square of the actual current after passing through a low pass filter exceeds the square of the continuous torque current value The square is used because the power dissipation in the motor is approximated as PR losses The continuous torque value may be in the range from 0 0078 to 255 9922 Amps Some manufacturers specify the rated current of a motor inrms Amps To convert from rms Amps to peak Amps use the formula 1 Amps 1414 Occasionally a manufacturer specifies only the rated torque and does not incl
289. rrect phasing Check the Hall phasing Bad connections Verify the Hall wiring RESERVED 12 RESERVED 13 RESERVED 14 RESERVED 15 RESERVED 16 Publication 1398 5 0 October 1998 Table 11 1 Maintenance and Troubleshooting Troubleshooting Guide continued 11 9 Problem or Symptom Error Code Possible Cause s Action Solution Excessive Average Current 17 Excessive time at peak cur rent Reduce acceleration rates Reduce duty cycle ON OFF of commanded motion Increase time permitted for motion User larger drive and motor Software parameter set too low Increase Average Current parameter to a less restric tive setting Insufficient bus voltage Correct the under voltage condition or intermittent AC power or install a larger size transformer Motor Overspeed 18 OVERSPEED parameter in the drive set to low for the application Using ULTRA Master refer to Drive Parameters section set Overspeed parameter to an acceptable range for the application Motor commanded to run above Overspeed seiting Reduce command from position controller or change velocity parameter in the position controller Motor Phasing is incorrect Check motor phasing Motor encoder phasing is incorrect Check encoder phasing Excess Following Error 19 Software position error limit was exceeded Increase the feed forward gain to 100 Increase the follo
290. s 2 Start ULTRA Master on the PC 3 Choose Cancel from the Drive Select dialog box 4 Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer s communica tion settings 5 Verify the communications port settings of the PC match those of the drive If the settings are correct select OK in the Port Settings dia log box If the settings are different correct the Port Settings to allow communications with the drive Factory default communications Port Settings for the drive are Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 Serial Port COM1 Refer to the section RS 232 Communication Test on page 11 11 for troubleshooting instructions 6 Select Read Drive Parameters from the Communications menu 7 Verify the Drive Name and Address are correct for the drive that is being addressed 8 Choose OK to load the drive parameters gt Note A motor must be selected for the parameters to load Publication 1398 5 0 October 1998 8 4 Application and Configuration Examples Publication 1398 5 0 October 1998 9 If the message box appears that a motor must be selected select OK The Drive Set Up window is displayed with Motor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected 10 Se
291. s The signal is either a torque velocity or position command depending on the software configuration of the drive The differential input is processed by a 16 bit analog to digital converter ADC to produce a digital value Table 6 13 Analog Command Input Analog Input Pin Description Internal Number Connections COMMAND J1 22 Analog command signal is a differential type sig J3 22 J1 23 nal to drive the servo controller J3 23 Separate scale and offset parameters are used for the input depending on whether the signal is a position velocity or torque command Table 6 14 Analog Command Input Specifications Specification Description Minimum Maximum Resolution Number of units that the input voltage is Bits converted to 16 Input Impedance Open circuit impedance measured between kOhms and 13 3 Input Signal Range Allowable voltage applied between and Volts inputs 0 10 Publication 1398 5 0 October 1998 6 16 Interfaces Analog Outputs Figure 6 19 ANALOG 1 and ANALOG 2 Output Circuits ANALOG OUTPUT J1 Drive 5 Volts Vv Two selectable outputs are available for monitoring by the user ANALOG 1 J1 30 and ANALOG 2 J1 31 A 12 bit digital to analog converter DAC generates ANALOG 1 ANALOG 2 is a filtered PWM signal with 8 bit resolution and a carrier frequency of 32 8 kHz Both outputs are scaled to a range
292. s as shown in the table below The connection diagram depicts the minimum hardware necessary Interfacing the drive to a controller requires similar circuitry from the controller to J1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional TouchPad also may be used Table 8 1 Preset Binary Inputs Inputs B A Description Preset 0 0 0 Preset 0 is a preprogrammed speed or cur rent All inputs are OFF Preset 1 0 1 Preset 1 is a preprogrammed speed or cur rent Only Preset Select A input is Preset 2 1 0 Preset 2 is a preprogrammed speed or cur rent Only Preset Select B input is ON Preset 3 1 1 Preset 3 is a preprogrammed speed or cur rent Preset Select A and Preset Select B ON Preset 4 0 0 Preset 4 is a preprogrammed speed or cur rent Only Preset Select input is ON Preset 5 0 1 Preset 5 is a preprogrammed speed or cur rent Preset Select A and Preset Select C ON Preset 6 1 0 Preset 6 is a preprogrammed speed or cur rent Preset Select B and Preset Select C are ON Preset 7 1 1 Preset 7 is a preprogrammed speed or cur rent All Preset Select inputs are ON 1 A preset input signal that is OFF is inactive which means no current flows through the optocoupler 2 A preset input signal that is ON is active which means current flows through the optocoupler Publication 1398 5 0 October 1998 Hard
293. s D 7 If a motor operates with trap drives the torque constant is specified as a square wave torque constant However ULTRA 200 Series drives are sinusoidal drives and the torque constant must be specified as a sine wave torque constant or sinusoidal torque constant To convert between sinusoidal torque constants and square wave torque constants usually a factor of 5 10 is required The motor manufacturer should be able to specify the sinusoidal torque constant even if it is not shown in the data sheet Jy Inertia The rotor inertia specifies the inertia of the motor not including the load and is required in units of Kg cm The inertia can be in the range of 0 0156 to 1023 9844 Kg cm The conversion formulas between Kg cm Kg m in Ib s and oz in s are 1 Kg cm 0 0001 Kg m in Ib s oz in s 71129 85 70 6155 Back EMF The back EMF is the peak value of the line to line sinusoidal EMF generated at 1000 RPM and is required in units of Volts KRPM or Volts 1000 RPM The back EMF value can be in the range of 0 0039 to 255 9961 Volts KRPM Note that the required value is a peak value rather than an rms value To convert back EMF from units of Volts rms kRPM use the formula Volts Volts rms 1000 1000 RPM Also a line to line value is required rather than a line to neutral A line to line value equals a line to neutral value times two Publication 139
294. sWin Within Position 0 Speed Zero Speed SpdWin Speed Window lLimit Positive Current Limit ILimit Negative Current Limit UpToSpd Up to Speed DrvEnab Drive Enable BusChg Bus Charged Fault Disabling Fault AtHome At Home SeqEnd Sequence Complete Moving In Motion InDwell In Dwell Homed Axis Homed Publication 1398 5 0 October 1998 C 16 TouchPad Instructions Table C 16 Analog Output Parameter List for TouchPad Display Parameter Current Command I Avg Average Current Command Positive Current Peak Negative Current Peak ILimit Positive Current Limit ILimit Negative Current Limit VelMtr Motor Velocity VelCmd Velocity Command VelErr Velocity Error PosMtr Motor Position PosCmd Position Command Slewed PosErr Position Error PosEPk Positive Position Peak Error PosEPk Negative Position Peak Error PosMstr Master Position Table C 17 Drive Status List for TouchPad Display Parameter DrvEnab Drive Enabled DrvRdy Drive Ready 24 Fuse 24 VDC Fuse blown 5v Fuse 5 VDC Fuse blown EncFuse Encoder Power Fuse blown MtrOvT Motor Thermostat Overtemperature IPMFalt IPM Fault Overtemperature Overcurrent Short Circuit IMLinBk Channel IM Line Break BMLinBk Channel BM Line Break AMLinBk Channel AM Line Break BusOvV Bus Undervoltage BusUndV Bus Overvoltage Illegal H
295. sconnect the motor from the drive when personnel have access to moving parts of the machine Note also that the motor must be securely mounted at all times Stored energy hazards are both electrical and mechanical e Electrical hazards can be avoided by disconnecting the drive from its power source and measuring the DC bus voltage to verify it has reached a safe level or by waiting for the time indicated in the warning on the front of the drive prior to removing the protective covers or touching any connections e Mechanical hazards require a risk analysis on the effects of stored mechanical energy when the machine is running at speed as well as the potential for the conversion of electrical energy stored in the drive being converted to mechanical energy Electrical energy may be stored in drive for the time indicated in the warning on the front of the drive The following points should be observed for the safety of personnel These safety notes do not represent a complete list of the steps necessary to ensure safe operation of the equipment Contact your nearest Allen Bradley representative for additional information e Only qualified personnel familiar with the equipment are permitted to install operate and maintain the device e System documentation must be available and observed at all times All non qualified personnel are kept at a safe distance from the equipment e The system must be installed in accordance with local reg
296. scription J4 J5 to PC RS 232 9 pin D shell connector J4 J5 to customer supplied connector no connector J4 J5 to J4 J5 four wire RS 485 communications J4 J5 D shell 9 pin Mating Connector AMP 205204 4 J4 J5 Crimp Pins for Connector AMP 66506 3 m ft 3 10 7 6 25 15 50 3 10 7 6 25 15 50 1 3 Part Number 9101 1372 010 9101 1372 025 9101 1372 050 9101 1379 010 9101 1379 025 9101 1379 050 9101 1374 001 003 5529 001 0003 5326 001 Publication 1398 5 0 October 1998 A 4 Options and Accessories Encoder Feedback Cables Diagrams and schematics for cables listed below are shown in Appendix B Interface Cables beginning on page B 14 Description m ft Part Number F or H Series Motor to customer supplied connector 3 10 9101 1365 010 1 no connector 7 6 25 9101 1365 025 15 50 9101 1365 050 ULTRA 200 Series drives only 23 75 9101 1365 075 ULTRA 200 Series drives only 30 100 9101 1365 100 J2 to F or H Series Motor 3 10 9101 1366 010 7 6 25 9101 1366 025 15 50 9101 1366 050 ULTRA 200 Series drives only 23 75 9101 1366 075 ULTRA 200 Series drives only 30 100 9101 1366 100 N Series Motor to customer supplied connector 3 10 9101 1469 010 i e no connector 7 6 25 9101 1469 025 15 50 9101 1469 050 ULTRA 200 Series drives only 23 75 9101 1469 075 ULTRA 200 Series drives only 30 100 9101 1469 100 J2 to N Series Motor 3 10 9101 1468
297. splay between the two operating modes Parameter mode shows the abbreviated command name of the selected parame ter Refer to the TouchPad Command Tree Chart for a full text definition Modify mode shows the setting often a number for the selected parameter Key functions in each mode are explained below The Parameter mode displays for the TouchPad Command Tree are explained in the Supplemental Instructions on page C 6 Mode of Operation Key Parameter Modify K Left Arrow Previous Branch Decrement Selects the previous branch in the com mand tree or Decreases the Preset number when in Preset Drive Parameter mode Move Left Moves the flashing character selection to the left advancing the level of the cur sor setting For example 0005200 0005200 Right Arrow Next Branch Increment Selects the next branch in the command tree or Increases the Preset number when in Preset Drive Parameter mode Move Right Moves the flashing character selection to the right lowering the level of the cur sor setting For example 0005200 0005200 I Down Arrow Next Parameter Selects the next parameter down the branch of the command tree Decrement Character Decreases the selected character s For example 2 1 or L A 4 Up Arrow Previous Parameter Selects the next parameter up the b
298. structions Connector Type Part Number J1 50 pin mini D shell 24 80 AWG ribbon cable solder 9101 1476 cup squeeze latch J2 20 pin mini D shell 24 30 AWG ribbon cable solder 9101 1477 cup squeeze latch J3 26 pin mini D shell 24 30 AWG ribbon cable solder 9101 1478 cup squeeze latch J4 or J5 50 pin D shell solder cup for RS 232 or RS 485 9101 1479 Mating Connectors The following connectors are listed solely to provide a cross reference of mating connectors for the J1 J2 or J3 connectors on the ULTRA 200 Series drives The connectors are not available from Allen Bradley Please contact the manufacturer or a distributor for additional information Manufacturer phone numbers are 3M AMP 1 800 225 5373 1 800 522 6752 ULTRA 200 Series drive conformance to the European EMC Directive is contingent on the use of Allen Bradley cables DDM Mating Connector Mating Backshell Description J1 AMP 2 175677 7 3M 10150 6000EC 3M 10150 3000VE AMP 176793 7 3M 10350 A200 00 3M 10350 52F0 008 50 pin Mini D Ribbon 28 30 AWG Insulation Displacement Plastic Backshell Squeeze Latch 50 pin Mini D Ribbon 28 30 AWG Insulation Displacement Metal Backshell Squeeze Latch 50 pin Mini D Ribbon 24 30 AWG Solder Cup Plastic Backshell Squeeze Latch J2 AMP 2 175677 2 3M 10120 6000EC 3M 10120 3000VE AMP 176793 2 3M 10320 A200 00 3M 10320 52F0 008 20 pin M
299. t the motor may be moving quite a lot while the load is not moving nearly as much Mechanical resonance occurs as a result of compliance springiness between the motor inertia and load inertia It may result from belts flexible couplings or the finite torsional stiffness of shafts In general the stiffer the couplings the higher the resonant frequency and lower the amplitude If the motor shaft is directly coupled to the load a mechanically resonating system usually emits a buzz or squeal at the motor There are several ways of dealing with this problem but they fall into two groups change the mechanical system or change the servo motor response Changing the mechanical system might involve reducing the inertia ratio via gearboxes or pulleys or by increasing the stiffness of the couplings For very high performance systems and systems with low resonance frequencies the mechanics may require changing to effectively deal with the resonance The second way of dealing with mechanical resonance is by changing the servo motor response This may be done by using a negative D gain value and by reducing the P gain I gain velocity loop update rate or low pass filter value The D term of the PID velocity regulator see the velocity and torque current conditioning structure subtracts or adds a proportion of the motor acceleration from the velocity error The D gain has the effect of increasing the acceleration current if the motor is accelerating i
300. t Power Module technology in the output stage provides a high frequency digital PWM Pulse Width Modulation sine wave that controls the current loop including overcurrent short circuit and overtemperature protection Analog and Digital Interfaces All ULTRA 200 Series drives allow the user to select one of the following analog or digital command interfaces e 10 Volt analog interface position velocity or torque control e Presets from one to eight binary inputs torque or velocity control e Quadrature encoder digital interface electronic gearing position follower e Step Direction digital interface position control e CW CCW step up step down interface position control e Indexing available only on 1398 DDM 010X 1398 DDM 020X 1398 DDM 030X 1398 DDM 075X and 1398 DDM 150X Encoder Control A single motor mounted encoder provides complete commutation information and velocity feedback Selecting Other System Components 2 3 Encoder Output A selectable output allows the encoder resolution to be specified for maximum performance without adding circuitry Outputs are differential line drivers capable of dividing the motor encoder signal PPR pulses per revolution by a factor of 1 2 4 or 8 Digital 1 0 Digital I O channels allow the user to program the drive to fit the specific application Selections include e Five selectable 24 Volt current sinking optically isolated active high inputs
301. ted to the installation of industrial electronic equipment is so misunderstood as electrical noise The subject is complex and the theory easily fills a book This section provides guidelines that can minimize noise problems The majority of installations do not exhibit noise problems However the filtering and shielding guidelines are provided as counter measures The grounding guidelines provided below are simply good grounding practices They should be followed in all installations Electrical noise has two characteristics the generation or emission of electromagnetic interference EMI and response or immunity to EMI The degree to which a device does not emit EMI and is immune to EMI is called the device s Electromagnetic Compatibility EMC Figure shows the commonly used EMI model The model consists of an EMI source a coupling mechanism and an EMI victim Devices such as servo drives and computers which contain switching power supplies and microprocessors are EMI sources The mechanisms for the coupling of energy between the source and victim are conduction and radiation Victim equipment can be any electromagnetic device that is adversely affected by the EMI coupled to it Immunity to EMI is primarily determined by equipment design but how you wire and ground the device is also critical to achieving EMI immunity Therefore it is important to select equipment that has been designed and tested for industrial environments Th
302. tentiometer is adjusted If you determine that an analog input is defective return the unit for repair Maintenance and Troubleshooting 11 17 Testing Encoder Inputs The following test verifies both reception and transmission of the line count from an encoder by the drive The tests require a PC running ULTRA Master and a motor encoder To test encoder inputs 1 mcn 9 Disable the drive by opening the connections between the ENABLE input and 24VDC Choose the Drive Parameters command icon from ULTRA Master Choose Master Encoder as the Command Source Choose the Drive Set Up command icon from ULTRA Master Choose Divide by 1 as the Master Encoder Command Input Make the following hardware connections Disconnect all connections to 73 Connect the motor encoder to J2 Jumper the Encoder Inputs to the Encoder Outputs by con necting the following pins J1 7 to J1 14 J1 8 to J1 15 J1 9 to J1 16 J1 10 to J1 17 J1 11 to J1 18 J1 12 to J1 19 Choose the Encoder Diagnostics command icon from ULTRA Master Choose Zero Count for both the Motor Encoder and Master Posi tion Input Slowly rotate the encoder shaft by hand while observing the counts for both the Motor Encoder and Master Position Input The Motor Encoder and Master Position Input line counts should be equal Publication 1398 5 0 October 1998 11 18 Maintenance and Troubleshooting Publication 1398 5 0 October 1998 ULT
303. the drive can be power cycled and after power up will use the parameters selected in the steps above When motion is required 1 Close the switch between J1 26 and J1 20 to enable the drive 2 Close the toggle switch between J1 26 and J1 32 to start Index 0 Registration Indexing Velocity Outputs In Motion In Dwell Registered Application and Configuration Examples 8 33 Note This feature is available only on drives capable of indexing 1398 DDM 010X 1398 DDM 020X 1398 DDM 030X 1398 DDM 075X and 1398 DDM 150X The ULTRA 200 Series drive can be set up as a registration indexer by making the hardware connections and performing the software setup and tuning described below A connection diagram depicts the minimum hardware necessary Interfacing the drive to an external controller requires similar circuitry from the controller to J1 refer to J1 Controller on page 6 1 Instructions are provided to configure the drive using a PC with ULTRA Master software but the optional TouchPad also may be used The following example depicts a batched multiple move using registration indexing Figure 8 8 Registration Indexing Examples r Registration Distance Executing Registration P Index Distance x Sensor Detected Defined Velocity Defined Defined Acceleration Deceleration Dwell Publication 1398 5 0 October 1998 8 34 Application and Configuration Examples
304. the unit If you find damage either concealed or obvious contact your buyer to make a claim with the shipper If degraded performance is detected when testing the unit contact your distributor or Allen Bradley to obtain a Return Material Authorization RMA Do this as soon as possible after receipt of the unit Publication 1398 5 0 October 1998 4 2 Unpacking Inspecting and Storing Testing the Unit Publication 1398 5 0 October 1998 Drives are burned in and individually tested before they leave the factory However damage may occur during shipping Perform the procedures below to ensure the ULTRA 200 Series drive is operational and undamaged Abbreviated directions for connecting the drive to a motor and a PC are provided The test requires e Approximately 20 minutes to complete e A motor with appropriate power and encoder cables e A PC with the ULTRA Master software package installed e AnRS 232 communications cable e A single phase or three phase 100 240 VAC 50 60 Hz power source Standard wall outlet power is suitable for verification testing of ULTRA 200 Series drives except the 1398 DDM 150 or 1398 DDM 150X which require three phase power e A test cable constructed from two normally open switches several pieces of 1 5 mm 16 AWG wire and a mating connector Connectors are listed in Mating Connectors on page A 6 Appendix A Options and Accessories lists the cables During the test p
305. tion 1398 5 0 October 1998 Testing Digital Inputs This test verifies the functionality of the selectable inputs Test equipment requirements are e PC running ULTRA Master jumper wire It assumes there are no error codes displayed and the 24V power supply is connected correctly 1 Enable the drive by closing the switch connecting J1 26 and J1 20 2 Choose the Display command icon from the Drive Window A Connect 71 20 to 71 26 The Enable indicator activates Connect 71 21 to 26 The Reset Faults indicator activates Connect J1 31 to J1 26 The Input 1 indicator activates Connect J1 32 to J1 26 The Input 2 indicator activates 7 a Connect J1 33 to J1 26 The Input 3 indicator activates F Connect J1 33 to J1 26 The Input 4 indicator activates 3 Choose Close to exit the I O Display window If you determine that a digital input is defective return the unit for repair Testing Analog Outputs The following tests verify the functionality of the analog outputs Test equipment requirements are e A PCrunning ULTRA Master e A voltmeter Testing Analog Output 1 1 Disable the drive by opening the connections between the ENABLE input and the 24 VDC Disconnect the connections to J1 30 From the Output Diagnostics window select Analog Output 1 Enter 1000 in the D A level box Y M Connect a DC voltmeter across analog test points Al and COM The meter should
306. tion Examples 8 25 16 Choose Close to exit the Drive Parameters window 17 Select the Configuration command icon from the Drive Win dow 18 Select an appropriate digital input from the pull down lists avail able as Digital Input Assignments in the I O Configuration win dow For example Follower Enable as Input 1 Not Assigned as Inputs 2 through 4 Not Assigned as Outputs 1 through 4 19 Choose Close to exit the I O Configuration window Tuning Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 Choose the Tuning command icon from the Drive window 2 Select AutoTune from the Tuning mode group 3 Select the appropriate values for the following Auto Tune com mands Distance and Step Current 4 Select the appropriate entry for the Motor Direction BiDirectional Forward Only or Reverse Only 5 Close the toggle switch between J1 26 and J1 20 to enable the drive ATTENTION Rotating motor shafts can cause extensive damage and injury Motors must be properly guarded dur ing testing and installation 6 Choose Start from the Tuning window The drive powers the motor shaft for a short period and then motion will cease Then ULTRA Master displays the calculated gains and disables the drive 7 Choose Normal Drive Operation from the Tuning window Publication 1398 5 0 October 1998 8 26 Application
307. tions on page 6 3 J3 7 Motor Output Channels A and A Differ J1 7 J3 8 ential TTL levels from line driver J1 8 Refer to Motor Encoder Output Signal on page 6 18 and Figure 6 20 BOUT 43 9 Motor Output Channels B and B Differ J1 9 BOUT J3 10 ential TTL levels from line driver J1 10 Refer to Motor Encoder Output Signal on page 6 18 and Figure 6 20 IOUT J3 11 Motor Output Channels 1 Differen J1 11 IOUT J3 12 tial TTL levels from line driver J1 12 Refer to Motor Encoder Output Signal on page 6 18 and Figure 6 20 and AX J3 14 Auxiliary Channel A and A Differential J1 14 or J3 15 quadrature or TTL level encoder input The J1 15 Step and Step signals are selectable as AX and AX or or Step and Step or CW Step Up and CW Step Up and CW Step Up CW Step Up For encoder information refer to Quadrature Interface Specifications on page 6 20 and Figure 6 23 6 24 6 25 6 26 6 27 6 28 and 6 29 For stepper information refer to Step Direc tion and CW CCW Step Up Step Down Interface Specifications on page 6 24 and Figure 6 30 6 31 6 32 and 6 33 Publication 1398 5 0 October 1998 Table 6 23 Interfaces J3 Auxiliary Connector Pin Outs continued 6 33 Motor Encoder Pin Number
308. to find an Allen Bradley motor with similar capability and use its thermal time constant value for the custom motor The motor thermal protection algorithm filters the square of the torque current using the motor thermal time constant value and generates a motor thermal protection fault if the output of the filter exceeds the square of the motor s continuous torque current rating The square of the current is used because the power dissipated in the motor is approximated as I2R losses Figure D 6 shows the method to be used for protection with t defined as the motor thermal time constant Figure D 6 Motor Thermal Protection Software Method Motor 1 Overcurrent hon p 148 445 S Fault 457 gt gt P d 2 Integral Thermostat The integral thermostat check box should be checked if the motor has a built in thermostat If this box is not checked the thermostat inputs to the drive are ignored When the integral thermostat check box is selected a motor overtemperature fault is displayed if the thermostat inputs to the drive are in an open state Maximum Speed This value specifies the maximum speed in RPM that the motor can safely maintain on a continuous basis The maximum speed value can be in the range from 0 00002 to 32767 99998 RPM Publication 1398 5 0 October 1998 D 14 Creating Custom Motor Files Example of Custom Motor File Creation
309. tor Model selection parameter active The motor may be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select Indexing as the Operation Mode for the drive Choose Close to exit the Drive Set Up window Choose the Drive Parameters command icon from the Drive window and then select the Indexing tab Select the following values for Index 0 Absolute as Mode 8000 as Position 1 as Batch Count 0 as Dwell Appropriate values for Velocity Acceleration and Deceleration Choose Close to exit the Drive Parameters window Select the Configuration command icon from the Drive Win dow Select an appropriate digital input from the pull down lists avail able as Digital Input Assignments in the I O Configuration win dow For example Start Index as Input 1 Define Home as Input 2 Not Assigned as Inputs 3 and 4 Not Assigned as Outputs through 4 Choose Close to exit the I O Configuration window Application and Configuration Examples 8 43 Tuning Note Do not attempt to Auto Tune systems that have gravitational effects The ULTRA 200 Series will not hold initial position 1 Choose the Tuning command icon from the Drive window 2 Select AutoTune from the Tuning mode gr
310. tromagnetic Compatibility General Guidelines Appendix E Electromagnetic Compatibility Guidelines for Machine Design contains guidelines for reducing electrical noise and increasing electromagnetic compatibility EMC plus a discussion of electromagnetic interference EMI European Union EMC Directives The ULTRA 200 Series drives are designed and tested to meet the European EMC Directive Declarations of conformity which enumerate the standards used are available upon request Two installation requirements are necessary to meet the directives 1 Use of an external AC line filter on the main AC input and 2 Use of Allen Bradley cables Qualified AC Line Filters Listed below are AC line filters that have been qualified for use with ULTRA 200 Series drives Filters equivalent to those listed are widely available and Allen Bradley does not recommend one manufacturer over another The machine builder is responsible for the suitability of the filter selection when using different filters These filters can be used for distributing power to multiple drives rather than using an individual filter for each drive Further information is available from the manufacturer Installation 5 7 Table 5 1 Qualified AC Line Filters Drive Manufacturer and Part Number Schaffner Roxburgh 1 800 367 5566 01724 281770 011 44 1724 281770 from the USA 1398 DDM 010 and FN 350 12 MIF 10 or MDF 16 1398 DDM 010X 1398
311. ts are made in software which immediately sets the servo system compensation parameters This eliminates the time consuming adjustments required by potentiometers Agency Approvals UL listed cUL listed e CE marked Options e Power and feedback cables are potted and molded with 360 degree shielding e AC line filters e Breakout boards for I O control and encoder interface e TouchPad a compact and highly portable input and display device Publication 1398 5 0 October 1998 2 6 Selecting Other System Components Motors Publication 1398 5 0 October 1998 The ULTRA 200 Series is compatible with many motors both Allen Bradley motors and motors from other manufacturers Drive and motor parameters for all compatible Allen Bradley motors are programmed into each ULTRA 200 Series drive at the factory Allen Bradley motors that are compatible with the ULTRA 200 Series of drives include all F Series H Series N Series Y Series ULTRA Master software speeds drive and motor set up by predefined parameters for each drive and motor combination Refer to the Torque Speed curves in the Allen Bradley standard product catalog and handbook Publication 1398 2 0 or contact your local Allen Bradley distributor for motor sizing and compatibility assistance Custom motors or motors not manufactured by Allen Bradley may be used with the ULTRA 200 Series Appendix D Creating Custom Motor Files explains how to
312. ts to the drive 2 The ABS signal is only available on selected encoders J2 Terminal Strip Breakout Board A 25 pin terminal strip kit is available for extending the encoder signals from the J2 connector The kit includes a 3 foot 1 meter interface cable a 25 pin terminal strip and mounting hardware Refer to Options and Accessories on page 1 Cabling Examples on page B 26 depicts the use of this kit to pass a cable through a bulkhead Publication 1398 5 0 October 1998 J3 Auxiliary Port Pin Signal Description Pin Signal Description 1 5VDC Encoder 5V 14 AX Auxiliary DG Channel A 2 ECOM Encoder 15 AX Auxiliary Common Channel A 3 5VDC Encoder 5V 16 BX Auxiliary DC Channel B 4 ECOM Encoder 17 BX Auxiliary Common Channel B 5 24VDC Isolated 24 18 IX Auxiliary VDC Channel 6 24VCOM Isolated 24V 19 IX Auxiliary Common Channel 7 AOUT Motor Output 20 ENABLE ENABLE Channel A 8 AOUT Motor Output 21 RESET FAULT Channel A RESET 9 Motor Output 22 COMMAND Analog Channel B Command 10 BOUT Motor Output 23 COMMAND Analog Channel B Command 11 IOUT Motor Output 24 READY READY Channel 12 IOUT Motor Output 25 READY READY Channel 13 24VCOM Isolated 24V 26 24VDC lsolated 24 Common VDC Interfaces
313. ude the rated current specification In such a case the rated current can be computed using the rated torque and the torque constant A factor of 1 1 is included to allow for degradation of the torque constant at high temperatures etc The formula assuming the torque constant has already been converted to N m A peak is rated torque lareo 1 1 K z Publication 1398 5 0 October 1998 D 12 Creating Custom Motor Files Publication 1398 5 0 October 1998 Peak Torque The peak or maximum torque specifies the maximum current capability of the motor in peak Amps Note This is peak Amps rather than rms The drive uses the maximum torque value to limit the current applied to the motor At run time the instantaneous current of the drive is limited to the minimum of this value the drive s peak rating the analog current limit inputs and the software current limits The maximum torque value can be in the range from 0 0078 to 255 9922 Amps Some manufacturers specify the maximum current of a motor in rms Amps To convert from rms Amps to peak Amps use the formula 1 Amps 1 414 Amps rms Occasionally a manufacturer specifies only the maximum instantaneous torque and does not include the maximum current specification In such a case the peak current can be computed using the peak torque and the torque constant A factor of 1 1 is included to allow for degradation of the torque constant at high temperatures
314. ulations e The equipment is intended for permanent connection to a main power input It is not intended for use with a portable power input e Do not power up the unit without the covers in place and the protective conductor connected e not operate the unit without connecting the motor conductor to the appropriate terminal on the drive e Always remove power before making or removing any connection on the unit Publication 1398 5 0 October 1998 1 4 Safety Publication 1398 5 0 October 1998 Before removing the cover of the unit shut off the main and auxiliary power and measure the DC bus voltage to verify it has reached a safe level or wait for the time indicated in the warning on the front of the drive Do not make any connections to the internal circuitry Connections on the front panel are the only points where users should make connections Be careful of the DC bus and shunt terminals High voltage is present when power is applied to the ULTRA 200 Series Never connect the DC terminal to earth ground the drive requires a floating DC bus Do not use the ENABLE input as a safety shutdown Always remove power to the ULTRA 200 Series before maintaining or repairing the unit When operating a 1398 DDM 075 or 1398 DDM 075X with a single phase power input the current limits must be set correctly Motors without thermal protection devices require a valid thermal time constant Otherwise the motor overload pr
315. using a three phase power source e 1398 DDM 150 and 1398 DDM 150X with continuous output power of 15000 watts using a three phase power source The ULTRA 200 Series drives when combined with Allen Bradley brushless servomotors provide continuous torque ranging from 0 34 Nm to 50 8 Nm 3 to 450 Ib in and peak torque ranging from 1 02 Nm to 125 Nm 9 Ib in to 1100 Ib in Publication 1398 5 0 October 1998 2 2 Selecting Other System Components ULTRA 200 Series Features Publication 1398 5 0 October 1998 Interface Cables Standard Allen Bradley motor power and encoder feedback cables as well as communications cables are available to complete your motion control system and provide reliable trouble free start up Refer to Options and Accessories on page A 1 for optional equipment Use of these cables is required for compliance to the European Electromagnetic Compatibility EMC Directive and to protect your warranty rights Stand alone Design A single unit fully encloses all electronics including both the power supply and a built in shunt regulator An external transformer is not required on the main power line All connectors and indicators are accessible and clearly marked on the front panel High Performance Microcontroller Technology Dual microcontrollers perform all digital current velocity and position loop calculations as well as the motor commutation calculation IPM Technology IPM Intelligen
316. ware Setup Make the connections described below and shown in Figure 8 2 The appendix Options and Accessories on page 1 lists the interconnect cables available from the factory 1 Connect an RS 232 cable between the serial port on the PC and the J4 connector on the drive A simple 3 wire cable is depicted in the figure below 2 Connect a Motor Feedback cable from the motor to the J2 connec tor on the drive Application and Configuration Examples 8 7 3 Connect a Power cable from the motor to terminals 5 and on the drive 4 Connect a jumper wire with a toggle switch between the follow ing pins J1 20 ENABLE and J1 26 PWR e J1 32 INPUT1 and J1 26 PWR e J1 33 INPUT2 and J1 26 PWR e J1 34 INPUTS and J1 26 PWR Connect a switch between 71 21 FAULT RESET and 71 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches 5 Connect the drive to a 100 240 VAC 50 60 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Publication 1398 5 0 October 1998 8 8 Application and Configuration Examples Close to ENABLE Drive C
317. ween the serial port on the PC and the J4 connector on the drive A simple 3 wire cable is depicted in the figure below 2 Connect a Motor Feedback cable from the motor to the J2 connec tor on the drive 3 Connect a Power cable from the motor to TB terminals R S and on the drive 4 Connect the Step Direction signals to the drive as shown in the diagram 5 Connect a jumper wire with a switches between the following pins J1 20 ENABLE and J1 26 PWR e J1 32 INPUT1 and J1 26 PWR e J1 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches Publication 1398 5 0 October 1998 8 18 Application and Configuration Examples 6 Connect the drive to a 100 240 VDC 50 60 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Connection Diagram Figure 8 4 Step Direction Controller Connection Diagram E a DRIVE _ 32 J4 Motor AME 2 RCV Encoder He 3 XMT TB1 5 COM 5 n
318. wer Cables 2 e RR A 5 Connector i us Soe Re GH x aee A 6 Mating 5 A 6 Cable Diagrams Schematics and Examples Interface Cables sis us lt lt sty X END S B 3 Serial Interface Cable i ca isi B 11 Encoder Feedback Cables B 14 Motor Power Cables B 21 Cabling Examples s aa lees B 26 Allen Bradley 9 Series CNC Family Connections B 30 TouchPad Instructions Installation and Operation 1 TouchPad Commands C 3 Supplemental Instructions C 6 Publication 1398 5 0 October 1998 Intro 6 Table of Contents Appendix D Appendix E Appendix F Appendix G Publication 1398 5 0 October 1998 Motor Selection C 6 DiSplayS c ues eal a ee Be pn Ps ete UR EUR C 6 Motor Tabler o 2222 65 a8 Bad C 10 TouchPad Options C 12 TouchPad Lists e se 35v o Rc yuyapuy bb ba ee aes C 13 Creating Custom Motor Files Drive and Motor File Configuration with ULTRA Master D 2 Motor Parameter Set ies uu ba ek D 2 General 5 D 5 Feedback Parameters D 8 Electrical 5 D 10 Rating D
319. wing error window refer to ULTRA Master Drive Param eters section Retune the drive to reduce the following error Increase the slew limit win dow refer to ULTRA Master Drive Parameters Motor Encoder State Error 20 Motor encoder encountered an illegal transition Replace the motor encoder Use shielded cables with twisted pair wires Route the feedback away from potential noise sources Check the system grounds Bad encoder Replace motor encoder Publication 1398 5 0 October 1998 Maintenance and Troubleshooting Table 11 1 Troubleshooting Guide continued Problem or Symptom Error Code Possible Cause s Action Solution Auxiliary Encoder state error 21 Auxiliary encoder encoun Use shielded cables with tered an illegal transition twisted pair wires Route the encoder cable away from potential noise sources Bad encoder replace encoder Check the ground connec tions Motor Thermal Protection 22 Internal filter protecting the Reduce acceleration rates Fault motor from overheating has Reduce duty cycle ON tripped OFF of commanded motion Increase time permitted for motion User larger drive and motor IPM Thermal Protection 23 Internal filter protecting the Reduce acceleration rates Fault IPM at slow speed has Reduce duty cycle ON tripped OFF of commanded motion Increase time permitted for motion User la
320. witches between the following pins J1 20 ENABLE and J1 26 PWR e J1 32 INPUT 1 and 11 26 PWR J1 21 FAULT RESET and J1 26 PWR These connections provide manual control for enabling or disabling the drive and resetting faults The figure below shows the jumper including normally open toggle switches 6 Connect the drive to a 100 240 VAC 50 60 Hz power source appropriate to the drive Single Phase 1398 DDM 010 1398 DDM 010X 1398 DDM 020 1398 DDM 020X 1398 DDM 030 1398 DDM 030X 1398 DDM 075 or 1398 DDM 075X Three Phase 1398 DDM 075 1398 DDM 075X 1398 DDM 150 or 1398 DDM 150X Application and Configuration Examples 8 13 Connection Diagram Figure 8 3 Master Encoder Connection Diagram DRIVE J2 J4 XMT Motor 2 RCV Encoder pov 3 XMT TB1 MOM 5 COM Master PhaseR 1 Encoder J1 PhaseS 2 1 45V 2 svcoM Phase 3 L 14 Motor Gnd 4 15 AX TBI 16 BX L1 100 240 VAC H 17 BX LOIN 50 60 Hz Single Phase 18 1 Gnd Power Source 19 1X Close to ENABLE Drive 20 ENABLE TB1 or L1 Close to RESET Faut 24 FAULT 100 240 VAC RESET L2 N 50 60 Hz L3 Three Phase Close to Turn ON LS INPUTI G Gnd Power Source Note 1
321. xt string is changed ULTRA Master assumes that a new motor file is being created and the user must supply a new filename This prevents the text string being changed on an existing motor file However a filename may be recycled by 1 Assign the new file a tentative filename 2 Delete the old file 3 Rename the new file using the old filename Table ID The table ID value determines whether the motor file represents a standard motor or a custom motor A table ID in the range of 0 to 65534 identifies a standard motor file and a table ID of 65535 also known as table ID 1 identifies a custom motor file Users may define motor parameters for multiple custom motors on a PC but only one custom motor files may be stored on the drive i e All custom motor files have the table ID value of 1 Motor File The motor file is the filename of the custom motor file it 1s different from the motor model text field The filename can have up to 8 characters and must have a MTR extension If the motor model text string is altered ULTRA Master prompts the user for a new filename Publication 1398 5 0 October 1998 D 6 Creating Custom Motor Files Publication 1398 5 0 October 1998 Synchronous Induction This field identifies whether the motor is a synchronous permanent magnet motor or an induction motor The motor type informs ULTRA Master which fields are valid for a particular motor and which fields are invalid gra
322. y be selected from the drop down box If this message box does not appear the motor displayed in the Motor Model box was previously selected Select or verify the correct motor model number from the drop down Motor Model list If a message advises that the drive must be reset choose Yes Select Indexing as the Operation Mode for the drive Choose Close to exit the Drive Set Up window Choose the Drive Parameters command icon from the Drive window and then select the Indexing tab Application and Configuration Examples 8 31 15 Enter the following values for Index 0 Refer to Incremental 16 17 18 Indexing Examples on page 8 27 for examples of Single and Batched Incremental Indexing profiles Single Move Settings Batched Move Settings Incremental as Mode Incremental as Mode 8000 as Distance 8000 as Distance 1 as the Batch Count 3 as the Batch Count 0 as Dwell 1000 as Dwell Appropriate values for Accelera Appropriate values for Accelera tion and Deceleration tion and Deceleration Choose Close to exit the Drive Parameters window Select the Configuration command icon from the Drive Win dow Select an appropriate digital input from the pull down lists avail able as Digital Input Assignments in the I O Configuration win dow For example Start Index as Input 1 Not Assigned as Inputs 2 through 4 Not Assigned as Outputs through 4 19 Choose Close to exit the I O Configuration window
323. y from TUV Product Service 0 C to 55 C 32 F to 131 F 0 C to 55 C 32 F to 131 F 0 C to 55 C 32 F to 131 F 0 C to 55 C 32 F to 131 F 0 C to 50 C 32 F to 122 F 40 C to 70 C 40 F to 158 F 5 to 95 non condensing 1500 meters 5000 feet Derate 3 for each 300 m above 1500 m 1000 ft above 5000 ft 10 to 2000 Hz 2g 15g 11 millisecond half sine 5 80 Kg 13 78 lbs 6 36 Kg 14 02 Ibs 6 48 Kg 14 28 lbs 9 67 Kg 21 32 lbs 14 06 Kg 31 00 Ibs 1000 VAC for 1 minute lt 5 0mA leakage current 1414 1500 VDC for 1 minute lt 5 0mA leakage current NOTE EMI filter capacitors on Aux AC require VDC tests 5 to 7 Volts DC Adjustable Automatic Sensing Fused A B Differential 26LS33 input 1 MHz 4 MHz Quadra ture Maximum Signal Frequency Line Break Detection 1 T Low Speed Measurement Normally closed Single ended 5 Volt Logic 0 to 5 Volt 10 bit RS 232 or four wire RS 485 1200 to 19200 baud Daisy chain connections accommodated by two connectors 7 segment LED 16 position Rotary DIP Publication 1398 5 0 October 1998 G 2 Specifications Item Selectable 5 ENABLE Digital Outputs Selectable 4 BRAKE READY Digital Power Supply Analog Inputs Positive Current Limit 1 LIMIT Negative Current Limit LIMIT COMMAND Analog Outputs ANALOG1 ANALOG2 Auxiliary Encoder Signal Input 5 Volt Power Supply Motor Encoder Output CPU Memory
324. y regulator by adjusting the control response proportional to the error The P term of the velocity regulator commands an acceleration current that is propor tional to the velocity error Integral gain of the velocity regulator Integration in the velocity regulator forces the motor velocity to precisely follow the commanded velocity This assumes operation under steady state conditions velocity command or load does not change controls The stiffness or the ability to reject load torque disturbance The amount of velocity overshoot which may cause the system to become unstable or oscillate The term of the velocity regulator commands an acceleration current proportional to the integral of the velocity error D gain Differential gain of the velocity regulator Positive D gain decreases the amount of overshoot caused by the I gain Negative D gain decreases the torsional resonance between the motor and the load Publication 1398 5 0 October 1998 Tuning 9 7 Table 9 2 Position Loop Gains Parameter Description Kp gain Proportional gain of the position loop Kp gain changes position loop bandwidth settling time of the position loop In general the higher the value of Kp gain the faster the settling time However a high value of Kp gain with inadequate velocity loop bandwidth results in overshoot and ringing Note Kp gain is only for use w
325. yed These instructions only cover permanent magnet motors so the Synchronous box must be checked Number of Poles The number of poles specifies the number of electrical cycles in two mechanical revolutions For example a 6 pole motor will have three electrical cycles per mechanical cycle The firmware can support only 2 4 6 and 8 pole motors Occasionally a manufacturer specifies the number of pole pairs in a motor data sheet Pole pairs should not be confused with the number of poles A 6 pole motor has 3 pole pairs Ky Torque Constant The torque constant also known as the torque sensitivity specifies the amount of torque that the motor can produce with a given value of sinusoidal current The torque constant is measured in units of N m Amp and its range is 0 0002 to 15 9998 N m Amp Conversion formulas between N m Amp in Ib Amp and oz in Amp are q Newton meter 8 85075 141 612 Amp mp Amp inch pound ounce inch A The denominator units of the required torque constant are peak Amps rather than rms Amps To convert the torque constant from units of N m Amp rms use the formula 1 Newton meter _ 0 707 Newton meter Amp Amp rms Many Allen Bradley motors specify the torque constant in units of N m rmsA phase In this case in addition to conversion from rms Amps to peak Amps the value needs to be multiplied by three because it has been defined as per phase Creating Custom Motor File

Download Pdf Manuals

Related Search

Related Contents

Mercedes- Benz WIS EPC  Coupe-Mots  ART 35    American Dryer Corp. AD-200 Clothes Dryer User Manual  Trax MY2013  Adaptador Concentrador HUB Ladrón USB 2.0 4 Puertos Reforzado  形 ZS-HLDC  HSC-40 User`s Manual  JVC KD-R330 User's Manual  

Copyright © All rights reserved. Failed to retrieve file