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2098-IN001A-EN-P-JUN00 Ultra5000 Installation Manual

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1. 83 82 mm 4 3 30in gt 131 83 mm 43 18 mm 20 32 mm l p lt 1 70 in gt 80 in 5 19 in A a A IE j a o o 7 H e i 8 E J oO ii 205 23 mm 193 55 mm bert mm te 8 08 in 7 62 in 7 28 in F o Y ee Vv SBAcRHAARN y 144 53 mm s 5 69 in gt A AnA A ball C m HJ Eo I WS D i fi 91 19 mm A A S 8591n izal VYVYVYVYOYVS WJ v Publication 2098 IN001B EN P July 2000 Specifications and Dimensions A 7 Figure A 2 Ultra5000 1 kW amp 2 kW Mounting Diag
2. Gree Mee eGo of o E oo Bonded ground bar 7 All ground wiring must optional comply with local codes o 0 oo Safety Ground pin 5 Always follow NEC and applicable local codes jel l Ground grid or power distribution ground Bonded cabinet ground bus Connecting Your Ultra5000 2 15 Grounding Multiple Subpanels To ground multiple subpanels refer to the figure below Figure 2 10 Subpanels Connected to a Single Ground Point Always follow NEC and applicable local codes Ground grid or power distribution ground EMC Motor Ground Termination For F Series H Series and N Series motors the factory supplied 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 removed which exposes the shield braid The exposed area must be clamped to the bottom of the drive chassis using the clamp provided Refer to Figure 2 11 for an illustration ATTENTION To avoid hazard of electrical shock ensure shielded power cables are grounded at a minimum of one point for safety Publication 2098 IN001B EN P July 2000 2 16 Connecting Your Ultra5000 Wiring Your Ultra5000 P
3. MY 91 wg OMv ZL 24WO y Omv pL zwwug Z SNOILVINDAY WOOT OL omy PL zwugZ mv 94 2wws L M079 MOS AVIAG AWIL LNSW373 TWN LNdNI IHL NOs V00 40 mv 94 2wws L INAYYND HSNYNI 40 GOMAd LYOHS Y SSYINOTY NOLLVZITWILINI YIMOd ALON omv 9 wwe OV SIOA OF2 001 1 OV sduy 0 8 I Mo00Z OV SOA OFZ 001 1e OW sdy 0 6 M0001 Naddo 9 22 MY zu OV SHON OFZ 001 1e OW SdUY O S NOOS NeTH EN AOA HOLINNO9 ONLY 7 YIMOd YOLOW roo le SWH OV SAW WANIXW INSWSHINOSY L NIYAN Sanya STVNINNAL YOLOSNNOO WONININ ON Lud SLNAWAYINDAY LNAYYND LNdNI FINGOW SAIC IWLISIG SAYIM YaMOd LANI YIMOd YOLOW AN9 ANY M A N SSYIM YIMOd YOLOW NIW Y3ddO9 9 92 OMy wu OMY wuwu 3ZIS LOVLNOO S YNIWYIL SAG YOLOW July 2000 Publication 2098 IN001B EN P 2 22 Connecting Your Ultra5000 Publication 2098 IN001B EN P July 2000 Chapter Objectives General Startup Precautions Chapter 3 Commissioning Your Ultra5000 This chapter provides you with information to power up and start your Ultra5000 This chapter includes General startup precautions Understanding communication switch settings Applying power to your system Configuring your Ultra5000 Before you begin these procedures be sure to read and understand the information in the previous chapters of this manual Note The procedures in this cha
4. Pin Pin INPUT Digital Input 1 INPUTS Digital Input9 15 INPUT2 Digital Input 2 2 INPUT10 Digital Input 10 16 INPUT3 Digital Input 3 3 INPUT11 Digital Input 11 17 INPUT4 Digital Input 4 4 INPUT12 Digital Input 12 18 INPUTS Digital Input 5 5 INPUT13 Digital Input 13 19 INPUT6 Digital Input 6 6 INPUT14 Digital Input 14 20 INPUT7 Digital Input 7 7 INPUT15 Digital Input 15 21 INPUT8 Digital Input 8 8 INPUT16 Digital Input 16 22 OUTPUT1 Digital Output 1 9 OUTPUTS Digital Output 5 23 OUTPUT2 Digital Output2 10 OUTPUTS Digital Output 6 24 OUTPUT3 Digital Output3 11 OUTPUT7 Digital Output 7 25 OUTPUT4 Digital Output 4 12 OUTPUT8 Relay Output 8 26 SHIELD Shield 13 OUTPUT8 Relay Output 8 27 Termination IOPWR 1 0 Power Supply 14 IOCOM 1 0 Ground 28 The following table provides the signal description and pin outs for the CN1B I O connector Signal Description CN1B Signal Description CN1B Pin Pin 5V 5v Power Supply 1 5VCOM 5v Ground 8 AX Auxiliary Encoder 2 AIN1 Analog Input 1 9 Input Output A AX Auxiliary Encoder 3 AIN2 Analog Input 2 10 Input Output A BX Auxiliary Encoder 4 5VCOM 5v Ground 11 Input Output B BX Auxiliary Encoder 5 AOUT1 Analog Output 1 12 Input Output B IX Auxiliary Encoder 6 AOUT2 Analog Output 2 13 Input Output l IX Auxiliary Encoder 7 SHIELD Shield Terminat
5. 00sec cece eee eee eeees P 3 Chapter 1 Chapter Objectives vy yt et heel seh pale ee te bee tN Bees 1 1 Complying with European Union Directives 000 eee eee 1 1 EMC Ditech Gr 15 6 siuonaee inspec ey est morro 1 1 Low Voltage Directive sesh co eae Cay aces anh wed fies pees PSs 1 2 Before Mounting Your System cece cece cece eee e een eees 1 2 Storing Y our Ultra5000 Before Installation 0 00 1 2 Unpacking Modules 4 5 5 dciaacaacunteaarte win wee emer ten eee 1 3 System Mounting Requirements ccc cece ee eee eeees 1 3 Ventilation Requirements cece eee eee eee eenes 1 4 Transtormer SZN geseen ytcne ehh hoe eRe ae as 1 5 Bonding Your VSL CLIN dares uch tetresec canon RS SG a 1 6 Bonding MOdUIES sco o nonn ere eee res Sek ees Rea Eee 1 6 Bonding Multiple Subpanels 0 cece cece cece ees 1 7 Mounting Your Ultra5000 Drive cece cece ence eee eee 1 8 Chapter 2 Chapter Objectives 43 4034 3d aaneaaed eck uneren arrera waa ee eG 2 1 Understanding Ultra5000 Connectors 0 e eee eens 2 1 Ultra5000 Block Diagranios 6i negesdccs soecare hee eevee Peeioe 2 1 Front Panel Connections 00S i eee ees 2 2 I O CONMECIONS 5 ccna web wetdetdatdetdateusdetdatesxnc eh 2 3 Motor Encoder Connector sess ous ee bad Seve aao ees nee Hee Oe ee 2 4 Serial Port Connectors 0 42 ceuckea ord ehedesapedso dag Rie rk ee Aes 2 4 Understanding Ultra5000 I O Speci
6. Allen Bradley Ultra5000 Intelligent Positioning Drives Catalog Numbers 2098 IPD 005 010 and 020 Installation Manual Automation Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety G uidelines for the A pplication Installation and M aintenance of Solid State C ontrol available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permission of Rockwell Automation is prohibi
7. igure Ultra5000 Power Wiring Diagram F S00 FXXX YESS NIN ued uep 7 eso NIG OL Y3A0 SNODYOL YSASN NILH9IL YJAO LON OG SMIYOS LIAOYY ONNS OLOO LLL6 JO uonewojujenuepyuog SaTONVIF STONY GASN SUV SAIGVO GICTSIHS NON 41 4313Y NIVULS X04 G3SN 39 NVO LaMOVUE SIHL GSGIAONd Go0s o00e VHA SMW Uzi SONN ON ONV SIST 13 OYY9 JHL HLIM JAINA JHL OL LI NIdWY7T9 A8 GTSIHS J18Y9 YIMOd YOLOW IHL SVNINYSL NNOO YIMOd 9V1A EA SNNT GSAYASAO 38 GINOHS SNOLLWINDZY 1Y907 40 SLNAWSYINDSY IHL SANTVA GAGNSNWOOSY WAWININ Suv SAZIS SHIM 20 66 6 1b WF ONIMVEG FTVOS LON OG HONG NOSE __alvd__Aa vivid A214192 SSWSHLO SSTIND A1gISSOd SV SANG IHL OL 3SO19 alva NOlLdiyosaa NOISIAay Aa 093 faas SY 39 CINOHS YY8 SNE GNNOYS NOWWOD JHL 31sISSOd SV LYOHS SY Lda 38 GINOHS YILI ANY FINGOW SAG IHL N33ML39 ONIMIM WWAOWSY YIMOd NOdN INIL SONVHOSIC SYINOSY ANY SINIYYNO JOVVST SOUVT SAVH SUA INIT OV 00 GASVAaTSY Wey e v NOLLAV SALLOSUIC ALMISILYAWO9 SILANDVWOULOS13 NV3dOUNS IHL LIIW OL CIYINOIY IAY ANY ALMIGLLWAWOO SHIN dN GAGA S3dAL if asozwoo ZO DLLSNOVWOYLOS7S SIINAON SAIMG IHL NIAOYANI HO4 A3SN 38 OL JYV 31GV9 YOLON GAGT7SIHS ANY YLT INIT OV AWNOIS 8 JAY GOHO ADYNOS AlddNS OV YSHLO YO YAWYOSASNVUL INO WOY4 G3Y3MOd 3d AVW SFINGOW JAYA A1dILINW AlddNS OV JHL OL ATLOAYIG SNOILOANNOD ALWeVdSS JAYN SNOILOANNOO YAMOd FINGOW SAIC NIVHO ASIYA LON Od CHVANVLS OVA 082 JOVLIOA LNdNI
8. 1 414 382 2000 Fax 1 414 382 4444 OCKVELL R kw il European Headquarters SA NV avenue Herrmann Debroux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 oc e Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Automation Publication 2098 IN001B EN P July 2000 PN 0013 1079 001 01 Supersedes Publication 2098 IN001A EN P June 2000 Copyright 2000 Rockwell International Corporation Printed in USA
9. overheating has tripped Reduce duty cycle ON OFF of commanded motion Increase time permitted for motion Use larger Ultra5000 and motor 23 IPM Thermal The internal filter protecting the IPM at slow speed Reduce acceleration rates Protection Fault has tripped Reduce duty cycle ON OFF of commanded motion Increase time permitted for motion Use larger Ultra5000 and motor 24to RESERVED Call your local Allen Bradley representative 99 Publication 2098 IN001B EN P July 2000 4 4 Maintaining Your Ultra5000 Publication 2098 IN001B EN P July 2000 Chapter Objectives Ultra5000 Specifications Specifications and Dimensions This chapter covers e Ultra5000 specifications e Dimensions This section lists the specifications for the Ultra5000 General Power Specifications Appendix A The table below lists general power specifications and requirements Specification Description IPD 005 IPD 010 IPD 020 AC Input 100 240 Vac nominal 100 240 Vac nominal 100 240 Vac ms nominal Voltage and Frequency Single Phase 47 63 Hz Single Phase 47 63 Hz Single Phase 47 63 Hz AC Input Current 5 Ams 9 Ams 18 Ams Bus Voltage 141 339 Vde 141 339 Vde 141 339 Vde Output Peak Current 0 peak 7 5 Amps 15 Amps 30 Amps Continuous Output Current 0 peak 2 5 Amps 5 Amps 10 Amps Bus Capacitance Energy Absorption 51 Joules 51 Joules 51 Joules from 325 400 Vde Bus 18
10. Outputs 2 6 Hardware Configuration 2 7 dimensions 1 and 2 kW Ultra5000 A 7 500W Ultra5000 A 6 Publication 2098 IN001B EN P July 2000 Index Documentation Related P 2 E EMC motor ground termination F H N series motors 2 15 motor ground termination Y series motors 2 16 Emergency stop contactor C 2 EMI ElectroMagnetic Interference Bonding 1 6 Problems C 5 Enclosure Sizing A 2 Error Codes and Messages 4 2 E stop wiring C 3 European Directive Compliance Emergency Stop Contactor C 2 F filter AC C 4 Firmware Upgrade 3 4 G Ground Torroid encoder shielding C 5 grounding multiple subpanels 2 15 system to subpanel 2 14 H Heat Heat Losses for sizing enclosures A 2 High frequency energy 1 7 Humidity A 2 I O Connectors 2 3 CN1A 2 3 CN1B 2 3 Inertia Possible Effects C 1 Input Digital I O 2 5 Installation Installing for European Union Compliance Publication 2098 IN001B EN P July 2000 Emergency Stop Contactor C 2 IPM Short see Troubleshooting IPM Thermal Protection Fault see Troubleshooting L low voltage directive 1 2 Maintenance 4 1 Cleaning 4 1 inspecting cables 4 1 Mechanical Resonance Application Information C 1 Possible Causes C 1 Motor Encoder connector 2 4 Encoder interface 2 9 Overload Protection C 2 Troubleshooting Encoder Error 4 3 Overtemperature 4 2 Thermal Protection Fault 4 3 Mounting Before mounting 1 2 Bonding 1 6 procedure 1 8 requirements system
11. Using an Emergency Stop Contactor Publication 2098 IN001B EN P July 2000 Backlash Backlash between the motor and load effectively unloads the motor over a small angle Within this small angle the increased gain 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 G earing 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 Some applications require that a contactor be inserted between the motor and Ultra5000 for emergency stop purposes To determine if this is necessary perform a hazard analysis of the machine If used the contactor must not simply break the motor current it must switch a 3 phase resistive load in parallel with the motor windings The three resistors provide dynamic braking and a category zero stop The resistors also prevent continuous arcing at the main contacts when breaking DC currents such as when the motor is at stall It is important to sequence the E stop string to disable the drive prior to or at the same time the contactor is released Conversely upon power up the contactor must be fully engaged before the drive is enabled Use an auxiliary contact on the contactor for the drive enable circuit f
12. 1 Ultra5000 Family nnou story aioe pa sorat wea amass eas ares elven ae B 1 Option CANS t s ee eee ne Pal mieten tend teh tien head pink EE S B 1 Ultra5000 Accessories 5s scars scence wine ee sey mea ety eG RSE KO wach ke BH B 2 Extemal Shunt Kit nay a ane ee ee arr B 2 AC Eine PUES e ets E aac eaten aw Sees a B 2 Mating Connector Kis Sr tes tects cb tebe eee ke behest eeu B 3 Break Out Board Cables and Kits ccc cece cece een aes B 3 Motor Power Cables 25sec ws eather pamuaip amma Kamran B 4 Motor Feedback Cables 3ty2 Gi cd tei Pat tabs oo 8 PO eRe oan B 4 Interface Cables nn i a OO ane ean ane ane re wa B 5 Table of Contents iii Application Information Appendix C Chapter Objectives 0 0 0c ccc cece cece ene teen nee e enn eeens C 1 Mechanical Resonance 09 gat eke eas eae kd eek ea eS C 1 Backlash ick aise ra ea sui ile ahi ee Ree C 2 Using an Emergency Stop Contactor ccc cece eee eee eee C 2 Grounding for Ultra5000 CE Requirements eee eeee C 4 Building Your Own Cables c5 vases ews ces eeese uae overran cereets C 5 Building Your Own Cables jh ics ade eag Sid S BFR CS eee C 5 Persistent EMI Problems ccceeeeeeeeeeeeenees C 5 Publication 2098 IN001B EN P July 2000 iv Table of Contents Publication 2098 IN001B EN P July 2000 Introduction Who Should Use this Manual Purpose of this Manual Preface Read this preface to fami
13. DC coils with a fly back 1N4004 diode connected across the coil e Suppressing EMI at AC coils with RC filters e g a 200 ohm 1 2 watt resistor in series with a 1 2 micro farad 600 volt capacitor e Suppressing EMI at motor power windings by grounding shielding and filtering Refer to Figure C 3 and Figure C 4 for additional information Publication 2098 INO01B EN P July 2000 Application Information Figure C 3 Torroid Encoder Shielding Method for Brushless Servo Motors Ultra5000 Brushless a A Motor I I L l Encoder Cable Encoder Vy Mog Shield W y PS d id Motor Case n e Recommended raw cable for building your own cable Belden Part number Carol Part number 8337 C0625 Figure C 4 Motor Power Winding Methods to Minimize Noise Emissions Ultra5000 Preferred Method Twisted together Brushless ki A D U g t t az i ie a Ve 4 4 I l l l V W g i i gt W L L Chassis h W W A Motor Case l Shield oe To single point earth ground Brushless Motor Ultra5000 Common mode choke 4 10 20 turns on common ie ferrite torroid core U e Ve e Ww Chassis ry N To single point earth ground Publication 2098 IN001B EN P July 2000 Twisted together Motor Case A A D converter 2 8 AC Coils suppressed with RC filters C 5 Current input A 1 Frequency input A 1 Pow
14. high and low voltage cables on parallel runs Do not run low and high voltage wires in the same wire way Minimize unshielded lead length Publication 2098 IN001B EN P July 2000 2 14 Connecting Your Ultra5000 Grounding Your Ultra5000 Publication 2098 IN001B EN P July 2000 We recommend that all equipment and components of a machine or process system have a common earth ground point connected to their chassis A grounded system provides a safety ground path for short circuit protection Grounding your modules and panels minimizes shock hazards to personnel and damage to equipment caused by short circuits transient overvoltages and accidental connection of energized conductors to the equipment chassis For CE grounding requirements refer to A ppendix C Grounding Your System to the Subpanel The National Electrical Code contains grounding ae requirements conventions and definitions Follow all applicable local codes and regulations to safely ground your system Refer to the illustration below for details on grounding your Ultra5000 Refer to Figure 2 15 for the power wiring diagram Figure 2 9 Safety Ground Configuration with Multiple Ultra5000 Systems on One Panel Ultra5000 Intelligent Positioning Drives EAN oo
15. of the auxiliary encoder interface is shown in the figure below Figure 2 6 Schematic of the Auxiliary Encoder Circuitry Connecting Your Ultra5000 2 11 The following table provides a description of the auxiliary encoder interface specifications Parameter Description Minimum Maximum ON State Input Voltage Input voltage difference between the input and the input that is 1 0V 12 0 V detected as an ON state OFF State Input Voltage Input voltage difference between the input and the input that is 1 0 V 12 0 V detected as an OFF state Common Mode Input Voltage Potential difference between any encoder signal and logic ground 7 0 V 12 0 V DC Current Draw Current draw into the or input 5 mA 5 mA Input Signal Frequency Frequency of the AX or BX signal inputs In A B I mode the count 2 5 MHz frequency is 4 times this frequency since the circuitry counts all four transitions of these lines In Step Direction or CW CCW mode the count frequency is the same as the signal frequency IX Pulse Width A B I Mode Pulse width of the index input signal Since the index is active for a 125 nS percentage of a revolution the speed will determine the pulse width AX BX Phase Error 2 5 MHz Line Amount that the phase relationship between the AM and BM inputs 22 5 22 5 Frequency A B Mode can deviate from the nominal 90 AX BX Phase Error 1 MHz Line Amount that the phase relationship between
16. proper system operation Terminal block connections should be torqued to 1 25 Nm 11 lb in Refer to Figure 2 15 for a power wiring diagram The Motor Encoder and Auxiliary Encoder ports are powered by a single internal power supply The power supply has a resettable fuse that opens at 3 amps and automatically resets itself when the current falls below 3 amps There are no internal fuses requiring replacement The Ultra5000 utilizes solid state motor overload protection which operates in accordance with UL 508C Motor overload protection trips At Eventually 100 overload Within 8 minutes 200 overload Within 20 seconds 600 overload ATTENTION To avoid personal injury and or equipment damage ensure installation complies with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices The National Electrical Code NEC and local codes outline provisions for safely installing electrical equipment To avoid personal injury and or equipment damage ensure motor power connectors are used for connection purposes only Do not use them to turn the unit on and off To avoid personal injury and or equipment damage ensure shielded power cables are grounded to prevent potentially high voltages on the shield To wire your input power and motor connections 1 Prepare your wires for connection to the terminal block by stripping approximately 12 mm 0 50 in of insulation from
17. software and hardware are communicating and you are ready to configure your Ultra5000 Publication 2098 IN001B EN P July 2000 Chapter Objectives Maintaining the Drive Chapter 4 Maintaining Your Ultra5000 This chapter covers the following topics e Maintaining the drive e Troubleshooting The Ultra5000 D rive is designed to function with a minimum of maintenance ATTENTION DC bus capacitors may retain hazardous voltages after input power has been removed but will normally discharge in several seconds Before working on the drive measure the DC bus voltage to verify it has reached a safe level or wait the full time interval listed on the warning on the front of the drive Failure to observe this precaution could result in severe bodily injury or loss of life Periodic Maintenance Normally the only maintenance required is removal of superficial dust and dirt from the drive and a quick check of cabling insulation and connections Cleaning the Drive 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 Inspecting the Cables Ensure input power is disconnected before touching cabling or connections e Visually inspect all cables for abrasion e D shell connectors should be inspected for proper seating and signal continuity end to end Publication 2098 INO01B EN P July 2000 4 2 Maintai
18. the AM and BM inputs 45 45 Frequency A B Mode Understanding Serial Interfaces can deviate from the nominal 90 The Ultra5000 contains two identical serial port connectors Main Serial Port CN3A and Auxiliary Serial Port CN 3B that implement the standard NRZ asynchronous serial format and support RS 232 RS 422 and RS 485 communication standards Standard baud rates include 1 200 2 400 4 800 9 600 19 200 and 38 400 baud D ata lengths of 7 and 8 bits are supported The connector pinout dedicates separate pins for the RS 232 and RS 422 RS 485 signals so that the communication standard can be changed by just using a different cable Refer to Figure 2 7 for the serial interface hardware configuration Figure 2 7 Serial Interface Hardware Configuration RECEIVE TRANSMIT XMT RCV XMT XMT RCV RCV Publication 2098 IN001B EN P July 2000 2 12 Connecting Your Ultra5000 Understanding Basic This section contains basic wiring information for the Ultra5000 Wiring Requirements Plan the installation of your system so that you can perform all cutting drilling tapping and welding with the system removed from the enclosure Because the system is of the open type construction be careful to keep any metal debris from falling into it Metal debris or other foreign matter can become lodged in the circuitry which can result in damage to components This section contains common
19. the end Note Use caution not to nick cut or otherwise damage strands as you remove the insulation Publication 2098 IN001B EN P July 2000 Connecting Your Ultra5000 2 19 2 Check for continuity in the motor leads wires marked U V and W Verify that the resistance reading from each wire to earth ground is above 500k ohms If your resistance reading is T hen Above 500k ohms Go to main step 3 Below 500k ohms Go to the chapter Maintaining Your U ltra5000 3 Prepare your motor cable for the CE clamp on the bottom of the Ultra5000 drive by removing 12 mm 0 50 in of insulation 185 mm 7 25 in from the end of the motor leads wires marked U V and W Refer to the figure below for an illustration Figure 2 14 CE Clamp Cable Preparation gt lt 185 mm 7 25 in gt 12 mm 0 50 in U J Exposed Braid V J 9 W i Motor Cable L 4 Using a screw driver loosen the screw for each of the terminal locations and attach wires as shown in the table below Refer to Figure 2 2 for the location of the terminal block Refer to Figure 2 15 for the Ultra5000 power wiring diagram Insert the wire Into this terminal Terminal Block labeled block position Pin out DC bus eT 1 DC bus 2 amp 2 L1 Line 1 3 3 Line 1 Q gt l L2 Line 2 4 lt P 4 N Neutral Ta 5 Safety earth grou
20. the location in which you will install the Ultra5000 must not exceed 55 C 131 F You must install the panel on a flat rigid vertical surface that won t be subjected to shock vibration moisture oil mist dust or corrosive vapors You need to maintain minimum clearances refer to Figure 1 1 for proper airflow easy module access and proper cable bend radius Refer to A ppendix A for mounting dimensions power dissipation and environmental specifications for the Ultra5000 Publication 2098 IN001B EN P July 2000 Installing Your Ultra5000 Allow 12 7 mm 0 5 in 4 side clearance Publication 2098 IN001B EN P July 2000 Ventilation Requirements This section provides information to assist you in sizing your cabinet and locating your Ultra5000 drive s inside the cabinet Figure 1 1 Minimum Clearance Requirements 50 8 mm 2 00 in Clearance for Airflow and Installation oO A Y Motor cable entry area for ground clamp Dd 50 8 mm 2 00 in Clearance for Airflow and Installation Allow 12 7 mm 0 5 in side clearance Minimum Cabinet Depth 243 8 mm 9 6 in Minimum Front Clearance 76 2 mm 3 0 in If the cabinet is ventilated use filtered or conditioned air to IMPORTANT 3 prevent the accumulation of dust and dirt on electronic components The ai
21. 00 Inputs and Outputs The table below lists I O specifications Specification General Purpose Digital Inputs Description 16 Optically Isolated 12 24 Volt Inputs Inputs Outputs Sinking Sourcing Selection Software Selectable as a Group to be Active High Current Sinking or Active Low Current Sourcing General Purpose Digital Outputs 7 Optically Isolated 12 24 Volt Outputs 50 Milliamperes Maximum General Purpose Relay Output 1 Normally Open Relay 30 Volts DC Maximum 1 Ampere Maximum Current General Purpose I O Response 100 usec High Speed Input Response N 1 usec Inputs 1 and 2 Position Capture Response AN 1 usec Input 1 Input 2 Motor Encoder Index and Auxiliary Encoder Index General Purpose Analog Inputs 2 12 Bit Analog to Digital Converters 10V single ended General Purpose Analog Outputs Communications 2 12 Bit Digital to Analog Converters 10V 2mA single ended The table below lists communication specifications Specification Serial Motor Feedback Description 2 Independent RS 232 RS 422 RS 485 Ports 1200 38 400 Baud The table below lists motor feedback specifications Specification Description Input Modes Incremental with Index Maximum Input Frequency 2 5 MHz Encoder Lines Commutation Feedback Hall Sensor Specifications and Dimensions A 5 Auxiliary Feedback The table below li
22. 1 3 Noise Emission supression diagrams C 6 See Bonding 1 6 0 Operating Temperature A 2 Option cards 2 1 option cards B 1 options and accessories B 1 Output Current Continuous peak A 1 Peak A 1 Outputs Digital I O 2 6 P Power Applying Power 3 2 dissipation A 2 Losses A 2 Output Continuous A 1 Peak A 1 Wiring Diagram 2 21 Power Supply Protection 2 18 Precautions General Startup 3 1 Protection Circuitry Motor Overload C 2 R RS 232 2 11 RS 422 2 11 RS 485 2 11 S Safety ground C 3 Serial Serial Port Connectors 2 4 Serial port Interface 2 11 Shock A 2 Specifications AC Input Current A 1 Frequency A 1 AC Voltage A 1 Altitude A 2 Auxiliary Encoder 2 11 auxiliary feedback A 5 Bus Capacitance A 1 Bus Voltage A 1 communications A 4 connectors A 5 controller A 3 general power A 1 Humidity A 2 I O 2 5 Digital Inputs 2 5 Digital Outputs 2 7 inputs and outputs A 4 motor feedback A 4 Operating Temperature A 2 Output Current Continuous peak A 1 Peak A 1 Index 1 3 Power Output Continuous A 1 Peak A 1 Shock A 2 Storage Temperature A 2 user programming A 3 Vibration A 2 weight Ultra5000 A 2 specifications and dimensions A 1 dimensions A 6 specifications A 1 Status LE Ds 3 3 Storage Before installation 1 2 Responsibility P 3 Temperature A 2 Support Local product P 3 Technical product assistance P 3 System Mounting Requirements 1 3 minimum clearances 1 4 spacing 1 3 ventilatio
23. 80uF 1880uF 1880uF Peak Power Output 120 V AC 0 75 kWatts 120 V AC 1 5 kWatts 120 V AC 3 0 kWatts 240 V AC 1 5 kWatts 240 V AC 3 0 kWatts 240 V AC 6 0 kWatts Continuous Power Output 120 V AC 0 25 kWatts 120 V AC 0 5 kWatts 120 V AC 1 0 kWatts 240 V AC 0 5 kWatts 240 V AC 1 0 kWatts 240 V AC 2 0 kWatts Bus capacitance energy absorption is based on the following equations E E ic 4007 3257 C 27187 ifC 4x470uF 1 2 1 2s 5EY N 50 i 1 2 1 2 z5 C 400 50325 E 51 2 Peak Power is system and speed dependent and is not tested for the Drive alone Publication 2098 IN001B EN P July 2000 A 2 Specifications and Dimensions Publication 2098 IN001B EN P July 2000 Physical and Environmental The table below lists physical and environmental specifications and requirements Specification Description IPD 005 1 77 Kg 3 9 Ibs IPD 010 2 06 Kg 4 55 Ibs IPD 020 2 05 Kg 4 51 Ibs Operating Temperature 0 C to 55 C 32 F to 131 F Storage Temperature 40 C to 70 C 40 F to 158 F Humidity 5 to 95 non condensing Altitude 1500 meters 5000 ft Derate 3 for each 300 m above 1500 meters Vibration 10 to 2000 Hz 2g Shock 15g 11 millisecond half sine Power Dissipation The maximum power losses are shown below to help in sizing an enclosure and any required ventilation Typical heat losses can run approximately one half maximum power losse
24. 90V AC Install an uninterruptible power supply UPS on your AC input 10 Bus Overvoltage Excessive regeneration of power Change the deceleration or motion profile When the motor is driven by an external mechanical Use a larger system motor and Ultra5000 power source it may regenerate too much peak Use an Active Shunt energy through the Ultrad000 s power supply The system faults to save Itself from an overload Excessive AC input voltage Verify input is below 264V AC Output short circuit Check for shorts Motor cabling wires shorted together Check for shorts Internal motor winding short circuit Check for shorts 11 Illegal Hall State Incorrect phasing Check the Hall phasing Bad connections Verify the Hall wiring 12 to RESERVED 19 20 Motor Encoder The motor encoder encountered an illegal transition Replace the motor encoder State Error Use shielded cables with twisted pair wires Route the feedback away from potential noise sources Check the system grounds Ensure digital filtering of encoder signals is enabled Bad encoder Replace motor encoder 21 Auxiliary The auxiliary encoder encountered an illegal Use shielded cables with twisted pair wires Encoder state transition Route the encoder cable away from potential noise error sources Bad encoder replace encoder Check the ground connections 22 Motor Thermal The internal filter protecting the motor from Reduce acceleration rates Protection Fault
25. CARD i t Option Card Port 1 y i 1 k i 1 I A 1 Interface gt Option Card Port 2 1 1 i i l i 1 l i Digital Inputs gt Interface gt Field E l Programmable f PESA Sai 1 Low Spee lt Serial Por Digital Outputs _ Interface q __ Gate Array aa S Fl i a Serial i n si as Interface 4 Serial Port 2 i A 1 EEPROM 1 bei 1 Auxiliary Encoder Inputs i E 7 Segment Motor Encoder Outputs r gt Interface igs So 1 oe IED Displ i i Flash SREY i Motor Encoder a gt Int i 1 f delle oe a 12ekx32 Rotary DIP l High Speed Switches i Analog Inputs Interface 1 SRAM i 1 a I j oy 64Kx8 e TMS320032 Analog Outputs Interface a ra 1 Non Volatile DSP 1 l i SRAM l e Quad i 1 Interface Interface ADC 1 1 i 1 ieee t ER i a oe eee AF eee ee ee eee ates ee ee i POWER MODULE Y Bus Voltage Current PWM 1 Inpul Inputs Outputs Publication 2098 IN001B EN P July 2000 2 2 Connecting Your Ultra5000 Front Panel Connections The following table provides a brief description of the Ultra5000 front panel connectors and describes the connector type Designator Description Connector CN1A User Input Outpu
26. PWM servo system wiring IMPORTANT f configurations size and practices that can be used in a majority of applications National Electrical Code local electrical codes special operating temperatures duty cycles or system configurations take precedence over the values and methods provided For emergency stop E stop wiring information refer to A ppendix C Publication 2098 IN001B EN P July 2000 Connecting Your Ultra5000 2 13 Routing High and Low Voltage Cables Be aware that when you connect and route power and signal wiring on a machine or system radiated noise from nearby relays relay coils should have surge suppressors transformers and other electronic drives can be induced into motor or encoder feedback communications or other sensitive low voltage signals This can cause system faults and communication problems To minimize the levels of radiated noise route machine power and signal lines separately Figure 2 8 Routing Cables Inside Your Cabinet Low voltage Communications Control I O wiring Motor power Motor feedback cables 7 CT 120 240 Always separate all low voltage signal wiring AC power from high voltage power wiring to reduce affects eH of EMI and RFI i Always cross high and low voltage conductors at 90 degree angles Unshielded conductors Maximize distance between
27. SSVHd TIONIS SWY OVA 0 2 001 GALVe SAG ANODYOL LON LNG daad NI NOLLONGSY Y NI LINSSY THM SOVLIOA GaONdSY SOVLIOA LNdNI JHL JO LNAGN3d3GNI SYV SONILVY LNIYYNO CISNA YO GSHOLIMS 3d AYN 17 AINO ZI SO GVALSNI G3SN SI TWHLNAN GSGNNOND Y JI GAAYNASEO 39 GINOHS SNOILVINOSAY 1V907 ALSAVS 8 SONVNALNIVW HOS GaYINOAY SI 391430 ONILOANNOOSIG AlddNs Y SALON WNINYAL HLAV Yy9 SNA ONIGNNOYS NOWWO9 SNIHOWW FALOALOYd OL SIXY Yad INO WILSAS SISSVHO Sixv 43d INO WALSAS WaldlTdNW NOs LNIOd yanuodsnvel SISTA HOS LNIOd SNIGNNOYD NOWWOO ONIGNNOYS NOWWOO ANN IHL WOY4 ALOHA ZHO9 0S TAVITA SI SDVLIOA LNdNI a3YISIA INNT OV ASVHd JI NIS YAWYOASNVYL OLNV YO NOILV10S SHOLOW YANVIY LINDYID YO SANYIS AW 193NNO9 S10 03SN4 SIIYIS M ENEN EEO SAISAN SaHIS H SIIYIS AN Sardas N SIIYIS M SEHAT S313S 4 V YOLOANNOD YAMOd YOLON ONILWW YOLOANNOD YAMOd YOLOW H aara NOV ED VE uals 1 ann ov NOOX F1NGOW SAG CNT LL WN SZ OL anaon STWNINYSL Tv 3NDYOL WLI INYA omy Z1 02 zwwo p S 0 WALIDIG omy zww Feet oespv 1dN SONVY JYIM 319Y1d399Y OM EL zwwo y ozvy aN didLs TWNINYSL OerV IdN OMV pL zwwgZ OZY ocev TdN ozev 1dN OLEY TIAN 0907 4 OS0 H MY ZL 2uwo y NIZT O 0r 4 O 0 H 9L0 H Z00 H Saluas N SIIYIS A
28. allow setting addresses 0 99 Refer to Figure 2 2 for the switch locations Addresses are reserved for use as shown in the table below Switch Settings Description 0 63 Valid settings for normal drive operation 64 95 Reserved for factory use only 96 Disable Program Auto Run mode With this setting during power up programs are not allowed to run This mode is useful to correct programming problems that may have caused communications loss when the program Is running 97 Set Factory Default Objects mode With this setting during power up all internal firmware objects are reset to factory defaults Any objects created by a user program is also reset This mode is useful to return a drive to factory defaults 98 Reserved for factory use only 99 Boot mode With this setting during power up the only action that my be performed is to upgrade the drive firmware using Ultraware This procedure assumes you have wired your Ultra5000 system verified the wiring and are ready to begin using your Ultraware software To apply power to your Ultra5000 system 1 Disconnect any load to the motor Ensure the motor is free of all linkages when initially applying power to the system 2 Verify the input supply voltage The Ultra5000 requires single phase 100 240V AC rms power with an input frequency of 47 63 Hz If the input power is Then Within the acceptable range Go to main step 3 100 240V AC Not within t
29. at is 1 0 V 12 0 V OFF State Input Voltage detected as an OFF state Common Mode Input Voltage Potential difference between any encoder signal and logic ground 7 0 V 12 0 V DC Current Draw Current draw into the or input 30 mA 30 mA AM BM Input Signal Frequency Frequency of the AM or BM signal inputs The count frequency is 4 2 5 MHz times this frequency since the circuitry counts all four transitions IM Pulse Width Pulse width of the index input signal Since the index is active fora 125 nS percentage of a revolution the speed will determine the pulse width AM BM Phase Error Amount that the phase relationship between the AM and BM inputs 22 5 22 5 2 5 MHz Line Frequency can deviate from the nominal 90 AM BM Phase Error Amount that the phase relationship between the AM and BM inputs 45 45 1 MHz Line Frequency can deviate from the nominal 90 AM and BM Input Voltage Peak to peak input voltages of the AM and BM inputs for high 0 9 V p p 1 1 V p p Sine Cosine Interpolation Publication 2098 IN001B EN P July 2000 resolution interpolation Auxiliary Encoder Interface All encoder input signals CN 1B are filtered using analog and digital filtering including illegal state change detection The input circuitry includes pull up and pull down resistors for compatibility with single ended and open collector signals in addition to differential signals A single channel schematic
30. ate Current Current flow to guarantee an ON State 3 0 mA 12 0 mA OFF State Voltage Voltage applied to the input with 1 0 V 3 0 V Active High respect to OCOM to guarantee an OFF Configuration state OFF State Voltage Voltage applied to the input with 3 0 V 1 0 V Active Low respect to IOPWR to guarantee an OFF Configuration state Propagation Signal propagation delay from the high 0 5 uS Delay speed digital input to the firmware High Speed Inputs accessible registers active high or active low turning ON or turning OF Propagation Signal propagation delay from the low 100 uS Delay speed digital input to the Low Speed Inputs firmware accessible registers active high or active low turning ON or turning Digital Outputs There are eight general purpose digital outputs to use as needed They are not connected in hardware to perform any function D igital outputs O utputs 1 7 are transistor outputs as shown in Figure 2 4 Output 8 is a normally open relay output IMPORTANT There is no output short circuit protection on the transistor outputs To some degree the bipolar transistors limit their own current output but they have not been designed to specifically protect against shorts to power or ground Figure 2 4 Connecting Your Ultra5000 Transistor Output Hardware Configuration IOCOM Note X1 is controlled through software to be up for active high and down for acti
31. ctives i se lea ee ee sed 3 1 General Startup Precautions 0 cece cece cece e eee nes 3 1 Understanding Communication Switch Settings 00e eee 3 2 Applying Power To Your System cece cece een eee naes 3 2 Configuring Y our Wltra5000 00 435 Bane awes ee aera tie toe tow eat eed 3 3 Chapter 4 Chapter Objectives tas dace sis Gale eatin REN a REA ERS 4 1 Maintaining the Drive sic aaa yee any aa ne ene bao ne Pee Re eens 4 1 Periodic Maintenances 4 34 yaa cae ese rererere 4 1 Troubleshooting Ss BAe ppl al scl alae oA oi At gaat oa a aad oa 4 2 ETONG OUES tax trae aurea re ei AVAA VAEN ANVAN SANSA 4 2 Appendix A Chapter O BieCives seceecaceeash eek hohe role T T A 1 Ultra5000 Specifications nusunusu eater hermes 2s A 1 General Power Specifications n nosunu A 1 Physical and Environmental n on saue A 2 Power Dissipation usnsuusueunne nennen enerne ten eee oo A 2 User Programming esis a eee eke baie hale ete eae tai te A 3 Tana oN IIE ut atade TE E a Cease ae A 3 Inputs and Outputs cca ccecxescdenserhen bene eee ee kaos A 4 COMIN IMICAHONS 72ucisestaase aia Sten bien coats eA ee eat een Aae A 4 Motor Pecd back ancress ten ees eon eee oul eth AdS Sot Sond 28 A 4 Auxiliary Feedback isis ies nnna A 5 CONNECTOTS inaa a a E E exe ee E EAA S A 5 DiM nsionS sehre krne colt oar i ar aaa wian oh a eae A 6 Appendix B Chapter 0 Diet hives sireeni ei erase er es E E her A B
32. culation to get a system KW total Definitions KW power or real power KVA apparent power Transformer KVA rating Sum of average output power of each axis x 2 0 If you are using the Allen Bradley system sizing program IMPORTANT the average speed and average torque data has already been calculated and can be used in the above equation If you are not sure of the exact speed and torque in your application another approach is to look at the speed torque curve for your Ultra5000 motor combination and use the values for the worst case continuous speed and torque IMPORTANT Calculations are multiplied by a factor to compensate for the power and loss elements within a power system A factor of 2 0 is used with a single phase system and a factor of 1 5 is used with a three phase system This factor should minimize the effects of the secondary line voltage sagging in the transformer during peak current periods Example sizing a transformer to the voltage requirements of an 2098 IPD 020 and MPL A320P motor _ Speed RPM x Torque lb in 746 Watts KVA KYA 63 025 HP 1000Watts x 2 0 5 000 RPM x 26 Ib in 42 250 Transformer Size 3 1KVA KVA The speed torque curve information is based upon an Ultra5000 input voltage of 230 VAC Fora 115 VAC input voltage the maximum speed can be reduced up to one half Publication 2098 INO01B EN P July 2000 1 6 Installing Your Ultra5000 Bonding Yo
33. d to determine safe levels Failure to observe this precaution could result in personal injury Publication 2098 IN001B EN P July 2000 Building Your Own Cables Application Information C 5 This section provides information to assist you in building your own cables Allen Bradley power and feedback cables are available and recommended for robust system integrity to EMI Refer to A ppendix B for cable catalog number information For motor and encoder connector kit and wiring information refer to the appropriate Allen Bradley motor product data publication Building Your Own Cables When building your own cables follow the guidelines listed below e Connect the cable shield to the motor case and to the Ultra5000 chassis through the connectors for a complete 360 connection per the cable assembly diagram e Use a4 conductor cable with the 4 conductors twisted e Attach a ground conductor to the motor and the Ultra 5000 earth terminal Persistent EMI Problems If EMI problems persist use ferrite doughnuts or torroids around signal cables The ferrite will attenuate common mode noise but will do nothing for differential mode noise Specifically ferrite doughnuts help RS232 communication noise problems by e Suppressing EMI at each switched inductive device that is near the servo amplifier This includes solenoids relay coils starter coils and AC motors such as in motor driven mechanical timers e Suppressing E MI at
34. e appears in italics Publication 2098 IN001B EN P July 2000 Product Receiving and Storage Responsibility Allen Bradley Support Preface P 3 You the customer are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company Check the item s you receive against your purchase order If any items are obviously damaged it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill Should you discover any concealed damage during unpacking you are responsible for notifying the freight agent Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment Store the product in its shipping container prior to installation If you are not going to use the equipment for a period of time store using the following guidelines e Use a clean dry location e Maintain an ambient temperature range of 40 to 70 C 40 to 158 F e Maintain a relative humidity range of 5 to 95 non condensing e Store it where it cannot be exposed to a corrosive atmosphere e Store it in anon construction area Allen Bradley offers support services worldwide with over 75 Sales Support Offices 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone plus Allen Bradley representatives in every major country in the world Local Product Support Contact your l
35. een the option board designators Publication 2098 IN001B EN P July 2000 B 2 Options and Accessories Ultra5000 Accessories Publication 2098 IN001B EN P July 2000 External Shunt Kit Only the Active Shunt can be used with the Ultra5000 Use the following table to identify your External Shunt Description Catalog Number Active Shunt Module 300W 2090 UCSR A300 Ferrites are used at both ends of the DC Bus wires for CE radiated emissions compliance Use the following table to select a ferrite assembly Box shaped ferrite assembly in fully enclosed nylon case End ports are surrounded with flexible spring flutes to q grip a range of cable diameters from 125 to 500 3 2 to 12 7mm FerriShield Inc 350 Fifth Avenue Suite 7310 New York NY 10118 7591 Hon Mfg Part No D E Impedance S28B2034 0 250 0 120 125 Q SS28B2037 0 350 0 200 14 Q SS28B2032 0 500 0 200 230 Q AC Line Filters A single filter per Ultra5000 would have a matching fuse rating of 6 10 23 36 50 or 70 AMPS respectively Use the following table to identify the AC Line Filter for your application Description Catalog Number AC Line Filter 6 Amp Single phase 2090 UXLF 106 AC Line Filter 10 Amp Single phase 2090 UXLF 110 AC Line Filter 23 Amp Single phase 2090 UXLF 123 AC Line Filter 36 Amp Single phase 2090 UXLF 136 AC Line Filter 36 Amp Three phase 2090 UXLF 336 AC Line Fi
36. egulations apply EMC Directive This unit is tested to meet Council D irective 89 336 Electromagnetic Compatibility EMC using a technical construction file and the following standards in whole or in part e EN 5008x 2 EMC Emission Standard Part 2 Industrial Environment e EN 5008x 2 EMC Immunity Standard Part 2 Industrial Environment The product described in this manual is intended for use in an industrial environment Publication 2098 INO01B EN P July 2000 1 2 Installing Your Ultra5000 Before Mounting Your System Publication 2098 IN001B EN P July 2000 To meet CE requirements the following additions are required e You must run single phase input wiring in a conduit that is grounded to the enclosure You must install a power line filter Allen Bradley catalog number 2090 UX LF 106 2090 UX LF 110 2090 UX LF 123 or equivalent based on system current between the single phase input line and the system module input You must terminate the shields of the motor power cables and the motor feedback cables to the enclosure at the point of entry Low Voltage Directive These units are tested to meet Council D irective 73 23 EEC Low Voltage Directive The EN 60204 1 Safety of M achinery E lectrical E quipment of M achines Part 1 Spedfication for G meral Requirements standard applies in whole or in part Refer to A ppendix C for interconnect information Before you mount your Ultra5000 system make sure y
37. er 2 18 Voltage input A 1 Altitude A 2 Analog Inputs 2 8 Outputs 2 8 Application Information Backlash C 2 building your own cables C 5 Mechanical Resonance C 1 Auxiliary Encoder interface 2 11 Auxiliary Encoder Error see Troubleshooting Backlash Application Information C 2 Baud rate 2 11 Before Mounting Y our System 1 2 Bonding Mounting 1 6 Subpanels 1 7 building your own cables C 5 Bus Capacitance A 1 Overvoltage 4 3 Undervoltage 4 3 Voltage A 1 C cables building your own C 5 catalog numbers breakout board B 3 interface B 5 motor feedback B 4 motor power B 4 catalog numbers B 1 ac line filters B 2 Index breakout boards B 3 external shunt kit B 2 interface cables B 5 mating connector kits B 3 motor feedback cables B 4 motor power cables B 4 Ultra5000 family B 1 CE filter requirements C 4 grounding requirements C 4 low voltage directive 1 2 meeting requirements 1 2 Commissioning 3 1 Applying Power 3 2 Startup Precautions 3 1 Communication Address Switches Setting 3 3 Complying with European Union Directives 1 1 EMC directive 1 1 Configuring 3 3 Drive Detection 3 4 Firmware Upgrade 3 4 Ultraware software 3 3 Connector Block Diagram 2 1 CN2 2 4 CN3A 2 4 CN3B 2 4 Front Panel Connectors 2 2 Locator diagram 2 2 Motor Encoder 2 4 Serial Ports 2 4 Contents of manual P 2 Conventions Used in this manual P 2 D DC Coils suppressed with diode C 5 Digital Inputs 2 5 Hardware Configuration 2 5
38. es Motor Feedback Cable 2090 UXNFD MPSxx Feedback to no connector N Series Motor Feedback Cable 2090 UXNFB NSxx Ultra3000 5000 Feedback to drive N Series Motor Feedback Cable 2090 UXNFD NSxx Feedback to no connector Y Series Motor Feedback Cable 2090 UXNFB YSxx Ultra3000 5000 Feedback to drive Y Series Motor Feedback Cable Feedback to no connector 2090 UXNFD YSxx Interface Cables Options and Accessories B 5 Use the following table to identify controller cables for your Ultra5000 Length of cable xx is in meters 01 03 09 and 15 Description Catalog Number Interface Cable to Ultra3000 5000 Computer Connection 2090 UXPC D09xx Publication 2098 INO01B EN P July 2000 B 6 Options and Accessories Publication 2098 IN001B EN P July 2000 Chapter Objectives Mechanical Resonance Appendix C Application Information The following information is considered application specific and does not apply to all installations This appendix covers the following topics e Mechanical resonance e Using an emergency stop contactor e Grounding for Ultra5000 CE requirements e Building your own cables For additional information contact your local Allen Bradley sales representative 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 clockw
39. fications 00 c eee eee 2 5 Digital In pits o iaiativkoatiaudacacod che oko arcane areas 2 5 Digital OA OUES s issnin anaa ony e hasta aente RGAE RIE RS 2 6 Analoginputs cies ce ene seer acte ont let Sek Gre tel noe ote tts tis 2 8 Analog OC MIDUIS nia ee E AO tie O E ERAS 2 8 Understanding Encoder Feedback Specifications 000 2 9 Encoder Ii eriaCe lt 5 4 20 orinr eenean sean Ern e 2 9 Auxiliary Encoder Interface 0 cc cece eee eeeeees 2 10 Understanding Serial Interfaces cece cece eee eee ens 2 11 Understanding Basic Wiring Requirements 0000s eeeuee 2 12 Routing High and Low Voltage Cables 0 0 00 eee 2 13 Grounding Your Ultra5000 c y440 0e0 kel eee hae Hees tw Ree S es Deere ns 2 14 Grounding Y our System to the Subpanel e000 ee 2 14 Grounding Multiple Subpanels 0 cece eee eee es 2 15 EMC Motor Ground Termination 00 cece cece ees 2 15 Publication 2098 IN001B EN P July 2000 ii Table of Contents Commissioning Your Ultra5000 Maintaining Your Ultra5000 Specifications and Dimensions Options and Accessories Publication 2098 IN001B EN P July 2000 Wiring Your Ultra5000 nuunuu 2 16 Connecting Interface Cables 0 c cece cence ee naes 2 17 Wiring I O Connections susue eree wee toate bee eee s 2 17 Wiring Power Connections creas chee tak ek ek eles 2 18 Chapter 3 Chapter Obje
40. he acceptable range Stop and call for technical support Do not proceed until proper input power is supplied O nce you have proper input power proceed to main step 3 Commissioning Your Ultra5000 3 3 3 Set the communication address switches as shown in the example table below For the location of the address switches refer to Figure 2 2 Forexample if Setthe MSD Set the LSD you have switch to switch to 1 drive 0 1 2 drives 0 2 3 drives 0 3 A drives 0 4 4 Apply input power to the Ultra5000 and observe the power indicator LED on the Ultra5000 front panel refer to Figure 2 2 for LED location If the power LED Then Ison Go to main step 5 Is not on 1 Check your input power connections 2 Repeat main step 4 5 Check the seven segment status LEDs If the seven segment status LE Ds Then Actively cycle in a full circle The drive is ready Go to Configuring Your U ltra5000 Actively cycle in a half circle with address switches set to MSD 9 and LSD 9 Go to main step 3 and reset your address switches according to the table Actively cycle in a half circle with address switches set according to the table in step 3 Your firmware requires an upgrade Go to C onfiguring Your U ltra5000 Display an E indicates error Go to the chapter M aintaining Your U ltra5000 your Ultra5000 system Configu
41. he proper motor in Ultraware Software Digital 1 0 not 1 0 power supply disconnected Verify connections and O power source working Incorrectly configured for active high or active low Change configuration correctly 04 Motor Motor thermostat trips due to Operate within not above the continuous torque Overtemperature High motor ambient temperature and or rating for the ambient temperature 40 C maximum Excessive RMS torque Lower ambient temperature increase motor cooling 05 IPM Fault Motor cables shorted Verify continuity of motor power cable and connector Motor winding shorted internally Check for short on U V W and Gnd windings of the motor Ultra5000 temperature too high Check for clogged vents or defective fan Ensure cooling is not restricted by insufficient space around the unit Operation above continuous power rating Verify ambient temperature is not too high above 60 C Operate within the continuous power rating Ultra5000 has a bad IPM output short circuit or overcurrent Publication 2098 IN001B EN P July 2000 Replace Ultra5000 Maintaining Your Ultra5000 4 3 Error Problem or Possible Cause s Action Solution Code Symptom 09 Bus Low AC line AC power input Verify voltage level of the incoming AC power Undervoltage 100V AC minimum for safe Ultra5000 operation Check AC power source for glitches or line drop below
42. ion 14 Input Output l Publication 2098 INO01B EN P July 2000 2 4 Connecting Your Ultra5000 Publication 2098 IN001B EN P July 2000 Motor Encoder Connector CN2 is a 15 pin high density D shell connector used for connection to the motor encoder The following table provides the signal description and pin outs for the CN2 motor encoder connector Signal Description CN2 Signal Description CN2 Pin Pin A Motor Encoder 1 Limit Limit 9 Channel A A Motor Encoder 2 l DATA Motor Encoder 10 Channel A Channel Index Data B Motor Encoder 3 TS Thermostat 11 Channel B B Motor Encoder 4 S1 Hall Channel 1 12 Channel B l DATA Motor Encoder 5 S2 Hall Channel 2 13 Channel Index Data ECOM Encoder Common 6 EPWR Encoder Power 14 5v only Reserved 7 Limit Limit 15 s3 Hall Channel 3 8 Serial Port Connectors CN3A and CN3B are 9 pin serial port connectors The following table provides the signal description and pin outs for the CN3A and CN3B serial port connectors Signal Description CN3A and Signal Description CN3A and CN3B Pins CN3B Pins RCV RS 422 RS 485 Not Connected 6 Input RCV RS 232 Input 2 RCV RS 422 RS 485 7 Input XMT RS 232 Output 3 XMT RS 422 RS 485 8 Output XMT RS 422 RS 485 4 Not Connected 9 Output DGND Logic Ground 5 Understanding Ultra5000 1 0 Specificati
43. ise The amplitude of the motor and load oscillations is such that the total momentum of the oscillating system is zero Mechanical resonance occurs as a result of compliance 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 generally fall into one of two groups e Change the mechanical system e 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 Changing the servo motor response is done by reducing the P gain I gain or low pass filter value Reducing the value of the P gain and low pass filter frequency have the effect of reducing the servo motor bandwidth This is acceptable as long as the resonating frequency is fairly high But if the resonating frequency is low it may be necessary to modify the mechanics of the system Publication 2098 IN001B EN P July 2000 C 2 Application Information
44. liarize yourself with the rest of the manual This preface contains the following topics e Who should use this manual e The purpose of this manual e Contents of this manual e Related documentation e Conventions used in this manual e Product receiving and storage responsibility Allen Bradley support Use this manual for designing installing programming or troubleshooting the Ultra5000 Intelligent Positioning D rive IPD If you do not have a basic understanding of the Ultra5000 contact your local Allen Bradley representative for information on available training courses before using this product This manual describes the function and installation of the Ultra5000 products and standard Rockwell Automation Allen Bradley motors recommended for use with the Ultra5000 The manual is intended for engineers or technicians directly involved in the installation operation and field maintenance of the Ultra5000 Publication 2098 IN001B EN P July 2000 P 2 Preface Contents of this Manual Refer to the following listing for the descriptive contents of this installation manual Chapter Title Contents Preface Describes the purpose background and scope of this manual Also specifies the audience for whom this manual is intended 1 Installing Your Ultra5000 Provides mounting information for the Ultra5000 2 Connecting Your Ultra5000 Provides connection and wiring information for the Ultra5000 3 C
45. llowing sections provide information and procedures on how to wire your Ultra5000 Connecting Interface Cables Connect all interface cables as shown in the table bdow This cable Plugs into this connector 28 pin Digital 1 0 CN1A 14 pin Auxiliary encoder analog 1 0 CN1B 15 pin Motor encoder feedback CN2 9 pin Main serial port CN3A 9 pin Auxiliary serial port CN3B Wiring 1 0 Connections To wire your CN1A and CN1B I O connectors L Prepare your I O wires by stripping approximately 6 mm 0 25 in of insulation from the end Note Use caution not to nick cut or otherwise damage strands as you remove the insulation 2 Using the small blade type screw driver supplied with your Ultra5000 part number 9111 0031 depress the spring clamp next to the pin you re prepared to wire and insert the wire as shown in Figure 2 13 Figure 2 13 Inserting Wires into the Connector Housing 3 Remove the screw driver and gently pull on the wire to make sure it does not come out of its terminal Re insert and test any loose wires Publication 2098 IN001B EN P July 2000 2 18 Connecting Your Ultra5000 Wiring Power Connections The Ultra5000 requires single phase AC power 100 to 240 VAC The input power may be optionally isolated through a transformer Field wiring must be copper with 75 C 194 F minimum rating The phasing of L1 and L2 N is arbitrary The earth ground connection is required for safe and
46. lter 50 Amp Single phase 2090 UXLF 150 AC Line Filter 50 Amp Three phase 2090 UXLF 350 AC Line Filter 70 Amp Three phase 2090 UXLF 370 Options and Accessories B 3 Mating Connector Kits The Ultra5000 has two serial connectors one motor feedback connector two I O connectors and one terminal block for power connections Connectors are D shell type except for the terminal block connector and the I O connectors The I O connectors are plugable connectors and are not available in a connector kit Refer to the chapter C onnecting Your U ltra5000 for pin and signal information for wiring the connectors Description Catalog Number Mating Connector Kit 9 pin D Shell serial interface 2090 UXCK D09 Mating Connector Kit 15 pin D Shell motor feedback 2090 UXCK D15 Mating Connector Kit Terminal Block 2090 UXCK TB Break Out Board Cables and Kits Use the following table to identify your break out board components Description Catalog Number Break Out Board 2090 UXBB D15 Break Out Board cable 14 Pin D Shell 2090 UXBC D1501 Break Out Board cable 28 Pin D Shell 2090 UXBC D1503 Break Out Board Kit 14 Pin D Shell 2090 UXBK D1501 Break Out Board Kit 28 Pin D Shell 2090 UXBK D1503 Publication 2098 INO01B EN P July 2000 B 4 Options and Accessories Motor Power Cables Motor Feedback Cables Publication 2098 IN001B EN P July 2000 Use the following table
47. mber of bits Input Open circuit impedance measured between the 10kQ Impedance input and analog common Input Signal Voltage applied to the input Usable 10 V 10 V Range 9 Voltage applied to the input Limit 14V 14V Offset Error Deviation from the correct value expected from 50 mV analog to digital conversion when 0 V is applied to the input Gain Error Deviation of the transfer function from unity 1 gain expressed in a percent of full scale Propagation Delay from the input to the firmware accessible 100 uS Delay registers Analog Outputs There are two single ended general purpose analog outputs to use as needed A 12 bit D A converter generates an analog representation of the digital command value The two analog outputs are set to zero volts after power comes up The following table provides a description of the analog output specifications IMPORTANT Output values can vary during power up until the specified power supply voltage is reached Parameter Description Minimum Maximum Resolution Number of states that the output signal js 12 Bits divided into which is 21 the number of bits Output Current capability of the output 2mA 2 mA Current Output Range of the output voltage 10V 10V Signal Range Offset Error Deviation when the output should be at OV 50 mV Gain Error Deviation of the transfer function from unity 1 gain expre
48. motor power cable etc The best method of achieving this is to mount the filter near where the AC power enters the enclosure If the connections are not separated from each other the EMI on the Ultra5000 side of the filter can couple over to the source side of the filter thereby reducing or eliminating the filter s effectiveness The coupling mechanism can radiate or allow stray capacitance between the wires Filters need to be on all lines for filtering to be effective When multiple power cables enter an enclosure an unfiltered line can contaminate a filtered line Bond the filter and the Ultra5000 to a grounded conductive surface the enclosure to establish a high frequency HF connection To achieve the HF ground the contact surface interface between the filter Ultra5000 and the enclosure should be free from paint or any other type of insulator N The filter shown is sized for one Ultra5000 Equivalent filters may be used for multiple units Size the filter following the manufacturers recommendations 3 Ground bar is customer supplied item A Clamp motor power cable shield for EMC termination IMPORTANT All single phase power in the cabinet must be filtered to reduce EMI High voltage exists in AC line filters The filter must be ATTENTION grounded properly before applying power Filter capacitors retain high voltages after power removal Before handling the equipment voltages should be measure
49. n 1 4 T terminal block connections 2 18 Transformer Sizing 1 5 Troubleshooting 4 1 Auxiliary Encoder Error 4 3 Bus O vervoltage 4 3 Bus Undervoltage 4 3 Gain Adjustments C 1 Illegal Hall State 4 3 IPM Short 4 2 IPM Thermal Protection Fault 4 3 maintenance 4 1 Motor Buzz or Squeal C 1 Motor Encoder Error 4 3 Motor Overtemperature 4 2 Motor Thermal Protection Fault 4 3 U Ultraware 5000 User Manual 3 4 Ultraware software 3 3 understanding basic wiring requirements 2 12 routing cables 2 13 unpacking modules 1 3 Publication 2098 IN001B EN P July 2000 1 4 Index V Vibration A 2 W Wiring 2 16 Publication 2098 IN001B EN P July 2000 Connecting I F Cables 2 17 I O Connections 2 17 Power Connections 2 18 procedure 2 18 Wiring Diagram 2 21 For more information refer to our web site www ab com motion Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Allen Bradley PRANE DOQGE Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel
50. nd 5 o U Tat 3 y2 7 as 8 e w 8 S 3 TE Motor case ground 9 1 Do not connect an external I O power supply to the DC bus The DC and DC terminals connect directly to the power bus of the drive Ensure motor power is wired with proper phasing relative to the motor terminals Publication 2098 INO01B EN P July 2000 2 20 Connecting Your Ultra5000 Publication 2098 IN001B EN P July 2000 5 Tighten each screw with a torque of 1 25 Nm 11 lb in 6 Gently pull on each wire to make sure it does not come out of its terminal Re insert and tighten any loose wires If your motor is Then F Series H Series or N Series Go to Connecting F Series H Series and N Seis EMC Cable Shidd Y Series Go to Connecting Y Series EMC Cable Shidd Connecting F Series H Series and N Series EMC Cable Shield 1 Remove the two screws securing the cable clamp on the bottom of the Ultra5000 drive refer to Figure 2 11 for cable clamp location 2 Place the cable within the clamp and replace the screws do not tighten 3 Position the exposed portion of the cable braid directly in line with the clamp 4 Tighten the screws with a torque of 0 9 1 1 Nm 8 0 10 0 lb in Connecting Y Series EMC Cable Shield Connect the 152 4 mm 6 0 in termination wire to the closest earth ground refer to Figure 2 12 for pigtail location 2 21 Connecting Your Ultra5000 15 2
51. ning Your Ultra5000 Troubleshooting The normal state of the 7 segment LED is to actively cycle its segments and show an illuminated decimal point that indicates 5 volts Refer to the table below to identify problems potential causes and appropriate actions to take to resolve the problems If problems persist after attempting to troubleshoot the system please contact your Allen Bradley representative for further assistance Error Codes The following list of problematic symptoms no error code shown and problems with assigned error codes is designed to help you resolve problems The 7 segment LED located on the front of the drive displays the error codes An E will be displayed followed by flashing the two digit error code one digit at a time This is repeated until the problem is cleared Error Problem or Possible Cause s Action Solution Code Symptom Power PWR No AC power Verify power 115 230V AC single phase is applied to indicator not the Ultra5000 illuminated Internal power supply malfunction Call your Allen Bradley representative 7 Segment LED not cycling Firmware corrupt Set node address to 99 and reload firmware Call your A B representative Small LED segment cycling Node address set to 99 Change node address Firmware corrupt Set node address to 99 and reload firmware Motor jumps Motor encoder wiring error Check motor encoder wiring v Incorrect motor chosen Select t
52. ocal Allen Bradley representative for e Sales and order support e Product technical training e Warranty support e Support service agreements Technical Product Assistance If you need to contact Allen Bradley for technical assistance please review the information in the M aintaining Y our U ltra5000 chapter first Then call your local Allen Bradley representative For the quickest possible response please have the catalog numbers of your products available when you call Publication 2098 INO01B EN P July 2000 P 4 Preface Publication 2098 IN001B EN P July 2000 Chapter Objectives Complying with European Union Directives Chapter 1 Installing Your Ultra5000 This chapter covers the following topics e Complying with European Union directives e Before mounting your system e Bonding your system e Mounting your Ultra5000 drive ATTENTION The following information is a guideline for proper installation The National Electrical Code and any other governing regional or local codes overrule this information The Allen Bradley Company cannot assume responsibility for the compliance or the noncompliance with any code national local or otherwise for the proper installation of this system or associated equipment If you ignore codes during installation hazard of personal injury and or equipment damage exists If this product is installed within the European Union or EEC regions and has the CE mark the following r
53. ole ot Ground bus or NR mounting bracket w Ne Star washer Scrape paint on both sides of panel and use star washers Star washer Flat washer NS If ie mounting Dracat is a with a non conductive material Star washer anodized painted etc scrape the material around each mounting hole Publication 2098 IN001B EN P July 2000 Installing Your Ultra5000 1 7 Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet Subpanels that are not bonded together may not share a common low impedance path This difference in impedance may affect networks and other devices that span multiple panels Refer to the figure below for recommended bonding practices Figure 1 3 Multiple Subpanels and Cabinet Recommended Bond the top and bottom of each subpanel to the cabinet using 25 4 mm 1 0 in by 6 35 mm 25 in minimum wire braid A XXXXXXYO XXXXXXXO Bonded cabinet ground bus to subpanel IXXXXXXXO BOXXX Scrape the paint around each fastener to maximize Publication 2098 IN001B EN P July 2000 1 8 Installing Your Ultra5000 Mounting Your Ultra5000 Drive Publication 2098 IN001B EN P July 2000 The procedures in this section assume you have prepared your panel and understand how to bond your system For installation instructions regarding other equipment and accessorie
54. ommissioning Your Outline steps when applying power to Ultra5000 equipment for the first time 4 Maintaining Your Ultra5000 Diagnostic aids that help isolate problems to a system module Appendix A Specifications and Provides physical electrical environmental Dimensions and functional specifications for the Ultra5000 Appendix B Options and Accessories Provides identification numbers and descriptions of the Ultra5000 and related products Appendix C Application Information Provides information for specific Related Documentation applications The following documents contain additional information concerning related Allen Bradley products To obtain a copy contact your local Allen Bradley office or distributor For information about Configure and operate Ultra5000 drives Read This Document Ultraware User Manual Product Number 2098 UM001A EN P Ultra5000 Programming Instructions Manual Ultraware Programming 2098 PM001A EN P Ultraware Installation Instructions Conventions Used in this Manual Ultraware CD Installation Instructions 2098 UM002A EN P The following conventions are used throughout this manual e Bulleted lists such as this one provide information not procedural steps e Numbered lists provide sequential steps or hierarchical information e Words that you type or select appear in bold e When we refer you to another location the section or chapter nam
55. ons INPUTS E i Connecting Your Ultra5000 2 5 A description of the Ultra5000 input output specifications is provided on the following pages Digital Inputs There are 16 general purpose digital inputs to use as needed They are not connected in hardware to perform a particular function Thhintia Configure your digital inputs as a group as active high current sinking or active low current sourcing All digital inputs have the same configuration Inputs 1 and 2 use high speed circuitry with minimal propagation delays suitable for use in registration applications Any input can be assigned through firmware to latch the motor or auxiliary position in hardware refer to Figure 2 3 Figure 2 3 Digital Input Hardware Configuration TLP121 DGND or HCTL 2631 8 2mA Diode NPY Note X1 is controlled through software to be up for active low and down for active high Publication 2098 INO01B EN P July 2000 2 6 Connecting Your Ultra5000 Publication 2098 IN001B EN P July 2000 The following table provides a description of the digital input specifications Parameter Description Minimum Maximum ON State Voltage Voltage applied to the input with 10 8 V 26 4V Active High respect to IOCOM to guarantee an ON Configuration state ON State Voltage Voltage applied to the input with 26 4V 10 8 V Active Low respect to IOPWR to guarantee an ON Configuration state ON St
56. or sequencing ATTENTION To avoid personal injury and or equipment damage do not simply break the motor current This can result in very high voltages due to motor inductance prolonged arcing in the contactor and eventually can cause fire in extreme cases Application Information C 3 Shield and ground cable connection methods are shown in Figure C 1 ATTENTION Implementation of safety circuits and risk assessment is the responsibility of the machine builder Please reference international standards EN 1050 and EN 954 estimation and safety performance categories For more information refer to U nderstanding the M achinery D irective publication SHB 900 Figure C 1 Emergency Stop Contactor Wiring Contactors Resistor 1 Resistor l ees 1 1 Resistor TR PoE u OO T tv l l Drive V a O a V Motor w U O Low l an HO GND N 2 U Unbraided shield a Grounded terminal or stud Enclosure wall Exposed power wiring conductors that are not shielded are a source of RFI noise Keep exposed conductors as short as possible and isolated from sensitive devices and wiring N The safety ground GND and shield connections are permanently connected This is essential for electrical safety w Unbraid all cable shields and bond together connecting directly to the grounded terminal or stud Do not use the shield d
57. ou understand the following e how to store your Ultra5000 before installation e how to unpack the system e the minimum mounting requirements Storing Your Ultra5000 Before Installation The Ultra5000 should remain in the shipping container prior to installation If the equipment is not to be used for a period of time store it as follows e Use a clean dry location e Maintain an ambient temperature range of 40 to 70 C 40 to 158 F e Maintain a relative humidity range of 5 to 95 non condensing e Store it where it cannot be exposed to a corrosive atmosphere e Store it in anon construction area Installing Your Ultra5000 1 3 Unpacking Modules Each Ultra5000 ships with the following One Ultra5000 drive One screwdriver One instruction manual publication 2098 IN001B EN P Two I O connector plugs 14 and 28 pin Remove all packing material wedges and braces from within and around the components After unpacking check the item s nameplate catalog number against the purchase order System Mounting Requirements There are several things that you need to take into account when preparing to mount the Ultra5000 The Ultra5000 must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 IEC 529 to IP55 such that they are not accessible to an operator or unskilled person A NEMA 4X enclosure exceeds these requirements providing protection to IP66 The ambient temperature of
58. pter do not include information regarding integration with other products The following precautions pertain to all of the procedures in this chapter Be sure to read and thoroughly understand them before proceeding ATTENTION ATTENTION A This product contains stored energy devices To avoid hazard of electrical shock verify that all voltages on the system bus network have been discharged before attempting to service repair or remove this unit O nly qualified personnel familiar with solid state control equipment and safety procedures in publication NFPA 70E or applicable local codes should attempt this procedure This drive contains ESD Electrostatic D ischarge sensitive parts and assemblies You are required to follow static control precautions when you install test service or repair this assembly If you do not follow ESD control procedures components can be damaged If you are not familiar with static control procedures refer to Allen Bradley publication 8000 4 5 2 G uarding A gainst E lectrostatic D amage or any other applicable ESD Protection Handbook Publication 2098 INO01B EN P July 2000 3 2 Commissioning Your Ultra5000 Understanding Communication Switch Settings Applying Power To Your System Publication 2098 IN001B EN P July 2000 The Ultra5000 communication address selector switches MSD and LSD allow setting a unique address for each Ultra5000 connected on a serial network The switches
59. r should be free of oil corrosives or electrically conductive contaminates Use the following approximate equations as an aid in sizing an enclosure when no active method of heat dissipation is available Metric Tce 79 05 Q A 1 98 Standard English Tp 4 08 Q A 1 1 Where T is temperature difference between inside air and outside ambient C Q is heat generated in enclosure Watts and A is enclosure surface area m2 The exterior surface of all six sides of an enclosure is calculated as Where T is temperature difference between inside air and outside ambient F Q is heat generated in enclosure Watts and A is enclosure surface area ft2 The exterior surface of all six sides of an enclosure is calculated as A 2Zdw 2dh 2wh A 2dw 2dh 2wh 144 Where d depth w width and h height are in meters Where d depth w width and h height are in inches Installing Your Ultra5000 1 5 Transformer Sizing The Ultra5000 does not require isolation transformers A transformer may be required however to match the voltage requirements of the controller to the available service To size a transformer the power output KVA of each axis must be known This can be derived by calculating the horsepower for each axis and converting that horsepower into units of watts If you are supplying power to more than one motor and an Ultra5000 simply add the KW ratings together from each cal
60. rain wire for this bonded connection The safety ground is not connected to local ground at the IMPORTANT ok point where the contactor is inserted in the lines but the shield is This is done for EMC reasons Publication 2098 INO01B EN P July 2000 C 4 Application Information Grounding for Ultra5000 CE Refer to the figure below for Ultra5000 CE requirements Requirements Figure 2 Ultra5000 CE Requirements i Sound Conduit to Enclosure Enclosure i aa A I Single Phase 7 E User Supplied I Mains with Filter Discrete I O I Ground E I iw Z I fi 1 User Supplied E i Conduit Clamp 24V ij e I Power Source a I Unfiltered Hf e Filtered Conductors 1 Conductors Single Phase I i i Contactor i 2 I I I I I I 3 I I Bonded Cabinet I I Ground Bus I 1 I I I 1 Enclosure I I J 1 Mount the filter as close to the Ultra5000 as possible If the distance exceeds 600 mm 2 0 ft use a strap greater in width than length rather than a wire to connect the ground between the Ultra5000 and the filter This is particularly important for attenuation of higher frequency emissions 5 30 MHz Shield or separate the wires connecting the AC power to the filter from other power cables e g connections between the Ultra5000 and the filter
61. ram 63 82 mm 251 in gt 43 18 mm 20 32 mm 1 70 in gt gt 0 80 in r p a a A A AL U x o o Hule OE LI 193 55 mm zi 184 91 mm F3 205 23 mm F z LJ v y Sy a y 144 53 mm _ 689 in A SES Maa s Ww A H 114 30 mm 1 4 50 in HAT NA NANA _ Vv Fan only on 2 kW units Publication 2098 INO01B EN P July 2000 A 8 Specifications and Dimensions Publication 2098 IN001B EN P July 2000 Chapter Objectives Ultra5000 Family Options and Accessories Appendix B This appendix provides the Ultra5000 options and accessory catalog numbers This appendix covers catalog numbers for the e Ultra5000 family e Ultra5000 accessories e Motor power cables e Motor feedback cables e Interface cables Contact your local Allen Bradley sales office for additional information The Ultra5000 has power ratings from 500W to 15 KW The Ultra5000 family models are listed in the following table Model Description Power Rating 2098 IPD 005 Ultra5000 Intelligent Positioning Drive 500W 2098 IPD 010 Ultra5000 Intelligent Positioning Drive 1kW 2098 IPD 020 Ultra5000 Intelligent Positioning Drive 2 kW Option Cards Option cards added to the Ultra5000 Series drives are indicated by a suffix after the model number In the event that two option cards are added to the drive the model number will include a slash betw
62. ring Your Ultra5000 This procedure assumes you have applied power to your system To configure L Start your Ultraware software Refer to the U Itraware U ser M anual publication 2098 UM001A EN P for information on starting the Ultraware software on line drives O pen a recently used file or create a new file Ultraware will scan for Publication 2098 INO01B EN P July 2000 3 4 Commissioning Your Ultra5000 3 Click on the Stop Scanning button when your drive is detected or wait for the scanning to time out 4 Look for the Ultra5k icon under the On Line D rives tree The Ultra5k icon indicates that your drive is detected If your Ultra5000 drive Then Is detected and listed under the On Line The system is ready Go to Drives tree main step 5 Is not detected 1 Go to the previous section A pplying Power to Your System step 3 and verify your address switch settings 2 Check your serial cable connections 3 Go to main step 1 of this section 5 Refer to step 5 in the previous section A pplying Power to Your System If you were told Then The drive is ready Go to main step 6 below Your firmware requires an upgrade 1 Select File from the main menu bar 2 Select Upgrade Firmware 3 Go back to main step 1 and repeat procedure 6 Refer to the U Itraware U ser M anual publication 2098 UM001A EN P for further configuration and tuning instructions The
63. s Model Maximum Loss Watts IPD 005 48 dissipative shunt IPD 010 48 dissipative shunt IPD 020 50 dissipative shunt User Programming Specifications and Dimensions A 3 The table below lists physical and programming specifications Specification Language Description Compiled ANSI C with Library of Motion Functions Programming Environment Full featured Color Syntax Editor and C Compiler Integrated with Ultraware Operating System Real time multi tasking field upgradable flash User Program Memory 512 Kbytes Flash Memory 100 000 Write Cycles Non Volatile Memory Controller 32 Kbytes approximately 8000 non volatile user variables nvSRAM High speed SRAM EEPROM The table below lists controller specifications Specification Description Processor Texas Instruments TMS320C32 32 Bit Floating Point Digital Signal Processor Clock Speed 60 MHz Commutation 3 Phase Sinusoidal Space Vector Modulated SVM Current Loop SVM 125 usec update rate Velocity Loop Digital Pl 250 usec update rate Position Loop Digital Pl 500 psec update rate Position Range 32 bit signed Velocity Range 32 bit floating point Acceleration Range 32 bit floating point Electronic Gearing 64 bit signed Publication 2098 INO01B EN P July 2000 A 4 Specifications and Dimensions Publication 2098 IN001B EN P July 20
64. s refer to the instructions that came with each of the accessories for their specific requirements To mount your Ultra5000 drive 1 Layout the positions for the Ultra5000 and accessories in the enclosure Mounting hole dimensions for the Ultra5000 are shown in A ppendix A 2 Attach the Ultra5000 to the cabinet first using the upper mounting slots of the drive and then the lower The recommended mounting hardware is M5 metric 1 4 20 or 10 MS bolts O bserve bonding techniques as described in Bonding Your System 3 Tighten all mounting fasteners Chapter Objectives Understanding Ultra5000 Connectors Chapter 2 Connecting Your Ultra5000 This chapter describes how to make wiring and cable connections for your Ultra5000 This chapter includes Understanding Ultra5000 connectors Understanding Ultra5000 I O specifications Understanding encoder feedback specifications Understanding serial interfaces Understanding basic wiring requirements Grounding your Ultra5000 Wiring your Ultra5000 This section provides an overview of the Ultra5000 front panel connectors Ultra5000 Block Diagram The Ultra5000 uses a two stage circuit card solution with the capability of adding two additional option cards The first stage is the processor circuit board and the second stage handles I O connections including a power module interface as shown in Figure 2 1 Figure 2 1 Block Diagram of Ultra5000 Controller Functions PROCESSOR
65. ssed in a percent of full scale Understanding Encoder Feedback Specifications Connecting Your Ultra5000 2 9 The Ultra5000 offers two motor feedback interfaces A description of the Ultra5000 encoder feedback specifications is provided starting below Encoder Interface The Ultra5000 main encoder feedback connector is CN2 The motor encoder interface circuitry features include e 2 5 MHz maximum line frequency e RS 485 serial channel for communicating with intelligent encoders e Hall input for start up commutation only e Interpolation of sine cosine encoders All encoder signals are filtered using analog and digital filtering The inputs also include illegal state change detection Refer to Figure 2 5 for a schematic of the motor encoder inputs Hardware latches can be used for latching the encoder position based on an index input or a digital input transition Figure 2 5 Schematic of the Motor Encoder Inputs a AM and BM Channel Inputs b IM Channel Input Publication 2098 INO01B EN P July 2000 2 10 Connecting Your Ultra5000 The following table provides a description of the motor encoder interface specifications Parameter Description Minimum Maximum AM BM and IM Input voltage difference between the input and the input thatis 1 0 V 12 0 V ON State Input Voltage detected as an ON state AM BM and IM Input voltage difference between the input and the input th
66. sts auxiliary feedback specifications Specification Description Operation Auxiliary Feedback Input Input Modes A quad B Input Type Line Receiver Maximum Input Frequency 2 5 MHz Encoder Lines Connectors The table below lists connector specifications Specification Description Digital 1 0 Connector CN1A 28 Position Plugable Spring Clamp Terminal Block Auxiliary Feedback Analog 14 Position Plugable Spring Clamp Terminal Block 1 0 Connector CN1B Motor Feedback Connector 15 Position High Density Female D Sub Connector CN2 Serial Port Connectors 9 Position Female D Sub Connector CN3A and CN3B Main AC Motor Power and 9 Position ScrewTerminal Block DC Bus Connector Publication 2098 INO01B EN P July 2000 A 6 Specifications and Dimensions Dimensions The following diagrams show the dimensions and mounting hole locations for the 2098 IPD 005 010 and 020 Figure A 1 Ultra5000 500W Mounting Diagram
67. t 28 Pin 3 5mm double row plugable spring clamp CN1B User Input Output 14 Pin 3 5mm double row plugable spring clamp CN2 Motor Encoder 15 Pin high density D shell CN3A Main 9 Pin standard D shell Serial Port 1 CN3B Auxiliary 9 Pin standard D shell Serial Port 2 TB DC bus Motor and 9 position screw style barrier terminal strip AC power All connections on the Ultra5000 that require shielding use commonly available D Shell type connectors To locate the Ultra5000 front panel connectors switches and status LED refer to the figure below Figure 2 2 Ultra5000 Front Panel Connections CN1A 28 pin Digital I O Connector CN1B 14 pin Auxiliary Encoder and Seven Segment 8 i Status LED Analog I O Connector i 4 Power Indicator 4 F Communication L gt Address Selector we Switches Al DC Bus Connections for ni Active Shunt Resistor Kt gt gt CN3A 9 pin AC Input Power Main Serial Port Connections 2 Connector Motor Power CN3B 9 pin Connections gt Auxiliary Serial Port Connector CN2 15 pin Motor Encoder Connector Publication 2098 IN001B EN P July 2000 Connecting Your Ultra5000 2 3 1 0 Connectors CN1A 28 pin and CN1B 14 pin are plugable double row spring clamp connectors with 3 5mm spacing and are included with your Ultra5000 The following table provides the signal description and pin outs for the CN 1A I O connector
68. ted Throughout this manual we use notes to make you aware of safety considerations Identifies information about practices or ATENUO circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard e avoid a hazard e recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley is a registered trademark of Rockwell Automation Ultraware is a trademark of Rockwell Automation UL and cUL are registered trademarks of Underwriters Laboratories Windows is a trademark of Microsoft Corporation Preface Installing Your Ultra5000 Connecting Your Ultra5000 Table of Contents TOO GUICHONA Sesia ts unter aus le ede dt ale aides ie dt at bee P 1 Who Should Use this Manual 0 cee cece ene nes P 1 Purpose of this Manuals 225 ha chegctecichaegehecucheye en pantera ea tals P 1 Contents of this Manual 5 oicirescciee crs ceseivrenessratessre uae ereimesr gin ices eee beanie P 2 Related Documentation 25 5 a cone ee arene pee areeotos ees P 2 Conventions Used in this Manual cccce cee ne eee enees P 2 Product Receiving and Storage Responsibility 0 0 eee P 3 Allen Bradley Supp0thie s44scrs0ssoreneoare tieoeaemaxtane s P 3 Local Product OUP DOL exc aay cae Rete ped Bo Cale Hae wees alae cee P 3 Technical Product Assistance
69. to identify motor power cables for your F H MP N and Y Series motors Length of cable xx is in meters 01 03 09 15 and 30 Description Catalog Number H 2000 3000 Series Motor Power Cable 2090 UXNPA H16Sxx up to 2 kW Ultra3000 5000 non flex 16 AWG straight angle F 4000 Series Motor Power Cable 2090 UXNPA F148 xx 2 and 3 kW Ultra3000 5000 non flex 14 AWG straight angle H 4000 Series Motor Power Cable 2090 UXNPA H14S xx 2 and 3 kW Ultra3000 5000 non flex 14 AWG straight angle MP Series Motor Power Cable 2090 UXNPA MP16Sxx up to 2 kW Ultra3000 5000 non flex 16 AWG straight angle N Series Motor Power Cable 2090 UXNPA N16SXx Ultra3000 5000 non flex 16 AWG straight angle Y Series Motor Power Cable 2090 UXNPA Y 16S xx Ultra3000 5000 non flex 16 AWG straight angle Use the following table to identify motor feedback cables for your F H MP N and Y Series motors Length of cablexx is in meters 01 03 09 15 and 30 Description Catalog Number F Series Motor Feedback Cable 2090 UXNFB FSxx Ultra3000 5000 Feedback to drive F Series Motor Feedback Cable 2090 UXNFD FSxx Feedback to no connector H Series Motor Feedback Cable 2090 UXNFB HSxx Ultra3000 5000 Feedback to drive H Series Motor Feedback Cable 2090 UXNFD HSxx Feedback to no connector MP Series Motor Feedback Cable 2090 UXNFB MPS xx Ultra3000 5000 Feedback to drive MP Seri
70. ublication 2098 IN001B EN P July 2000 Figure 2 11 Motor Cable EMC Shield Connection Ultra5000 Motor Cable Jacket O e oO Y Series motors have a short pigtail cable which connects to the motor but is not shielded These motor power cables have a 152 4 mm 6 0 in shield termination wire with a ring lug that connects to the closest earth ground The termination wire may be extended to the full length of the motor pigtail if necessary but it is best to connect the supplied wire directly to ground without lengthening Refer to Figure 2 12 for an illustration Motor Cable Jacket Figure 2 12 Y Series Motor Cable EMC Connection Connectors Motor Power Cable ra Pigtail Cable _ 152 4 mm 6 0 in Termination Y Series Motor These procedures assume you have bonded and mounted your Ultra5000 to the subpanel and that there is no power applied to the system ATTENTION This drive contains ESD Electrostatic D ischarge sensitive parts and assemblies You are required to follow static control precautions when you install test service or repair this assembly If you do not follow ESD control procedures components can be damaged If you are not familiar with static control procedures refer to Allen Bradley publication 8000 4 5 2 G uarding A gainst E lectrostatic D amage or any other applicable ESD Protection Handbook Connecting Your Ultra5000 2 17 The fo
71. ur System Bonding is the practice of connecting metal chassis assemblies frames shields and enclosures to reduce the effects of electromagnetic interference EMI Bonding Modules Unless specified most paints are not conductive and they act as insulators To achieve a good bond between modules and the subpanel surfaces need to be paint free or plated Bonding metal surfaces creates a low impedance exit path for high frequency energy Improper bonding blocks that direct exit path and allows high frequency energy to travel elsewhere in the cabinet Excessive high frequency energy can effect the operation of other microprocessor controlled equipment The illustrations that follow refer to Figure 1 2 show details of recommended bonding practices for painted panels enclosures and mounting brackets Figure 1 2 Recommended Bonding Practices Stud mounting the subpanel Stud mounting a ground bus to the enclosure back wall or chassis to the subpanel Subpanel Back wall of enclosure Mounting bracket or Subpanel ground bus Welded stud Star washer Flat washer Scrape paint Flat washer Use a wire brush to remove paint from threads to maximize ground connection If the mounting bracket is coated with a non conductive material anodized painted etc scrape the material around the mounting hole Use plated panels or scrape paint on front of panel Bolt mounting a ground bus or chassis to the back panel Subpanel a h
72. ve low OUTPUT 1 The following table provides a description of the digital transistor output specifications Parameter Description Minimum Maximum ON State Current flow when the output transistor is ON 50 mA Current OFF State Current flow when the output transistor is OFF 0 1 mA Current ON State Voltage across the output transistor when ON 1 5V Voltage OFF State Voltage across the output transistor when OFF 50 V Voltage The following table provides a description of the digital relay output specifications Parameter Description Minimum Maximum ON State Current flow when the relay is closed 1A Current ON State Contact resistance when the relay is closed 1Q Resistance OFF State Voltage across the contacts when the relay is 30 V Voltage open OFF State Current flow when the relay is open 0 01 mA Current Publication 2098 IN001B EN P July 2000 2 8 Connecting Your Ultra5000 Publication 2098 IN001B EN P July 2000 Analog Inputs There are two single ended general purpose analog inputs to use as needed A 12 bit sampling A D converter generates the digital representation of the analog inputs The following table provides a description of the analog input specifications Parameter Description Minimum Maximum Resolution Number of states that the input plone is divided 12 Bits into which is 2 the nu

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