ULTRA 100 Series Drives Installation Manual

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Allen-BradleyULTRA100 SeriesDrives(Cat. No. 1398-5.2)InstallationManual

Important UserInformationBecause of the variety of uses for the products described in thispublication, those responsible for the application and use of thiscontrol equipment must satisfy themselves that all necessary stepshave been taken to assure that each application and use meets allperformance and safety requirements, including any applicable laws,regulations, codes and standards.The illustrations, charts, sample programs and layout examples shownin this guide are intended solely for purposes of example. Since thereare many variables and requirements associated with any particularinstallation, Allen-Bradley does not assume responsibility or liability(to include intellectual property liability) for actual use based upon theexamples shown in this publication.Allen-Bradley publication SGI-1.1, Safety Guidelines for theApplication, Installation, and Maintenance of Solid-State Control(available from your local Allen-Bradley office), describes someimportant differences between solid-state equipment andelectromechanical devices that should be taken into considerationwhen applying products such as those described in this publication.Reproduction of the contents of this copyrighted publication, in wholeor in part, without written permission of Allen-Bradley Company,Inc., is prohibited.Throughout this manual we use notes to make you aware of safetyconsiderations. For example:Intro!ATTENTION: This symbol identifies information aboutpractices or circumstances that can lead to personal injuryor death, property damage or economic loss.Attention statements help you to: identify a hazardavoid the hazardrecognize the consequencesNote: This symbol identifies information that is critical for successfulapplication and understanding of the product.Mathcad is a registered trademark of MathSoft, Inc.Microsoft, MS-DOS and Windows are trademarks of Microsoft Corporation.UL and cUL are registered trademarks of Underwriters Laboratories.

Table of ContentsIntroTable of ContentsTable of ContentsIntro-3List of FiguresIntro-9List of TablesIntro-13PrefaceIntro-17Who Should Use this Manual . . . . . . . . . . . . . . . . . . .Intro-17ULTRA 100 Series Product Receiving and Storage Responsibility. .Intro-17Rockwell Automation Support . . . . . . . . .Local Product Support. . . . . . . . . . . . . .Technical Product Assistance . . . . . . . . .Purpose and Contents of this Manual . . . . .Additional Instructions and Manuals . . . . .Host Commands and ULTRA Master . . .TouchPad . . . . . . . . . . . . . . . . . . .Symbols and Conventions . . . . . . . . . . .Typographical and Wording Conventions .Graphical Symbols . . . . . . . . . . . . . .Pictorial Index . . . . . . . . . . . . . . . . . .Chapter 1. . . . . . . . . .Intro-18. . . . . . . . . .Intro-19. . . . . . . . . .Intro-19. . . . . . . . . .Intro-19. . . . . . . . . .Intro-22. . . . . . . . . .Intro-22. . . . . . . . . .Intro-22. . . . . . . . . .Intro-23. . . . . . . . . .Intro-23. . . . . . . . . .Intro-24. . . . . . . . . .Intro-25SafetyInstalling and Using the ULTRA 100 Series DrivePotential Hazards . . . . . . . . . . . . . . . . . .Voltage Potentials . . . . . . . . . . . . . . . . .Your Responsibilities . . . . . . . . . . . . . . . . .General Safety Guidelines . . . . . . . . . . . . . .Chapter 2. . . . . . . . . 1-1. . . . . . . . . 1-2. . . . . . . . . 1-2. . . . . . . . . 1-3Unpacking, Inspecting and StoringUnpacking the Drive . .Inspection Procedure .Testing the Unit . . . .Hardware Set Up . .Drive Checkout TestStoring the Unit . . .Chapter 3. . . . . . . . . 1-1. . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . . . . . . . . 2-2. . . . . . . . . . . . . . . . . . . . . . . . . 2-2. . . . . . . . . . . . . . . . . . . . . . . . . 2-3. . . . . . . . . . . . . . . . . . . . . . . . . 2-8Selecting Other System ComponentsULTRA 100 Series Overview . . . . . . . . . . . . . . . . . . . . . 3-1Publication 1398-5.2 – PDF 1997

Intro-4Table of ContentsULTRA 100 Series Features . . . . . . . . . . . . .Drive Power Ratings . . . . . . . . . . . . . . . .High Performance Microcontroller Technology .IPM Technology . . . . . . . . . . . . . . . . . . .Analog and Digital Interfaces . . . . . . . . . . .Encoder Control . . . . . . . . . . . . . . . . . . .Encoder Output . . . . . . . . . . . . . . . . . . .Digital I/O . . . . . . . . . . . . . . . . . . . . . .Analog I/O . . . . . . . . . . . . . . . . . . . . . .AC Input Power . . . . . . . . . . . . . . . . . . .Personality Module . . . . . . . . . . . . . . . . .Multiple Protection Circuits . . . . . . . . . . . .Command Sources . . . . . . . . . . . . . . . . . . .Serial Command Sources . . . . . . . . . . . . . .Analog Command Sources . . . . . . . . . . . . .I/O Interface . . . . . . . . . . . . . . . . . . . . . . .Analog Input . . . . . . . . . . . . . . . . . . . . .Analog Output . . . . . . . . . . . . . . . . . . . .Digital Inputs . . . . . . . . . . . . . . . . . . . .Digital Outputs. . . . . . . . . . . . . . . . . . . .Auxiliary Encoder Interface . . . . . . . . . . . .ULTRA Master Software . . . . . . . . . . . . . . .Autotuning . . . . . . . . . . . . . . . . . . . . . .Agency Approvals . . . . . . . . . . . . . . . . . . .Interface Cables . . . . . . . . . . . . . . . . . . . . .Motors . . . . . . . . . . . . . . . . . . . . . . . . . .Options . . . . . . . . . . . . . . . . . . . . . . . .European Union Requirements . . . . . . . . . .Chapter 4. . . . . . . . . 3-1. . . . . . . . . 3-2. . . . . . . . . 3-2. . . . . . . . . 3-2. . . . . . . . . 3-2. . . . . . . . . 3-2. . . . . . . . . 3-2. . . . . . . . . 3-3. . . . . . . . . 3-3. . . . . . . . . 3-3. . . . . . . . . 3-3. . . . . . . . . 3-3. . . . . . . . . 3-3. . . . . . . . . 3-4. . . . . . . . . 3-4. . . . . . . . . 3-4. . . . . . . . . 3-5. . . . . . . . . 3-5. . . . . . . . . 3-5. . . . . . . . . 3-6. . . . . . . . . 3-6. . . . . . . . . 3-7. . . . . . . . . 3-7. . . . . . . . . 3-7. . . . . . . . . 3-7. . . . . . . . . 3-8. . . . . . . . . 3-9ULTRA Master InstallationHardware and Software Requirements . .Installing ULTRA Master . . . . . . . . .Starting and Quitting ULTRA Master . .From the C: Prompt . . . . . . . . . .From Windows . . . . . . . . . . . . .The ULTRA Master Start-Up Screen .Version Level . . . . . . . . . . . . . . . .Miscellaneous Files. . . . . . . . . . . . .The readme File . . . . . . . . . . . . .Firmware Files . . . . . . . . . . . . . .Chapter 5. . . . . . . . . 3-1. . . . . . . . . . . . . . . 4-1. . . . . . . . . . . . . . . 4-1. . . . . . . . . . . . . . . 4-2. . . . . . . . . . . . . . . 4-2. . . . . . . . . . . . . . . 4-3. . . . . . . . . . . . . . . 4-4. . . . . . . . . . . . . . . 4-4. . . . . . . . . . . . . . . 4-5. . . . . . . . . . . . . . . 4-5. . . . . . . . . . . . . . . 4-5InstallationMechanical Installation Requirements . . . . . . . . . . . . . . . . . 5-1Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Publication 1398-5.2 – PDF 1997

Table of ContentsIntro-5Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . 5-7AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Chapter 6InterfacesJ1 – Controller . . . . . . . . . . . . .Digital I/O Power . . . . . . . . . .Digital Inputs . . . . . . . . . . . .Input Interface Circuit ExamplesAuxiliary Encoder Input Types . .Interface Cable Examples . . . . .J1 Terminal Strip/Breakout BoardJ2 – Encoder . . . . . . . . . . . . . .J5 – Serial Port . . . . . . . . . . . . .Serial Communications OverviewFour Wire RS-485 Connections . .Interface Connections . . . . . . . . .Chapter 7. . . . . . . . . . . . . . . . . 6-1. . . . . . . . . . . . . . . . . 6-1. . . . . . . . . . . . . . . . . 6-3. . . . . . . . . . . . . . . 6-5. . . . . . . . . . . . . . . . 6-20. . . . . . . . . . . . . . . . 6-21. . . . . . . . . . . . . . . . 6-24. . . . . . . . . . . . . . . . 6-29. . . . . . . . . . . . . . . . 6-31. . . . . . . . . . . . . . . . 6-33. . . . . . . . . . . . . . . . 6-35. . . . . . . . . . . . . . . . 6-39Power ConnectionsMotor Power Cabling . . . . . . . . . . .Shield Termination of Power CablesMotor Overload Protection . . . . . .Power Supply Protection . . . . . . . .Emergency Stop Wiring . . . . . . . .AC Power Cabling . . . . . . . . . . . . .DC Bus . . . . . . . . . . . . . . . . . . .Chapter 8. . . . . . . . . . . . . . . 7-2. . . . . . . . . . . . . . . 7-2. . . . . . . . . . . . . . . 7-4. . . . . . . . . . . . . . . 7-5. . . . . . . . . . . . . . . 7-5. . . . . . . . . . . . . . . 7-7. . . . . . . . . . . . . . . 7-9Application and Configuration ExamplesAnalog Control . . . . . . . . . . . . .Hardware Set Up . . . . . . . . . .Connection Diagram . . . . . . . .Configuration . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . .Preset Controller . . . . . . . . . . . .Hardware Set Up . . . . . . . . . .Connection Diagram . . . . . . . .Configuration . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . .Position Follower (Master Encoder) .Hardware Set Up . . . . . . . . . .Connection Diagram . . . . . . . .Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. . . . . . . . . . . . . . . . . 8-1. . . . . . . . . . . . . . . . . 8-2. . . . . . . . . . . . . . . . . 8-2. . . . . . . . . . . . . . . . . 8-4. . . . . . . . . . . . . . . . . 8-5. . . . . . . . . . . . . . . . . 8-6. . . . . . . . . . . . . . . . . 8-6. . . . . . . . . . . . . . . . . 8-7. . . . . . . . . . . . . . . . . 8-7. . . . . . . . . . . . . . . . . 8-9. . . . . . . . . . . . . . . . 8-10. . . . . . . . . . . . . . . . 8-12. . . . . . . . . . . . . . . . 8-12. . . . . . . . . . . . . . . . 8-13. . . . . . . . . . . . . . . . 8-13Publication 1398-5.2 – PDF 1997

Intro-6Table of ContentsTuning . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . .Position Follower (Step/Direction) . . .Hardware Set Up . . . . . . . . . . .Connection Diagram . . . . . . . . .Configuration . . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . .Position Follower (Step Up/Down) . . .Hardware Set Up . . . . . . . . . . .Connection Diagram . . . . . . . . .Configuration . . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . .Incremental Indexing . . . . . . . . . .Hardware Set Up . . . . . . . . . . .Connection Diagram . . . . . . . . .Configuration . . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . .Registration Indexing . . . . . . . . . .Hardware Set Up . . . . . . . . . . .Connection Diagram . . . . . . . . .Configuration . . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . .Absolute Indexing . . . . . . . . . . . .Hardware Set Up . . . . . . . . . . .Connection Diagram . . . . . . . . .Configuration . . . . . . . . . . . . .Tuning . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . .Modifying User Units . . . . . . . . . .Changing the Display Units SettingsChapter 9. . . . . . . . . . . . . . . 8-16. . . . . . . . . . . . . . . 8-18. . . . . . . . . . . . . . . 8-18. . . . . . . . . . . . . . . 8-19. . . . . . . . . . . . . . . 8-19. . . . . . . . . . . . . . . 8-22. . . . . . . . . . . . . . . 8-22. . . . . . . . . . . . . . . 8-24. . . . . . . . . . . . . . . 8-24. . . . . . . . . . . . . . . 8-25. . . . . . . . . . . . . . . 8-25. . . . . . . . . . . . . . . 8-28. . . . . . . . . . . . . . . 8-28. . . . . . . . . . . . . . . 8-30. . . . . . . . . . . . . . . 8-31. . . . . . . . . . . . . . . 8-31. . . . . . . . . . . . . . . 8-31. . . . . . . . . . . . . . . 8-35. . . . . . . . . . . . . . . 8-35. . . . . . . . . . . . . . . 8-37. . . . . . . . . . . . . . . 8-37. . . . . . . . . . . . . . . 8-38. . . . . . . . . . . . . . . 8-38. . . . . . . . . . . . . . . 8-41. . . . . . . . . . . . . . . 8-41. . . . . . . . . . . . . . . 8-43. . . . . . . . . . . . . . . 8-43. . . . . . . . . . . . . . . 8-45. . . . . . . . . . . . . . . 8-45. . . . . . . . . . . . . . . 8-48. . . . . . . . . . . . . . . 8-48. . . . . . . . . . . . . . . 8-50. . . . . . . . . . . . . . . 8-50TuningTuning Guidelines . . . .General Tuning Rules .High Inertia Loads . . .Mechanical Resonance . .Backlash . . . . . . . .Auto Tune Mode . . . . .Auto Tuning . . . . . .Publication 1398-5.2 – PDF 1997. . . . . . . . . . . . . . . 8-16. . . . . . . . . . . . . . . . . . . . . . . . 9-1. . . . . . . . . . . . . . . . . . . . . . . . 9-1. . . . . . . . . . . . . . . . . . . . . . . . 9-1. . . . . . . . . . . . . . . . . . . . . . . . 9-2. . . . . . . . . . . . . . . . . . . . . . . . 9-3. . . . . . . . . . . . . . . . . . . . . . . . 9-3. . . . . . . . . . . . . . . . . . . . . . . . 9-3

Table of ContentsManual Tune Mode . . . . . . . . .Filters . . . . . . . . . . . . . . .Gains . . . . . . . . . . . . . . .Manual Tuning . . . . . . . . . .Velocity Loop Tuning ExamplesChapter 10. . . . . . . . . . . . . . . . . . 9-6. . . . . . . . . . . . . . . . . . 9-6. . . . . . . . . . . . . . . . . . 9-6. . . . . . . . . . . . . . . . . . 9-6. . . . . . . . . . . . . . . . . . 9-9Status DisplayStatus Indicator . . . . . . .Error Messages . . . . . . .Run Time Error Codes .Power-Up Error Codes .Chapter 11. . . . . . . . . . . . . . . . . . . . . . 10-1. . . . . . . . . . . . . . . . . . . . . . 10-1. . . . . . . . . . . . . . . . . . . . . . 10-1. . . . . . . . . . . . . . . . . . . . . . 10-2Maintenance and TroubleshootingMaintenance . . . . . . . . . . . . . . . . . . . . . . . . .Periodic Maintenance . . . . . . . . . . . . . . . . . .Firmware Upgrading . . . . . . . . . . . . . . . . . . . .Firmware Upgrade Procedure using ULTRA Master .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .Error Codes . . . . . . . . . . . . . . . . . . . . . . . .RS-232 Communication Test . . . . . . . . . . . . . .Testing Digital Outputs . . . . . . . . . . . . . . . . .Testing Digital Inputs . . . . . . . . . . . . . . . . . .Testing Analog Output . . . . . . . . . . . . . . . . . .Testing Analog Input . . . . . . . . . . . . . . . . . . .Testing Encoder Inputs . . . . . . . . . . . . . . . . . .Appendix A. . . . . 11-1. . . . . 11-1. . . . . 11-2. . . . . 11-2. . . . . 11-3. . . . . 11-4. . . . . 11-8. . . . . 11-9. . . . . 11-11. . . . . 11-11. . . . . 11-12. . . . . 11-13Options and AccessoriesULTRA 100 Series DrivesFuses . . . . . . . . . . . .Interface Cables . . . . . .Serial Interface Cables . .Encoder Feedback Cables .Motor Power Cables . . . .Connector Kits . . . . . . .Mating Connectors . . . . .Appendix BIntro-7. . . . . . . . . . . . . . . . . . . . . . . A-1. . . . . . . . . . . . . . . . . . . . . . . A-1. . . . . . . . . . . . . . . . . . . . . . . A-1. . . . . . . . . . . . . . . . . . . . . . . A-3. . . . . . . . . . . . . . . . . . . . . . . A-3. . . . . . . . . . . . . . . . . . . . . . . A-4. . . . . . . . . . . . . . . . . . . . . . . A-6. . . . . . . . . . . . . . . . . . . . . . . A-6Cable Diagrams, Schematics and ExamplesInterface Cables . . . . . . . . . . . . . . . . . . . .Serial Interface Cables . . . . . . . . . . . . . . . .Encoder Feedback Cables . . . . . . . . . . . . . . .Motor Power Cables . . . . . . . . . . . . . . . . .Cabling Examples . . . . . . . . . . . . . . . . . . .Allen-Bradley 9/Series CNC Family Connections . . . . . . . . . B-3. . . . . . . . B-11. . . . . . . . B-14. . . . . . . . B-21. . . . . . . . B-24. . . . . . . . B-26Publication 1398-5.2 – PDF 1997

Intro-8Table of ContentsAppendix CTouchPad InstructionsInstallation and Operation . .TouchPad Commands . . . .Supplemental InstructionsMotor Selection . . . . . .Analog Output Scaling . .Displays . . . . . . . . . .Motor Table . . . . . . . . . .TouchPad Options and Lists .TouchPad Lists . . . . . . . .Appendix D. . . . . . . . . . . . . . . . . . . . . .C-1. . . . . . . . . . . . . . . . . . . . . .C-3. . . . . . . . . . . . . . . . . . . . . .C-6. . . . . . . . . . . . . . . . . . . . . .C-6. . . . . . . . . . . . . . . . . . . . . .C-6. . . . . . . . . . . . . . . . . . . . . .C-7. . . . . . . . . . . . . . . . . . . . . C-11. . . . . . . . . . . . . . . . . . . . . C-16. . . . . . . . . . . . . . . . . . . . . C-16Creating Custom Motor FilesDrive and Motor File Configuration with ULTRA MasterMotor Parameter Set . . . . . . . . . . . . . . . . . . . .General Parameters . . . . . . . . . . . . . . . . . . . . .Feedback Parameters . . . . . . . . . . . . . . . . . . . .Electrical Parameters . . . . . . . . . . . . . . . . . . . .Rating Parameters . . . . . . . . . . . . . . . . . . . . . .Example of Custom Motor File Creation . . . . . . . . . .Manufacturer’s Data . . . . . . . . . . . . . . . . . . . . .Parameter Conversions . . . . . . . . . . . . . . . . . . .Custom Motor File . . . . . . . . . . . . . . . . . . . . .Troubleshooting Custom Motor Files . . . . . . . . . . . .Appendix E. . . . D-2. . . . D-5. . . . D-9. . . . D-11. . . . D-13. . . . D-16. . . . D-16. . . . D-16. . . . D-17. . . . D-19Electromagnetic Compatibility Guidelinesfor Machine DesignFiltering . . . . . . . . . . .AC Line Filter SelectionGrounding . . . . . . . . . .Shielding and Segregation .Appendix F. . . . D-1. . . . . . . . . . . . . . . . . . . . . . .E-2. . . . . . . . . . . . . . . . . . . . . . .E-4. . . . . . . . . . . . . . . . . . . . . . .E-5. . . . . . . . . . . . . . . . . . . . . . .E-7Dynamic Braking Resistor SelectionDynamic Braking Equations. . . . . . . . . . . . . . . . . . . . . . . F-1Sample Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . F-3Appendix GSpecificationsPower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5IndexPublication 1398-5.2 – PDF 1997Index-1

List of FiguresIntroList of FiguresProduct Parts Explained . . . . . . . . . . . . . . . . . . . . . Intro-25Chapter 1SafetyChapter 2Unpacking, Inspecting and StoringHost Mode Connection Diagram . . . . . . . . . . . . . . . . . . . . 2-3Chapter 3Selecting Other System ComponentsChapter 4ULTRA Master InstallationChapter 5Installation1398-DDM-005 and -005X Mounting Dimensions . . . . . . . . . . ngDimensions5-4MIF Single Phase AC Line Filter Mounting Diagram . . . . . . . . 5-9Power Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 5-11Chapter 6InterfacesDigital Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . .Drive Input Connected to a Switch/Relay Contact . . . . . . .Drive Input Connected to an Opto-Isolator . . . . . . . . . . . .Drive Input Connected to an Active High Sourcing TransistorDrive Input Connected to Active Low Outputusing a Switch/Relay . . . . . . . . . . . . . . . . . . . . . .Drive Input Connected to Active Low Outputusing an Opto-Isolator . . . . . . . . . . . . . . . . . . . . . .Drive Input Connected to Sourcing Output . . . . . . . . . . .READY and BRAKE/DRIVE ENABLED Circuits . . . . . . . .Digital Output Circuit . . . . . . . . . . . . . . . . . . . . . . . .BRAKE/DRIVE ENABLE Application Examples . . . . . . . .Drive Output Connected to an Opto-Isolator . . . . . . . . . . .Drive Output Connected to an LED Indicator . . . . . . . . . .Drive Output Connected to a Resistive Load . . . . . . . . . . .Drive Output Connected to a Switch/Relay . . . . . . . . . . .Drive Output Connected to Active Low Inputusing a Switch/Relay . . . . . . . . . . . . . . . . . . . . . .Drive Output Connected to Active Low Inputusing an Opto-Isolator . . . .

Publication 1398-5.2 – PDF 1997 Table of Contents IntroTable of Contents Table of Contents Intro-3 List of Figures Intro-9 List of Tables Intro-13 Preface Intro-17 Who Should Use this Manual.Intro-17 ULTRA 100 Series Product Receiving and Storage Responsibility. .

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