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    User ManualULTRA 200 SeriesDigital Servo Drives Allen-Bradley

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    Important User InformationBecause 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 perfo...

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    Publication 1398-5.0 – October 1998Table of ContentsIntroTable of Contents 3,Table of ContentsIntro-1 9,List of FiguresIntro-7 13,List of Tables 13,Intro-11 17,Preface 17,Intro-15 18,About 18, This 18, Manual 18,.. 18,.. 18,.. 18,.. 18,.. 18,.. 18,.. 18,. 18,. 18,. 18,. 18,. 18,. ...

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    Publication 1398-5.0 – October 1998Intro-2Table of Contents 34,Communications. 34,... 34,.. 34,.. 34,.. 34,.. 34,.. 34,.. 34,... 34,.. 34,.. 34,.. 34,.. 34,. 34,2-4 35,Autotuning 35,.. 35,.. 35,... 35,.. 35,.. 35,.. 35,.. 35,.. 35,.. 35,... 35,.. 35,.. 35,.. 35,.. 3...

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    Publication 1398-5.0 – October 1998Table of ContentsIntro-3 94,J2 Terminal 94, Strip/Breakout 94, Board 94,. 94,. 94,. 94,... 94,.. 94,.. 94,.. 94,.. 94,.. 94,6-30 95,J3 95,– 95,Auxiliary Port 95, 95,.. 95,.. 95,.. 95,.. 95,.. 95,.. 95,.. 95,. 95,. 95,. 95,. 95,. 95,...

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    Publication 1398-5.0 – October 1998Intro-4Table of Contents 145,Operation 145,. 145,. 145,. 145,. 145,. 145,... 145,.. 145,.. 145,.. 145,.. 145,.. 145,.. 145,... 145,.. 145,.. 145,.. 145,.. 145,8-21 146,Position 146, Follower 146, (Step 146, Up/Step 146, Down) 146,.. 146,.. ...

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    Publication 1398-5.0 – October 1998Table of ContentsIntro-5 184,Error Messages 184,. 184,... 184,.. 184,.. 184,.. 184,.. 184,.. 184,.. 184,... 184,.. 184,.. 184,.. 184,.. 184,.. 184,10-2 184,Run-Time Error Codes 184,.. 184,.. 184,.. 184,.. 184,.. 184,... 184,.. 184,.. 18...

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    Publication 1398-5.0 – October 1998Intro-6Table of Contents 252,Motor Selection 252,. 252,... 252,.. 252,.. 252,.. 252,.. 252,.. 252,.. 252,... 252,.. 252,.. 252,.. 252,.. 252,.C-6 252,Displays 252,. 252,. 252,. 252,. 252,. 252,... 252,.. 252,.. 252,.. 252,.. 252,.. 25...

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    Publication 1398-5.0 – October 1998List of Figures 23,IntroList of Figures 23,Product 23, 23,Parts 23, 23,Explained 23, 23,.. 23,.. 23,.. 23,... 23,.. 23,.. 23,.. 23,.. 23,.. 23,.. 23,Intro-21 27,Chapter 1Safety 31,Chapter 2Selecting Other System Components 39,Chapter 3ULTRA Mast...

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    Publication 1398-5.0 – October 1998Intro-8List of Figures 85,External Encoder Interface via 85,TTL Differential Line Drivers 85,.. 85,. 85,6-21 85,Complementary Encoder Interface via 85,7406 85, Line Drivers 85,with Pull-up Resistors . 85,. 85,. 85,. 85,. 85,. 85,. 85,. 85,. 85,...

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    Publication 1398-5.0 – October 1998List of FiguresIntro-9 159,Registration Indexing 159, Connection 159, Diagram 159, 159,.. 159,.. 159,.. 159,.. 159,.. 159,..8-35 163,Absolute Indexing 163, Examples 163,.. 163,.. 163,... 163,.. 163,.. 163,.. 163,.. 163,.. 163,.. 163,..8-39 16...

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    Publication 1398-5.0 – October 1998Intro-10List of Figures 237,N-Series 237, 237,Power 237, 237,Cable 237, 237,(P/N 237, 237,9101-1467) 237, 237,... 237,.. 237,.. 237,.. 237,.. 237,.. 237,..B-25 238,F or H-Series 238, Motors to ULTRA 238,200 Series Drive 238, 238, 238, 238, ...

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    Publication 1398-5.0 – October 1998List of TablesIntroList of Tables 27,Chapter 1Safety 31,Chapter 2Selecting Other System Components 39,Chapter 3ULTRA Master Installation 43,Chapter 4Unpacking, Inspecting and Storing 51,Chapter 5Installation 57,Qualified AC Line 57, Filters 57,.. 57,.. 57,....

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    Publication 1398-5.0 – October 1998Intro-12List of Tables 111,Chapter 7Power Connections 113,TB1 113,– 113,Motor Power Termina 113,ls 113,.. 113,.. 113,.. 113,... 113,.. 113,.. 113,.. 113,.. 113,.. 113,.. 113,7-3 115,Motor Power Contact 115, and 115, Wire Sizing R 115,ecommendati...

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    Publication 1398-5.0 – October 1998List of TablesIntro-13 260,Home 260, Type Parameter 260,List 260, for TouchPad 260,.. 260,.. 260,.. 260,.. 260,.. 260,.. 260,.. C-14 260,Homing 260, Auto-Start Parameter List 260,for TouchPad 260,.. 260,.. 260,.. 260,.. 260,. C-14 261,Reverse Ena...

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    Publication 1398-5.0 – October 1998Intro-14List of Tables

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    Publication 1398-5.0 – October 1998PrefaceIntroPrefaceThis manual provides a step-by-step approach to building a servo system using a ULTRA 200 Series drive. The manual is divided into chapters that cover specific phases of the system design process; from ordering components that will complemen...

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    Publication 1398-5.0 – October 1998Intro-16PrefaceAbout This ManualThis manual provides instructions on how to setup and connect the ULTRA 200 Series drive to a controlling device and a motor. A ULTRA 200 Series drive may operate in one of several different functional modes. The hardware connec...

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    Publication 1398-5.0 – October 1998PrefaceIntro-17Additional Instructions and ManualsHost Commands and ULTRA MasterAll ULTRA 200 Series drives are setup through serial Host Commands. The drives may be configured directly through the Host Command language or indirectly through the ULTRA Master s...

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    Publication 1398-5.0 – October 1998Intro-18PrefaceAll documentation for both the Host Commands and ULTRA Master is on-line. Host Command information is available through a comprehensive on-line reference manual. ULTRA Master information is available through Help menus. The on-line documents pro...

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    Publication 1398-5.0 – October 1998PrefaceIntro-19Symbols and ConventionsTypographical and Wording ConventionsThis manual uses the following typographical and wording conventions: ExampleDescription»Text preceded by right guillemet explains how to access the particular function in the precedi...

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    Publication 1398-5.0 – October 1998Intro-20PrefaceGraphical Symbols and Warning ClassificationsThis manual uses the following graphical symbols and warning classifications. The use of a symbol and signal word is based on an estimation of the likelihood of exposure to the hazardous situation and...

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    Publication 1398-5.0 – October 1998PrefaceIntro-21Pictorial IndexShown here are face views of the product, with pointers to where individual parts are discussed. Product Parts Explained (sheet 1 of 3)IntroWARNING: HIGH VOLTAGEMAY EXIST FOR UP TO FIVE MINUTESAFTER REMOVING POWER.pag 117,e 7-7pa...

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    Publication 1398-5.0 – October 1998Intro-22PrefaceIntroProduct Parts Explained (sheet 2 of 3)WARNING: HIGH VOLTAGEMAY EXIST FOR UP TO EIGHT MINUTESAFTER REMOVING POWER.page 117,7-7page 116,7-6page 120,7-10pag 121,e 7-11page 116,7-6page 113,7-3pa 98,ge 6-34pa 98,ge 6-34pa 95,ge 6-31pa 91,ge...

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    Publication 1398-5.0 – October 1998PrefaceIntro-23IntroProduct Parts Explained (sheet 3 of 3)pag 117,e 7-7pag 116,e 7-6pag 120,e 7-10pag 121,e 7-11pag 116,e 7-6pag 113,e 7-3page 98,6-34page 98,6-34page 95,6-31page 91,6-27page 65,6-1page 108, 6-44page 100, 6-36page 183, 10-1, 194,11-6Model...

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    Publication 1398-5.0 – October 1998Intro-24Preface

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    Publication 1398-5.0 – October 1998Chapter 1SafetyChapter 1Installing and Using the ULTRA 200 Series Read the complete manual before attempting to install or operate the ULTRA 200 Series drive. By reading the manual you will become familiar with practices and procedures that allow you to operat...

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    Publication 1398-5.0 – October 19981-2SafetyYour ResponsibilitiesAs the user or person installing this drive, you are responsible for determining the suitability of the product for the intended application. Rockwell Automation is neither responsible nor liable for indirect or consequential dama...

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    Publication 1398-5.0 – October 1998Safety1-3Safety GuidelinesElectrical shock and fire hazards are avoided by using normal installation procedures for electrical power equipment in an industrial environment. Installation must be undertaken by suitably qualified personnel. Note that this amplifi...

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    Publication 1398-5.0 – October 19981-4SafetyqBefore removing the cover of the unit, shut off the main and auxiliary power and measure the DC bus voltage to verify it has reached a safe level or wait for the time indicated in the warning on the front of the drive. qDo not make any connections to...

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    Publication 1398-5.0 – October 1998Chapter 2Selecting Other System ComponentsChapter 2The Allen-Bradley ULTRA 200 Series drives are part of a family of digital drives that use microcontrollers to manage the current, velocity, and position. All system and application parameters are set in softwa...

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    Publication 1398-5.0 – October 19982-2Selecting Other System ComponentsInterface CablesStandard Allen-Bradley motor power and encoder feedback cables, as well as communications cables, are available to complete your motion control system and provide reliable, trouble free start-up. Refer to 20...

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    Publication 1398-5.0 – October 1998Selecting Other System Components2-3Encoder OutputA selectable output allows the encoder resolution to be specified for maximum performance without adding circuitry. Outputs are differential line drivers capable of dividing the motor encoder signal, PPR (pulse...

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    Publication 1398-5.0 – October 19982-4Selecting Other System ComponentsMultiple Protection CircuitsDevice and circuit protection, and diagnostic information is provided by: qSeven segment drive status displayqOvertemperature, short circuit and overcurrent protection for the power outputqI2T (po...

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    Publication 1398-5.0 – October 1998Selecting Other System Components2-5AutotuningDigital auto tuning allows easy setup. All adjustments are made in software, which immediately sets the servo system compensation parameters. This eliminates the time-consuming adjustments required by potentiometer...

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    Publication 1398-5.0 – October 19982-6Selecting Other System ComponentsMotorsThe ULTRA 200 Series is compatible with many motors, both Allen-Bradley motors and motors from other manufacturers. Drive and motor parameters for all compatible Allen-Bradley motors are programmed into each ULTRA 200 ...

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    Publication 1398-5.0 – October 1998Selecting Other System Components2-7European Union RequirementsULTRA 200 Series drives conform to the following European Union Directives:qMachinery Directive (89/392/EEC, Article 4.2 and Annex II, sub B)qLow Voltage Directive (72/23/EEC, 93/68/EEC)qElectromag...

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    Publication 1398-5.0 – October 19982-8Selecting Other System Components

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    Publication 1398-5.0 – October 1998Chapter 3ULTRA Master InstallationChapter 3Installation of ULTRA Master on a PC is covered in this chapter, which: qLists the minimum PC hardware and software necessary to run ULTRA Master. qProvides step-by-step instructions on how to load ULTRA Master.qShows...

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    Publication 1398-5.0 – October 19983-2ULTRA Master InstallationInstalling ULTRA Master To install ULTRA Master software on a hard drive:1. Make a backup copy of the ULTRA Master disk in one of the fol-lowing ways: • Copy the ULTRA Master disk using the disk menu in the Windows File Manager. ...

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    Publication 1398-5.0 – October 1998ULTRA Master Installation3-3Starting and Quitting ULTRA MasterVersion LevelThe release level and date for ULTRA Master may be displayed by selecting About ULTRA Master from the Help menu. This information also appears in the initial ULTRA Master screen. The Ab...

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    Publication 1398-5.0 – October 19983-4ULTRA Master InstallationFrom the C:> Prompt1. Type win c:\ultramst\ultramst.exe. The ULTRA Master start-up screen will open. From Windows1. Choose the ULTRA Master program group from the Program Manager in Windows. 2. Choose the ULTRA Master icon fr...

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    Publication 1398-5.0 – October 1998Chapter 4Unpacking, Inspecting and StoringChapter 4This chapter describes four steps which should ensure that the drive functions correctly. The steps include:qUnpacking the ULTRA 200 Series drive qInspecting the drive for shipping damage qTesting the basic fu...

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    Publication 1398-5.0 – October 19984-2Unpacking, Inspecting and StoringTesting the UnitDrives are burned-in and individually tested before they leave the factory. However, damage may occur during shipping. Perform the procedures below to ensure the ULTRA 200 Series drive is operational and unda...

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    Publication 1398-5.0 – October 1998Unpacking, Inspecting and Storing4-3Hardware SetupMake the connections described below and shown in 46, Figure 46,4.1. 1. Connect an RS-232 cable between the serial port on the PC and the J4 connector on the ULTRA 200 Series. • An Allen-Bradley cable connec...

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    Publication 1398-5.0 – October 19984-4Unpacking, Inspecting and StoringDrive Checkout Test This test sequentially verifies that:qDrive power wiring is correct and start-up logic is functioning qThe drive and motor are correctly wired qDrive serial communications are operational Before beginni...

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    Publication 1398-5.0 – October 1998Unpacking, Inspecting and Storing4-5Initial Power-up1. Verify the AC power is within specifications. 2. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display is not flashing.3. Switch the power OFF and wait until the DC Bus Voltage is belo...

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    Publication 1398-5.0 – October 19984-6Unpacking, Inspecting and Storing11. Switch AC power ON.12. Select Read Drive Parameters from the Communications menu in ULTRA Master.13. Select OK in the Drive Select dialog box. A dialog box indicating that the PC is reading drive parameters should appear...

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    Publication 1398-5.0 – October 1998Unpacking, Inspecting and Storing4-724. Choose Drive Enable and verify the motor shaft has holding torque. (i.e., The shaft cannot be moved or moves with resis-tance.)25. Open the connection between J1-26 and J1-20 to disable the drive. 26. Choose Close from t...

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    Publication 1398-5.0 – October 19984-8Unpacking, Inspecting and Storing

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    Publication 1398-5.0 – October 1998Chapter 5InstallationChapter 5Mechanical Installation Requirements1. Mount the unit in an enclosure providing protection to IP54 (pro-tected against dust and splashing water), or IP65 (dust free and protected against water jets) if the work environment is poor...

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    Publication 1398-5.0 – October 19985-2InstallationVibration and shock, altitude and humidity limits are:• Vibration: 2g at 10 to 2000 Hz• Shock: 15g 11 msec half sine• Altitude: 1500 meters (5000 feet), Derate power performance 3% for each 300 m above 1500 m (1000 ft above 5000 ft). • H...

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    Publication 1398-5.0 – October 1998Installation5-3Figure 5.11398-DDM Mounting Dimensions (sheet 1 of 2)IntroCAA8C1A2A3B1B2B3BKEY mm (in)1398-DDM-010 / 010X1398-DDM-020 / 020X1398-DDM-075,1398-DDM-030 / 030X1398-DDM-075XA360.6 (14.2)360.6 (14.2)A1332.7 (13.1)332.7 (13.1)A2349.3 (13.75)349.3 (13....

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    Publication 1398-5.0 – October 19985-4InstallationIntroFigure 5.11398-DDM Mounting Dimensions (sheet 2 of 2)BB5B4AB7CA2B1B61398-DDM-150 and 1398-DDM-150Xmm (in)A360.7(14.20)A1331.5(13.05)A2349.0(13.74)A36.86(0.27)A433.02(1.30A536.32(1.43)A626.92(1.06)A7196.09(7.72)A812.95(0.51)B203.20(8.00)B131...

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    Publication 1398-5.0 – October 1998Installation5-5Interface ConnectionsInput/output and power cables connect to the front panel of a ULTRA 200 Series drive, no internal connections are necessary. I/O Connections are fully described in the following sections:q 65,“J1 65,– 65,Controller”...

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    Publication 1398-5.0 – October 19985-6InstallationWiringWiring sizes and practices, as well as grounding and shielding techniques are described in the sections listed below. Refer to the 61,“Power 61, Wiring 61, Diagrams” on 61, page 61,5-11 for graphic depictions and recommended wire gag...

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    Publication 1398-5.0 – October 1998Installation5-7Allen-Bradley AC Line Filters An AC line filter is not required on the auxiliary line input, when it is used. Refer to 208, “Options and 208,Accessories” on 208, page 208,A-2 for part numbers. Mounting dimensions for single and three...

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    Publication 1398-5.0 – October 19985-8InstallationFigure 5.2MDF AC Line Filter Mounting DiagramsIntroIntroMDF Single-phaseA3A2A1C3C1C2B2B3BD1D2D3AB1MDF Three-phaseAB1BA1A2B2B3B4B5C1C2C3D1D2D3

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    Publication 1398-5.0 – October 1998Installation5-9 Table 5.2:MDF AC Line Filter DimensionsDIMENSIONSINGLE PHASE36 A and 50 ATHREE PHASE36 ATHREE PHASE50 ATHREE PHASE70 AmminmminmminmminA1746.852309.062309.062389.37A1104 (2)4.09 (2)110 (3)4.33 (3)110 (3)4.33 (3)150 (3)5.91 (3)A280 (2)3.15 ...

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    Publication 1398-5.0 – October 19985-10InstallationFigure 5.3MIF Single Phase AC Line Filter Mounting DiagramIntroTable 5.3:MIF AC Line Filter DimensionsDIMENSIONSINGLE PHASE10 ASINGLE PHASE23 AmminmminA2148.432148.43A1192 (2)7.56 (2)192 (2)7.56 (2)A211 (2)0.43 (2)11 (2)0.43 (2)B1455.712048.03B...

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    Installation5-11Publication 1398-5.0 – October 1998 51,5Installation Figure 5.4Power Wiring Diagrams (sheet 1 of 3)IntroBYECOREVDO NOT SCALE DRAWINGDIMENSIONS ARE IN INCHESBREAK ALL EDGES .02 MAXFILLETS AND ROUNDS .02 R MAXTOLERANCE ON:ANGLES ±1ANGLES ° FRACTIONS: ±1/64&quo...

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    5-12InstallationPublication 1398-5.0 – October 1998IntroFigure 5.4Power Wiring Diagrams (sheet 2 of 3)1398-DDM-075 or 1398-DDM-075XNOTE:

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    Installation5-13Publication 1398-5.0 – October 1998IntroFigure 5.4Power Wiring Diagrams (sheet 3 of 3)BYECOREVUNLESS OTHERWISE SPECIFIEDDO NOT SCALE DRAWINGDIMENSIONS ARE IN INCHESBREAK ALL EDGES .02 MAXFILLETS AND ROUNDS .02 R MAXTOLERANCE ON:ANGLES ±1ANGLES ° FRACTIONS: ±1...

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    5-14InstallationPublication 1398-5.0 – October 1998

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    Publication 1398-5.0 – October 1998Chapter 6InterfacesChapter 6This chapter provides information about:qInterface signals available on the ULTRA 200 Series drive qCommonly encountered interface cabling methods qOptional signal extension kits and standard Allen-Bradley cables.J1 – ControllerJ1...

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    Publication 1398-5.0 – October 19986-2InterfacesPin SignalDescriptionPin SignalDescriptionPin SignalDescription1 +5VDCEncoder +5V DC21 RESETFault Reset 41Reserved2 ECOMEncoder Common22 COMMAND+ Analog Command+42 OUTPUT1 Selectable Output 13 +5VDCEncoder +5V DC23 COMMAND-Analog Command-43 OUTPUT...

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    Publication 1398-5.0 – October 1998Interfaces6-3Digital I/O PowerULTRA 200 Series drives provide +24VDC and +5VDC to power external devices within the following specifications. 24 Volt I/O PowerOne isolated 24 Volt power supply is accessible from the connector: qThe allowable load is <500 mA...

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    Publication 1398-5.0 – October 19986-4InterfacesDigital InputsULTRA 200 Series drives have active high, current sinking inputs, which prevent disconnects and ground faults from activating a drive. Two discrete input circuits types are available on the J1 connector. Both circuits support log...

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    Publication 1398-5.0 – October 1998Interfaces6-5Refer to the I/O Configuration section of the ULTRA Master manual for information on choosing the input type for each channel. Table 6.3:General and Dedicated InputsDigital InputPin NumberFunction/DescriptionInternal ConnectionsENABLEJ1-20En...

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    Publication 1398-5.0 – October 19986-6InterfacesThe specifications for these inputs are as follows:Preset Select APreset Select BPreset Select CActivea or Inactiveb states select one of the eight presets shown in the follow-ing binary table: BINARY CODECBADescriptionPreset 0000Preset 0 or Index...

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    Publication 1398-5.0 – October 1998Interfaces6-7Input Interface Circuit Examples Figure 6.2Drive Input Connected to a Switch/Relay ContactIntroFigure 6.3Drive Input Connected to an Opto-IsolatorIntroFigure 6.4Drive Input Connected to an Active High Sourcing TransistorIntr...

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    Publication 1398-5.0 – October 19986-8InterfacesFigure 6.6Drive Input Connected to Active Low Output using an Opto-IsolatorIntroFigure 6.7Drive Input Connected to Sourcing OutputIntro(Drive)INPUTOUTPUT5K1K24VCOM24VCOM+24VDC24VCOM+24VDC1K5KINPUT(Drive)OUTPUT24VCOMJ1-6 or J1-13

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    Publication 1398-5.0 – October 1998Interfaces6-9Digital OutputsTwo types of discrete output circuits are available on the J1 connector:qDedicated relay outputsqSelectable transistor based outputs Both types support 24 VDC logic interfaces:Dedicated Relay OutputsBRAKE and DRIVE READY. Each outpu...

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    Publication 1398-5.0 – October 19986-10InterfacesSelectable Output Circuits Table 6.7:BRAKE Output SpecificationsParameterDescriptionMaximumON state resistanceInternal resistance between J1-49 (+) and J1-50 (-) when the contacts are closed. 1 OhmON state currentCurrent flow through the ...

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    Publication 1398-5.0 – October 1998Interfaces6-11Output Interface Circuit Examples Current LimitAn active state indicates the torque current is limited. Up To SpeedAn active state indicates the velocity loop AT SPEED signal is active. The at speed level is a selectable sett...

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    Publication 1398-5.0 – October 19986-12InterfacesFigure 6.11Drive Output Connected to an LED IndicatorIntroFigure 6.12Drive Output Connected to a Resistive LoadIntroFigure 6.13Drive Output Connected to a Switch/RelayIntro1K+24VDCPin 13Pin 6DriveJ124VCOMPin 13Pin 6DriveJ124VCOM+24VDC1KPin 13Pin ...

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    Publication 1398-5.0 – October 1998Interfaces6-13Figure 6.14Drive Output Connected to Active Low Input using a Switch/RelayIntroFigure 6.15Drive Output Connected to Active Low Input using an Opto-IsolatorIntroFigure 6.16Drive Output Connected to Active High (Sinking) InputIntroSolid StateRela...

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    Publication 1398-5.0 – October 19986-14InterfacesAnalog InputsTwo types of analog input circuits are available on the J1 connector:qThe current limiting inputs support 0 to +10 Volt signalsqThe command input supports 0 to ±10 Volt signals.Positive Current Limit (+I LIMIT) and Negative Current ...

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    Publication 1398-5.0 – October 1998Interfaces6-15Command Input The analog command signal to the drive has a range of ±10 Volts. The signal is either a torque, velocity or position command, depending on the software configuration of the drive. The differential input is processed by a 16 bit a...

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    Publication 1398-5.0 – October 19986-16InterfacesAnalog Outputs Two selectable outputs are available for monitoring by the user: ANALOG 1 (J1-30) and ANALOG 2 (J1-31). A 12 bit digital to analog converter (DAC) generates ANALOG 1. ANALOG 2 is a filtered PWM signal with 8 bit resolution and a ...

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    Publication 1398-5.0 – October 1998Interfaces6-17Motor Encoder Output Signals The motor quadrature encoder signals are supplied to an external position controller. The signals are differential, quadrature, and TTL level. The output resolution is selectable and can be divided by 1, 2, 4 or 8.T...

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    Publication 1398-5.0 – October 19986-18InterfacesFor example, a motor with a 2000 line encoder is rotating at 3000 rpm, and the Motor Encoder Output signal is set to Divide by 1, the encoder signal frequency is: A counter counting all edges registers 400 kHz for this example. fout3000 200...

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    Publication 1398-5.0 – October 1998Interfaces6-19Auxiliary Encoder Inputs The ULTRA 200 Series drive may be electronically geared by a remote signal. Electronic gearing may be driven by any of the following three signals: qA master incremental encoder that generates quadrature encoder signals ...

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    Publication 1398-5.0 – October 19986-20InterfacesThe input circuits shown in the following diagrams support connections to differential TTL line drivers, single-ended TTL line drivers and open collector devices. These inputs are selectable under software control. Table 6.19:Auxiliary Encoder/S...

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    Publication 1398-5.0 – October 1998Interfaces6-21Interface Cable ExamplesThe use of differential signals is highly recommended. This is due to the immunity of differential signals to common mode interference. Single-ended encoder interface circuits are not recommended, and may result in system ...

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    Publication 1398-5.0 – October 19986-22InterfacesFigure 6.25Complementary Encoder Interface via Standard TTL LogicFigure 6.26Single-Ended Encoder Interface via Open Collector Transistor without Pull-up (not recommended)Ch AAX+AX-1415twisted pairCh BBX+BX-1617twisted pairCh IIX+IX-1819twisted pa...

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    Publication 1398-5.0 – October 1998Interfaces6-23Figure 6.27Single-Ended Encoder Interface via Standard TTL Signals (not recommended)Figure 6.28Single-Ended Encoder Interface via Open Collector Transistor with 5 VDC to 12 VDC Pull-up (not recommended)twisted pairtwisted pairCh BENCODERBX+BX-16J...

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    Publication 1398-5.0 – October 19986-24Interfaces Figure 6.29Single-Ended Encoder Interface via Open Collector Transistor with 24 VDC Pull-up (not recommended)twisted pairtwisted pairCh AENCODERAX+AX-14J1DriveBX+BX-16Drive ChassisEncoder CaseCh B24VDC24VDC42SupplyReturnECOMIX+IX-18Ch I...

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    Publication 1398-5.0 – October 1998Interfaces6-25Figure 6.30External Step/Direction Interface via TTL Differential Line DriversFigure 6.31External Step/Direction Interface via Single-Ended TTL Line Drivers (not recommended)Figure 6.32External CW/CCW (Step Up/Step Down) Interface via TTL Differe...

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    Publication 1398-5.0 – October 19986-26InterfacesJ1 Terminal Strip/Breakout BoardA 50-pin terminal strip kit is available for extending the signals from the J1 connector. The kit includes a 1 meter (3-foot) interface cable, a 50-pin terminal strip and mounting hardware. Refer 207,to “Options...

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    Publication 1398-5.0 – October 1998Interfaces6-27 65,6InterfacesJ2 – Encoder J2 is a 20 pin female mini-D ribbon connector (AMP 2-178238-2). It connects the motor encoder, hall effect switches, and the thermostat to the ULTRA 200 Series drive. Contact between the connector shell and a ground...

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    Publication 1398-5.0 – October 19986-28Interfaces Figure 6.34Motor Encoder Interface CircuitIntroFigure 6.35Hall Effect Sensor CircuitIntro1K-+26LS33AM(-)1K220pFAM220pFAM(+)1K200.01uF1KLINEBREAKDETECTDriveJ2-+AM26C31200+2.5VU,1KDriveJ2+5VV orWTable 6.22:J2- Motor Encoder Connector Pin-OutsMo...

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    Publication 1398-5.0 – October 1998Interfaces6-29 HALL AJ2-13Hall Effect A sensor logic level input. Internally pulled up to +5VDC through a 1 kOhm resistor. The input signal interfaces to both a differential and single-ended Hall effect sensor, using either a TTL level signal or open collec...

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    Publication 1398-5.0 – October 19986-30InterfacesJ2 Terminal Strip/Breakout BoardA 25-pin terminal strip kit is available for extending the encoder signals from the J2 connector. The kit includes a 3-foot (1 meter) interface cable a 25-pin terminal strip, and mounting hardware. Refer to 207,...

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    Publication 1398-5.0 – October 1998Interfaces6-31 65,6InterfacesJ3 – Auxiliary Port J3 is a 26 pin female mini-D ribbon connector (AMP 2-178238-4). It duplicates the first 26 pins of J1, the Controller connector, which are discussed in detail beginning on 65, page 65,6-1. Contact between the...

  • Page 96

    Publication 1398-5.0 – October 19986-32InterfacesTable 6.23:J3 – Auxiliary Connector Pin-OutsMotor Encoder Pin NumberDescriptionInternal Connections+ 5VJ3-1 J3-3Encoder +5 VDC @ 250 mA power source for auxiliary encoder electronics. The output is fused internally by a 1 Amp fast acting fuse (...

  • Page 97

    Publication 1398-5.0 – October 1998Interfaces6-33BX+ and BX-, orDIR+ and DIR-, orCCW (Step Down+) and CCW (Step Down-)J3-16 (+)J3-17 (-)Auxiliary Channel B(+) and B(-). Differential, quadrature, or TTL level encoder input. The signals are selectable as BX+ and BX-, or DIR+ and DIR-, or CCW (Ste...

  • Page 98

    Publication 1398-5.0 – October 19986-34Interfaces 65,6InterfacesJ4 and J5 – Serial Port J4 and J5 are 9 pin female D-shell (AMP 205204-4, pins AMP 66506-3) connectors. Each connector is a serial interface that allows communication with another ULTRA 200 Series drive, a PC, a terminal, a host ...

  • Page 99

    Publication 1398-5.0 – October 1998Interfaces6-35qEven, odd, and no parity generation/checking are supported. No parity is the factory default setting.qThe maximum number of ULTRA 200 Series drives allowable on an RS-485 bus is 32.qThe maximum length of an RS-232 cable is 15 meters (50 feet).qT...

  • Page 100

    Publication 1398-5.0 – October 19986-36InterfacesSerial Communications OverviewULTRA 200 Series drives communicate via a standard NRZ (non-return to zero) asynchronous serial format, which supports either RS-232 or four wire RS-485. The pin-out arrangement on the drive serial ports provides sel...

  • Page 101

    Publication 1398-5.0 – October 1998Interfaces6-37Addressing Examples: qSetting the rotary switch to position 0 forces the drive to communicate using the factory default settings (refer to 100,Table 100,6.25). The drive ignores any software address assigned to it. However, the drive may be ass...

  • Page 102

    Publication 1398-5.0 – October 19986-38InterfacesRS-232 Connections The physical address is set using the 16 position rotary switch on the front panel. Single Axis RS-232 Set Up A single ULTRA 200 Series drive may be selected using RS-232 communications. After cabling is attached to the un...

  • Page 103

    Publication 1398-5.0 – October 1998Interfaces6-393. Verify the computer can communicate with the drive by perform-ing the following:• Switch drive power to ON• Start ULTRA Master on the attached PC• Choose CANCEL from the Drive Select window• Select Communications from the menu• Selec...

  • Page 104

    Publication 1398-5.0 – October 19986-40InterfacesFour Wire RS-485 Connections The ULTRA 200 Series drives use a variation of the RS-485 standard, known as four wire RS-485. Four wire RS-485 uses one differential signal for host to drive transmissions, and another differential signal for drive t...

  • Page 105

    Publication 1398-5.0 – October 1998Interfaces6-41Multiple Axes Four-Wire RS-485 Communications 1. Set the rotary address switch on each drive to an unassigned address:• If physical addressing is used, set the rotary switch to a previ-ously unused address (1-A).• If software addressing is...

  • Page 106

    Publication 1398-5.0 – October 19986-42InterfacesFour wire RS-485 connections are shown below. The cable diagram provides a wiring example of a daisy chain connection in a typical installation A multi-drop cable 107,(Figure 107,6.42) may also be used. Multiple axes systems may be control...

  • Page 107

    Publication 1398-5.0 – October 1998Interfaces6-43Figure 6.42RS-232 to RS-485 Multi-Drop Connection DiagramIntroPC* Pin-outs may vary by manufacturer.Drive 1RCV+ RCV- XMT+J41748XMT-COMRCV-RCV+XMT-XMT+Drive 2RCV+ RCV- XMT+J41748XMT-Drive nRCV+ RCV- XMT+J41748XMT-RS-232 toRS-485 Adapter.......CO...

  • Page 108

    Publication 1398-5.0 – October 19986-44Interfaces 65,6InterfacesA1, A2, and COM – Analog Outputs Analog outputs may be monitored with external equipment, such as an oscilloscope, on the external output pins A1 (ANALOG 1), A2 (ANALOG 2) and COM (COMMON). These output signals are parallel conne...

  • Page 109

    Publication 1398-5.0 – October 1998Interfaces6-45Interface ConnectionsShown here are typical components and connections for a ULTRA 200 Series drive. Figure 6.441398-DDM Interface Connection DiagramIntro

  • Page 110

    Publication 1398-5.0 – October 19986-46Interfaces

  • Page 111

    Publication 1398-5.0 – October 1998Chapter 7Power ConnectionsChapter 7TB1 – DC Bus and AC Power Refer 61,to Figure 61,5.4 on 61, page 61,5-11 for power wiring connection diagrams for the drives. DescriptionIdentifier1398-DDM-010 and 1398-DDM-010X1398-DDM-020 and 1398-DDM-020X1398-DDM-030...

  • Page 112

    Publication 1398-5.0 – October 19987-2Power ConnectionsThe 1398-DDM-075 and 1398-DDM-075X are rated for either single phase or three phase power inputs. When connected to a single phase input, the user must change the current limits of the drive. The following drive parameters must be set:qPosi...

  • Page 113

    Publication 1398-5.0 – October 1998Power Connections7-3Motor Power Cabling Terminals 1 through 4 connect the drive to the windings of the motor. 113,Table 113,7.1 113, lists the drive terminals and typical motor connections; 115,Table 115,7.2 lists the minimum wire size for making power wir...

  • Page 114

    Publication 1398-5.0 – October 19987-4Power ConnectionsY-Series Power CablesY-Series motors have a short “pigtail” cable which connects to the motor but is not shielded. The motor power cables have a 6 inch shield termination wire with a ring lug which should be connected to the closest ear...

  • Page 115

    Publication 1398-5.0 – October 1998Power Connections7-5Motor Overload ProtectionThe drive utilizes solid state motor overload protection which operates:qwithin 8 minutes at 200% overload qwithin 20 seconds at 600% overload Table 7.2:Motor Power Contact and Wire Sizing RecommendationsMotorMotor ...

  • Page 116

    Publication 1398-5.0 – October 19987-6Power ConnectionsEmergency Stop WiringAn overlapping contactor may be inserted between the motor and the drive for emergency stop purposes. The contactor must not simply break the motor current, it also must switch a three phase resistive load in parallel w...

  • Page 117

    Publication 1398-5.0 – October 1998Power Connections7-7AC Power CablingThe ULTRA 200 Series drives require 100 to 240 VAC rms power with an input frequency of 47 - 63 Hz. The 1398-DDM-010, 1398-DDM-010X, 1398-DDM-020, 1398-DDM-020X, 1398-DDM-030 and 1398-DDM-030X require single phase input powe...

  • Page 118

    Publication 1398-5.0 – October 19987-8Power ConnectionsTerminals 7, 8 and 9 are the single phase AC input power connections for the 1398-DDM-010, 1398-DDM-010X, 1398-DDM-020, 1398-DDM-020X, 1398-DDM-030 and 1398-DDM-030X. Terminals 7, 8, 9 and 10 are the three phase AC input power connections f...

  • Page 119

    Publication 1398-5.0 – October 1998Power Connections7-9The inputs to the main (logic and motor supply) and the auxiliary (logic supply only) power sources are separated. This permits independent powering of the control power and the motor power. This dual power sourcing is useful for troublesho...

  • Page 120

    Publication 1398-5.0 – October 19987-10Power ConnectionsThe inputs to the main (logic and motor supply) and the auxiliary (logic supply only) power sources are separated. This permits the logic power to operate independently of the motor. This dual power sourcing is useful for troubleshooting a...

  • Page 121

    Publication 1398-5.0 – October 1998Power Connections7-11TB2 – Shunt Regulator The ULTRA 200 Series drive has a built-in shunt regulator. The figure depicts the internal shunt selection with a factory installed jumper between terminals TB-1 and TB-2. Removal of the internal shunt jumper and in...

  • Page 122

    Publication 1398-5.0 – October 19987-12Power Connections If the application requires a higher continuous power dissipation, the ULTRA 200 Series provides easy access to an external shunt connection. Connecting an external resistor requires disabling of the internal shunt resistor 123,. Figur...

  • Page 123

    Publication 1398-5.0 – October 1998Power Connections7-13Table 7.11:Minimum Ratings for Customer Supplied External Shunt ResistorDrive Model1398-DDM-010,1398-DDM-010X1398-DDM-020,1398-DDM-020X1398-DDM-030,1398-DDM-030X1398-DDM-075,1398-DDM-075X1398-DDM-150,1398-DDM-150XMinimum Resistance ± 10% ...

  • Page 124

    Publication 1398-5.0 – October 19987-14Power ConnectionsExternal Shunt ConnectionThe following procedure outlines the installation of an external shunt resistor.1. Remove jumper between TB1-1 and TB1-2, the internal shunt connection. The jumper is supplied with the drive.2. Wire an external shu...

  • Page 125

    Publication 1398-5.0 – October 1998Chapter 8Application and Configuration ExamplesChapter 8This section explains how to install and verify the ULTRA 200 Series drive for various modes of operation. The procedures verify the installation by:qShowing how the power and logic wiring is connected. q...

  • Page 126

    Publication 1398-5.0 – October 19988-2Application and Configuration Examples5. Connect a jumper wire with a toggle switch between the follow-ing pins:• J1-20 (ENABLE) and J1-26 (I/O PWR)• J1-21 (FAULT RESET) and J1-26 (I/O PWR). These connections provide manual control for enabling or disab...

  • Page 127

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-3ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (Analog, Fol-lower or Pr...

  • Page 128

    Publication 1398-5.0 – October 19988-4Application and Configuration Examples9. If the message box appears that a motor must be selected, select OK. The Drive Set Up window is displayed with Motor Model selection parameter active. The motor may be selected from the drop down box. If this message...

  • Page 129

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-55. Close the toggle switch between J1-26 and J1-20 to enable the drive. 6. Choose Start from the Tuning window. The drive powers the motor shaft for a short period and then motion will cease. Then ULTRA Master display...

  • Page 130

    Publication 1398-5.0 – October 19988-6Application and Configuration Examples 125,8Application and 125, Configuration ExamplesPreset ControllerThe ULTRA 200 Series drive can be set up as a preset controller in the Velocity or Torque mode by making the connections described below. Three discrete ...

  • Page 131

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-73. Connect a Power cable from the motor to TB1 (terminals R, S, T and ) on the drive. 4. Connect a jumper wire with a toggle switch between the follow-ing pins:• J1-20 (ENABLE) and J1-26 (I/O PWR)• J1-32 (INPUT1) an...

  • Page 132

    Publication 1398-5.0 – October 19988-8Application and Configuration ExamplesConnection Diagram ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (Ana...

  • Page 133

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-9• If the settings are different, correct the Port – Settings to allow communications with the drive. Factory default communications Port – Settings for the drive are: – Baud Rate: 9600– Data Bits: 8– Parity:...

  • Page 134

    Publication 1398-5.0 – October 19988-10Application and Configuration Examples16. Choose Close to exit the Drive Parameters window. 17. Select the I/O Configuration command icon from the Drive win-dow. 18. Assign one of the three Preset Selects (A, B and C) to each of the Digital Input Assignmen...

  • Page 135

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-115. Close the toggle switch between J1-26 and J1-20 to enable the drive. 6. Choose Start from the Tuning window. The drive powers the motor shaft for a short period and then motion will cease. Then ULTRA Master displa...

  • Page 136

    Publication 1398-5.0 – October 19988-12Application and Configuration Examples 125,8Application and 125, Configuration ExamplesPosition Follower (Master Encoder)The ULTRA 200 Series can be electronically geared to a master incremental encoder generating quadrature encoder signals by making the h...

  • Page 137

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-13Connection Diagram ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (An...

  • Page 138

    Publication 1398-5.0 – October 19988-14Application and Configuration Examples5. Verify the communications port settings of the PC match those of the drive. • If the settings are correct, select OK in the Port – Settings dia-log box.• If the settings are different, correct the Port – Set...

  • Page 139

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-1516. Choose Close to exit the Drive Parameters window. 17. Verify the Status indicator is green.18. Select the I/O Configuration command icon from the Drive Win-dow. 19. Select an appropriate digital input from the pull...

  • Page 140

    Publication 1398-5.0 – October 19988-16Application and Configuration Examples7. Choose Normal Drive Operation from the Tuning window.8. Open the switch between J1-26 and J1-20 to disable the drive. 9. Choose Close to exit the Tuning window.10. Close any open windows or dialog boxes.OperationThe...

  • Page 141

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-17 125,8Application and 125, Configuration ExamplesPosition Follower (Step/Direction)The ULTRA 200 Series drive can be set up as a Position Follower using Step/Direction commands by making the hardware connections and pe...

  • Page 142

    Publication 1398-5.0 – October 19988-18Application and Configuration Examples6. Connect the drive to a 100/240 VDC, 50/60 Hz power source appropriate to the drive: • Single Phase: 1398-DDM-010, 1398-DDM-010X, 1398-DDM-020, 1398-DDM-020X, 1398-DDM-030, 1398-DDM-030X, 1398-DDM-075 or 1398-DDM-0...

  • Page 143

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-192. Start ULTRA Master on the PC. 3. Choose Cancel from the Drive Select dialog box. 4. Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer’s communica-tion settings.5. Verif...

  • Page 144

    Publication 1398-5.0 – October 19988-20Application and Configuration Examples14. Choose the Drive Parameters command icon from the Drive window and then select the Follower tab. 15. Enter an appropriate Gear Ratio as the Follower Input. The default Gear Ratio is 1:1 (motor encoder pulses:master...

  • Page 145

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-215. Close the toggle switch between J1-26 and J1-20 to enable the drive. 6. Choose Start from the Tuning window. The drive powers the motor shaft for a short period and then motion will cease. Then ULTRA Master displa...

  • Page 146

    Publication 1398-5.0 – October 19988-22Application and Configuration Examples 125,8Application and 125, Configuration ExamplesPosition Follower (Step Up/Step Down)The ULTRA 200 Series can be set up as a Position Following using Step Up and Step Down signals typically used to control stepper dri...

  • Page 147

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-23Connection Diagram ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (A...

  • Page 148

    Publication 1398-5.0 – October 19988-24Application and Configuration Examples5. Verify the communications port settings of the PC match those of the drive. • If the settings are correct, select OK in the Port – Settings dia-log box.• If the settings are different, correct the Port – Set...

  • Page 149

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-2516. Choose Close to exit the Drive Parameters window. 17. Select the I/O Configuration command icon from the Drive Win-dow. 18. Select an appropriate digital input from the pull-down lists avail-able as Digital Input A...

  • Page 150

    Publication 1398-5.0 – October 19988-26Application and Configuration Examples8. Open the switch between J1-26 and J1-20 to disable the drive. 9. Choose Close to exit the Tuning window. 10. Close any open windows or dialog boxes. OperationThe drive is now configured as either a Position Follower...

  • Page 151

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-27 125,8Application and 125, Configuration ExamplesIncremental Indexing The ULTRA 200 Series drive can be set up as a incremental indexer by making the hardware connections and performing the software setup and tuning d...

  • Page 152

    Publication 1398-5.0 – October 19988-28Application and Configuration ExamplesHardware SetupMake the connections described below and shown in th 153,e Figure 153,8.7. The appendix 207,“Options and Accessories 207,” 207, on page 207,A-1 lists the interconnect cables available from the fact...

  • Page 153

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-29Connection Diagram ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (An...

  • Page 154

    Publication 1398-5.0 – October 19988-30Application and Configuration Examples5. Verify the communications port settings of the PC match those of the drive. • If the settings are correct, select OK in the Port – Settings dia-log box.• If the settings are different, correct the Port – Set...

  • Page 155

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-3115. Enter the following values for Index 0. Refer to 151, “Incremental 151, 151,Indexing Examples” 151, on page 151,8-27 for examples of Single and Batched Incremental Indexing profiles. 16. Choose Close to exi...

  • Page 156

    Publication 1398-5.0 – October 19988-32Application and Configuration Examples5. Close the toggle switch between J1-26 and J1-20 to enable the drive. 6. Choose Start from the Tuning window. The drive powers the motor shaft for a short period and then motion will cease. Then ULTRA Master displa...

  • Page 157

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-33 125,8Application and 125, Configuration ExamplesRegistration Indexing The ULTRA 200 Series drive can be set up as a registration indexer by making the hardware connections and performing the software setup and tuning...

  • Page 158

    Publication 1398-5.0 – October 19988-34Application and Configuration ExamplesHardware SetupMake the connections described below and shown in th 159,e Figure 159,8.9. The appendix 207,“Options and Accessories 207,” 207, on page 207,A-1 lists the interconnect cables available from the fact...

  • Page 159

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-35Connection Diagram ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (...

  • Page 160

    Publication 1398-5.0 – October 19988-36Application and Configuration Examples5. Verify the communications port settings of the PC match those of the drive. • If the settings are correct, select OK in the Port – Settings dia-log box.• If the settings are different, correct the Port – Set...

  • Page 161

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-3715. Enter the following values for Index 0. 16. Choose Close to exit the Drive Parameters window. 17. Select I/O Configuration command icon from the Drive Window. 18. Select an appropriate digital input from the pu...

  • Page 162

    Publication 1398-5.0 – October 19988-38Application and Configuration Examples5. Close the toggle switch between J1-26 and J1-20 to enable the drive. 6. Choose Start from the Tuning window. The drive powers the motor shaft for a short period and then motion will cease. Then ULTRA Master displa...

  • Page 163

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-39 125,8Application and 125, Configuration ExamplesAbsolute Indexing The ULTRA 200 Series drive can be set up as a absolute indexer by making the hardware connections and performing the software setup and tuning describe...

  • Page 164

    Publication 1398-5.0 – October 19988-40Application and Configuration Examples4. Connect a jumper wire with a toggle switch between the follow-ing pins:• J1-20 (ENABLE) and J1-26 (I/O PWR)• J1-32 (INPUT1) and J1-26 (I/O PWR)• J1-33 (INPUT2) and J1-26 (I/O PWR)• J1-21 (FAULT RESET) and J1...

  • Page 165

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-41ConfigurationCarefully check all connections before entering these parameters.1. Switch the AC Power to ON and verify:• green DC BUS LED is ON• display shows an operational status: A, F or P (Analog, Fol-lower or P...

  • Page 166

    Publication 1398-5.0 – October 19988-42Application and Configuration Examples9. If the message box appears that a motor must be selected, select OK. The Drive Setup window is displayed with Motor Model selection parameter active. The motor may be selected from the drop down box. If this message...

  • Page 167

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-43Tuning 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune com-mands: • Distance and• Step Current. ...

  • Page 168

    Publication 1398-5.0 – October 19988-44Application and Configuration ExamplesOperationThe drive is now configured as a Absolute Indexing controller. qThe servo parameters have been setup with the unloaded motor. qMotion is commanded through the inputs. The firmware saves the parameters in EEPRO...

  • Page 169

    Publication 1398-5.0 – October 1998Application and Configuration Examples8-45 125,8Application and 125, Configuration ExamplesModifying User UnitsThe units displayed for any ULTRA 200 Series drive may be modified using a PC with ULTRA Master software. The PC Display Units help menu defines the ...

  • Page 170

    Publication 1398-5.0 – October 19988-46Application and Configuration Examples5. Select the Acceleration Conversion Factor cell, and change 1. to .016. Mathematically 1.6 x 10-2 revs/sec2 is 1 RPM/sec, given the motor has a 2000 line (8000 count) encoder. 6. Choose OK to exit the PC Display Unit...

  • Page 171

    Publication 1398-5.0 – October 1998Chapter 9TuningChapter 9ULTRA 200 Series drives are tuned quickly and easily for a wide variety of applications. Two tuning modes are available through the software:qAuto TuneqManual Tune Tuning GuidelinesThe following tuning guidelines briefly describe the tu...

  • Page 172

    Publication 1398-5.0 – October 19989-2TuningMechanical ResonanceMechanical resonance between the motor and the load occurs when the motor and load are oscillating with the same frequency but opposite phase: when the motor is moving clockwise the load is moving counter clockwise. The amplitude o...

  • Page 173

    Publication 1398-5.0 – October 1998Tuning9-3BacklashBacklash between the motor and load effectively unloads the motor over a small angle. Within this small angle, the increased bandwidth can result in oscillations. Some backlash may be unavoidable, especially with gear reduction. If backlash is...

  • Page 174

    Publication 1398-5.0 – October 19989-4TuningAuto Tune ModeThe Auto Tune mode uses a “self-tuning” algorithm that automatically adjusts the drive’s velocity loop gain parameters. Adjustments do not require special equipment. This mode will tune a drive for constant velocity loop response a...

  • Page 175

    Publication 1398-5.0 – October 1998Tuning9-51. Choose the Tuning command icon from the Drive window. 2. Choose Auto Tune from the Tuning window. This activates the Auto Tune Command and Motor Direction boxes within the Tun-ing window. Then enter or select:• appropriate values for Distance in ...

  • Page 176

    Publication 1398-5.0 – October 19989-6TuningManual Tune ModeManual tuning may be used to adjust the gain settings and filter frequency of the velocity regulator. The following sections briefly explain these settings. An understanding of the function for each type of gain and filtering will allo...

  • Page 177

    Publication 1398-5.0 – October 1998Tuning9-7FiltersThe velocity regulator has one low pass filter. The filter bandwidth range is from 1 Hz to 992 Hz. The filter serves two purposes:qAdjust the frequency range to remove (filter) the noise produced by encoder resolution. qReduce the amount of the...

  • Page 178

    Publication 1398-5.0 – October 19989-8TuningManual Tuning Manual tuning may be used to adjust the gain control parameters P, I, D and the filters. A square wave is generated by the drive to assist in the adjustment. Manual velocity tuning requires the following:qStep Period value to be specifie...

  • Page 179

    Publication 1398-5.0 – October 1998Tuning9-914. Disable the drive. 15. Choose Normal Drive Operation. 16. Choose Close. 17. Enable the drive. The drive’s velocity loop is tuned. Tuning the Position LoopSpecify the step period and step position values, and then input a square wave to the posit...

  • Page 180

    Publication 1398-5.0 – October 19989-10Tuning17. Enable the drive. The position loop has been tuned. The drive may be operated as a master encoder, step/direction or step up/down configuration.Velocity Loop Tuning Examples Figure 9.3Signal NomenclatureIntroTransient StateVELOCITYTI...

  • Page 181

    Publication 1398-5.0 – October 1998Tuning9-11Figure 9.4Underdamped SignalIntroFigure 9.5Overdamped SignalIntroUNDERDAMPED Decrease P-gain Decrease I-gainMotor Velocity consistently overshootsthe Velocity Command. To correct:OVERDAMPED Increase I-gainMotor Velocity consistently under...

  • Page 182

    Publication 1398-5.0 – October 19989-12TuningFigure 9.6Critically Damped Signal (Ideal Tuning)IntroCRITICALLY DAMPEDMotor Velocity quickly settles tothe Velocity Command.

  • Page 183

    Publication 1398-5.0 – October 1998Chapter 10Status DisplayChapter 10Two front panel indicators display the status of the drive on a continuous basis:qThe Status display shows the operating mode of the drive. qThe DC Bus LED lights whenever the bus is energized. The 7-segment Status display ind...

  • Page 184

    Publication 1398-5.0 – October 199810-2Status DisplayError MessagesIf there is a fault, the drive provides specific error messages. Faults are detected by the drive in two ways: power-up hardware and run-time faults. A power-up fault usually requires servicing of the hardware, while a run-time ...

  • Page 185

    Publication 1398-5.0 – October 1998Status Display10-3Power-Up Error CodesA power-up error indicates in almost all cases that the drive should be returned to the factory for service. In general, any occurrence of a Power-up error should be treated with extreme caution. It may indicate the hardwa...

  • Page 186

    Publication 1398-5.0 – October 199810-4Status DisplayTable 10.2:Power-Up Error CodesStatus DisplayError CodeFault DescriptionE....5....151Program Memory Boot Block ErrorE....5....252Program Memory Main Block ErrorE....5....353Uninitialized Personality EEPROM ErrorE....5....454Personality EEPROM...

  • Page 187

    Publication 1398-5.0 – October 1998Status Display10-5E....7....9....n79-nPersonality Data Out of Rangewhere n = suberror parameter 1 - Serial baud rate selection 2 - Serial stop bits/parity selection 3 - Position Loop Kp 4 - Position Loop Ki 5- Position Loop Kff 6 - Position Loop Kd 7 - G...

  • Page 188

    Publication 1398-5.0 – October 199810-6Status Display

  • Page 189

    Publication 1398-5.0 – October 1998Chapter 11Maintenance and TroubleshootingChapter 11MaintenanceThe ULTRA 200 Series drive is designed to function with minimum maintenance. Periodic MaintenanceNormally the only maintenance required is removal of superficial dust and dirt from the drive and a q...

  • Page 190

    Publication 1398-5.0 – October 199811-2Maintenance and TroubleshootingEEPROM Personality ModuleThe serial EEPROM, or personality module, stores all the drive setup parameters. The setup parameters configure the drive to match a particular motor and operate in a particular mode of operation. The...

  • Page 191

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-35. Align the notch on the front of the personality module and the matching notch on the socket. 6. Place the properly orientated personality module in the IC chip insertion tool. Ensure the chip and socket notches are aligned...

  • Page 192

    Publication 1398-5.0 – October 199811-4Maintenance and Troubleshooting7. Select the drive to be configured, and then press ENTER or choose OK to load the parameters into the personality module. Figure 11.1Fuse and Jumper LocationsIntro+24VDC+5VDCENCODERRemove JUMPERS P6 and P5to power I/O ci...

  • Page 193

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-5Firmware UpgradingULTRA 200 Series drives may be upgraded in the field to the latest version of firmware. Firmware versions are available from the Allen-Bradley Product Support group. The procedure describes how to reload the...

  • Page 194

    Publication 1398-5.0 – October 199811-6Maintenance and TroubleshootingTroubleshootingTwo front panel indicators display the status of the drive on a continuous basis:qThe Status display indicates the operating mode of the drive (A, F, P, etc.). qThe DC Bus LED lights whenever the main AC input ...

  • Page 195

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-7+5V Fuse Blown02F2 BlownThe fuse on the encoder power output for the +5 VDC power supply has tripped.Check/replace fuse F2 if necessary.Check for shorts on Encoder output signals or +5V output. Check that J4 pin 9 or J5 pin 9...

  • Page 196

    Publication 1398-5.0 – October 199811-8Maintenance and TroubleshootingChannel BM line07Bad connectionsVerify continuity of the encoder cable and connec-tors.Verify continuity of the BM+ and BM- wiring signals.Bad EncoderReplace the motor or the encoder. Channel AM line08Bad connectionsVerify co...

  • Page 197

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-9Excessive Average Current17Excessive time at peak cur-rentReduce acceleration ratesReduce duty cycle (ON/OFF) of commanded motion. Increase time permitted for motion.User larger drive and motor.Software parameter set too lowI...

  • Page 198

    Publication 1398-5.0 – October 199811-10Maintenance and TroubleshootingAuxiliary Encoder state error21Auxiliary encoder encoun-tered an illegal transitionUse shielded cables with twisted pair wires.Route the encoder cable away from potential noise sources.Bad encoder - replace encoderCheck the ...

  • Page 199

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-11RS-232 Communication TestThis test verifies the functionality of the communications port on an MS-DOS® based personal computer.The test uses the Terminal mode available in Microsoft® Windows™. 1. Close all ULTRA Master w...

  • Page 200

    Publication 1398-5.0 – October 199811-12Maintenance and TroubleshootingA. If you see the character on the screen swap pins 2 and 3, close the Windows Terminal and restart ULTRA Master.B. If the character does not echo back on the screen, do the following:(a) Disconnect the cable from your PC.(b...

  • Page 201

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-13B. Brake Enable box, then measure the resistance between J1-49 and J1-50.(a) If the box is checked, the resistance should read approximately 1Ohm.(b) If the box is not checked, the resistance should be very high (> 1 MOhm...

  • Page 202

    Publication 1398-5.0 – October 199811-14Maintenance and TroubleshootingTesting Digital InputsThis test verifies the functionality of the selectable inputs. Test equipment requirements are: qA PC running ULTRA Master qA jumper wire. It assumes there are no error codes displayed, and the 24V powe...

  • Page 203

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-156. Repeat step 202,11.1 202, using different positive or negative values for the D/A Level. Verify the meter reads the values you enter.Testing Analog Output 21. Disable the drive, by opening the connections between the ENA...

  • Page 204

    Publication 1398-5.0 – October 199811-16Maintenance and Troubleshooting8. Choose OK to close the Set Up window and activate the Drive Signals window. 9. Slowly adjust the potentiometer while viewing the Drive Signals window. The Current - Input Limit + value should update as the potentiometer i...

  • Page 205

    Publication 1398-5.0 – October 1998Maintenance and Troubleshooting11-17Testing Encoder InputsThe following test verifies both reception and transmission of the line count from an encoder by the drive. The tests require:qa PC running ULTRA Master, and qa motor encoder. To test encoder inputs: 1....

  • Page 206

    Publication 1398-5.0 – October 199811-18Maintenance and Troubleshooting

  • Page 207

    Publication 1398-5.0 – October 1998Appendix AOptions and Accessories Appendix AULTRA 200 Series drives conformance to the European Union Directives is contingent on:qInstallation of AC line filters between the power source and the drive, and qUse of Allen-Bradley cables to connect F-, H-, N- or...

  • Page 208

    Publication 1398-5.0 – October 1998A-2Options and AccessoriesFusesOptions and AccessoriesDescriptionPart Number1 Ampere, fast acting, inline (Littelfuse R451001, or equivalent) for 1398-DDM-010 or 1398-DDM-010X, 1398-DDM-020 or 1398-DDM-020X, 1398-DDM-030 or 1398-DDM-030X, 1398-DDM-075 or 1398-...

  • Page 209

    Publication 1398-5.0 – October 1998Options and AccessoriesA-3Publications Interface CablesDiagrams and schematics for cables listed below are shown in Appendix B, “Interface Cables”, beginning on page B-3. Serial Interface CablesDiagrams and schematics for cables listed below are shown i...

  • Page 210

    Publication 1398-5.0 – October 1998A-4Options and AccessoriesEncoder Feedback CablesDiagrams and schematics for cables listed below are shown in Appendix B, “Interface Cables”, beginning on page B-14.Descriptionm (ft)Part NumberF- or H-Series Motor to customer supplied connector (i.e., no c...

  • Page 211

    Publication 1398-5.0 – October 1998Options and AccessoriesA-5Motor Power CablesDiagrams and schematics for cables listed below are shown in Appendix B, “Interface Cables”, beginning on page B-21.Descriptionm (ft)Part NumberDrive to 2000 or 3000 Motors (F- or H-Series)(ULTRA 200 Series drive...

  • Page 212

    Publication 1398-5.0 – October 1998A-6Options and AccessoriesConnector KitsConnector kits provide the ability to construct custom length cables. Kits are available for all ULTRA 200 Series connectors. Each kits consists of the appropriate 3M connector with the corresponding plastic backshell, a...

  • Page 213

    Publication 1398-5.0 – October 1998Appendix BCable Diagrams, Schematics and ExamplesAppendix BFactory supplied cables allow ULTRA 200 Series drives to conform to the European Union Directives when connecting the drive to motors, controllers or computers. The following diagrams provide informati...

  • Page 214

    Publication 1398-5.0 – October 1998B-2Cable Diagrams, Schematics and ExamplesqAlternate field wiring diagram for F-, H-, or N-Series encoder cables is shown below:

  • Page 215

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-3Interface Cables Figure B.1J1 to J3 Interface Cable (P/N 9101-1367)IntroH6SF@9 XDUCQ6SU Æ 6I9 S@W H6IVA68UVS@STQ6SU Æ S@W 6I9 96U@ 8P9@$$!!' #%%R&$$$"#!! %'$$%R $' $&0 [ 5(75$&7$%/(0$&+,1...

  • Page 216

    Publication 1398-5.0 – October 1998B-4Cable Diagrams, Schematics and ExamplesFigure B.2J1 to No Connector Interface Cable (P/N 9101-1370)Intro7$%

  • Page 217

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-5Figure B.3J3 to J3 Interface Cable (P/N 9101-1463)Intro

  • Page 218

    Publication 1398-5.0 – October 1998B-6Cable Diagrams, Schematics and ExamplesB 213,Cable 213, Diagrams, Sch 213,ematics 213, and Examples Figure B.4J3 to No Connector Interface Cable (P/N 9101-1368)Intro7$%

  • Page 219

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-7 Figure B.5J1 to 50-pin Terminal Block Kit Diagram (P/N 9101-1391 and 9101-1560)IntroMounting bracket 0002-7069 (shown) and cable 9101-1369-003 supplied with 9101-1391 kit.Mounting bracket 0002-7069 (shown) and cable ...

  • Page 220

    Publication 1398-5.0 – October 1998B-8Cable Diagrams, Schematics and ExamplesFigure B.6J1 to 50-pin D-Connector Cable (P/N 9101-1369)Intro

  • Page 221

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-9Figure B.7J2 to 25-pin Terminal Block Kit Diagram (P/N 9101-1392)IntroMounting bracket 0002-7068 (shown) and cable 9101-1371-003 (next page) supplied with kit.NOTES: The terminal block and cable provide a one-to-one tr...

  • Page 222

    Publication 1398-5.0 – October 1998B-10Cable Diagrams, Schematics and ExamplesFigure B.8J2 to 25-pin D-Connector Cable (P/N 9101-1371)Intro0.38

  • Page 223

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-11B 213,Cable 213, Diagrams, Sch 213,ematics 213, and ExamplesSerial Interface Cables Figure B.9J5 to 9-pin D-Shell Interface Diagram (P/N 9101-1372)IntroREDGREENBLACKWHITE/REDWHITE/GREENWHITE/BLACK

  • Page 224

    Publication 1398-5.0 – October 1998B-12Cable Diagrams, Schematics and ExamplesFigure B.10J5 to J5 Serial Interface Cable (P/N 9101-1374)Intro

  • Page 225

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-13Figure B.11J5 to No Connector Serial Interface Cable (P/N 9101-1379)Intro

  • Page 226

    Publication 1398-5.0 – October 1998B-14Cable Diagrams, Schematics and ExamplesB 213,Cable 213, Diagrams, Sch 213,ematics 213, and ExamplesEncoder Feedback Cables Figure B.12F- or H-Series Motors to No Connector Encoder Cable (P/N 9101-1365)Intro

  • Page 227

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-15 Figure B.13J2 to F- or H-Series Encoder Cable (P/N 9101-1366)Intro

  • Page 228

    Publication 1398-5.0 – October 1998B-16Cable Diagrams, Schematics and ExamplesFigure B.14J2 to Y-Series Encoder Cable (P/N 9101-1375)Intro0.38GRAY 16 AWGWHITE/GRAY 16 AWGWHITE/BROWN 28 AWGBROWN 28 AWGWHITE/BLACK 28 AWGBLACK 28 AWGWHITE/RED 28 AWGREDK 28 AWGWHITE/GREEN 28 AWGGREEN 28 AWGWHITE/OR...

  • Page 229

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-17Figure B.15No Connector to Y-Series Encoder Cable (P/N 9101-1373)IntroH6SF@9 XDUCQ6SU Æ 6I9 S@W H6IVA68UVS@STQ6SU Æ S@W 6I9 96U@ 8P9@(7@I9 S69DVT 02/',1*TU6SU PA 326,7,21 &3& 6+(// 6,=( :,7+ )(0$/( 62&....

  • Page 230

    Publication 1398-5.0 – October 1998B-18Cable Diagrams, Schematics and ExamplesFigure B.16J2 to No Connector Encoder Cable (P/N 9101-1380)Intro0.38WHITE/GRAY (16 AWG)GRAY (16 AWG)BLUE (28 AWG)RED (28 AWG)BLACK (28 AWG)GREEN (28 AWG)YELLOW (28 AWG)ORANGE (28 AWG)BROWN (28 AWG)VIOLET (28 AWG)WHITE...

  • Page 231

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-19Figure B.17J2 to N-Series Encoder Cable (P/N 9101-1468)IntroFGPRVSLUKHJTNCDEBAMKPSE05E14-19S-A71 CONNECTOR(FACE VIEW)WIRING DIAGRAMN/CNN/CPN/CCONNECTOR BACKSHELL SHIELDED 360° (BOTH ENDS)ORANGE 28 AWGVIOLET 28 AWGW...

  • Page 232

    Publication 1398-5.0 – October 1998B-20Cable Diagrams, Schematics and ExamplesFigure B.18No Connector to N-Series Encoder Cable (P/N 9101-1469)IntroNN/CPN/CTRULM20 AWG20 AWGN/CKJVHGFE20 AWG20 AWGCONNECTOR BACKSHELL SHIELDED 360°WHITE/BLUE 28 AWGWHITE/BROWN 28 AWGWHITE/VIOLET 28 AWGWHITE/GRAY 1...

  • Page 233

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-21B 213,Cable 213, Diagrams, Sch 213,ematics 213, and ExamplesMotor Power Cables !IntroATTENTION: Shielded power cables must be grounded at a minimum of one point for safety. Failure to ground a shielded ...

  • Page 234

    Publication 1398-5.0 – October 1998B-22Cable Diagrams, Schematics and Examples Figure B.204000 F- or H-Series Power Cable (P/N 9101-1382)IntroFigure B.216100 or 6200 F- or H-Series Power Cable (P/N 9101-1383)IntroH6SF@9 XDUCQ6SU Æ 6I9 S@W H6IVA68UVS@STQ6SU Æ S@W 6I9 96U@ 8P9@$'&%( ...

  • Page 235

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-23Figure B.226300 H-Series Power Cable (P/N 9101-1399)IntroFigure B.238000 H-Series Power Cable (P/N 9101-1384)Intro

  • Page 236

    Publication 1398-5.0 – October 1998B-24Cable Diagrams, Schematics and Examples Figure B.24Y-Series Power Cable (P/N 9101-1385)Intro

  • Page 237

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-25Figure B.25N-Series Power Cable (P/N 9101-1467)Introø1.16MOLDING ADAPTER, ALUMINUM,BLACK COBALT PLATEDCONNECTOR, ITT CANNON#KPSE05E14-5S-A71GLUE SHRINKRSTGRN/YELBROWNBLACKBLUECABLE, SINE #KA-50960,ULTI-MAX 90°C 600 ...

  • Page 238

    Publication 1398-5.0 – October 1998B-26Cable Diagrams, Schematics and ExamplesB 213,Cable 213, Diagrams, Sch 213,ematics 213, and ExamplesCabling Examples Figure B.26F or H-Series Motors to ULTRA 200 Series Drive IntroMotor Power CableClamp exposed to the chassisF or H-Series...

  • Page 239

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-27Figure B.27F- or H-Series Motors to ULTRA 200 Series Drive using P2 Terminal StripIntroNOTES:This wiring method provides the option to run cables through a restrictive bulkhead or enclosure.Cable 9101-1365-XXX has a...

  • Page 240

    Publication 1398-5.0 – October 1998B-28Cable Diagrams, Schematics and ExamplesFigure B.28Y-Series Motors to ULTRA 200 Series DriveIntroNotes:This wiring method should be used to run cables through a bulkhead or enclosure without removing the connectors.Cable 9101-1375-XXX has connectors on both...

  • Page 241

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-29Figure B.29Y-Series Motors to ULTRA 200 Series Drive using P2 Terminal StripIntroNotes:This wiring method provides the option to run cables through a restrictive bulkhead or enclosure.Cable 9101-1373-XXX has a connect...

  • Page 242

    Publication 1398-5.0 – October 1998B-30Cable Diagrams, Schematics and ExamplesAllen-Bradley 9/Series CNC Family ConnectionsThe tables below list the connections necessary between the connectors on Allen-Bradley 9/Series CNC Controllers. The controller may be wired to either a Breakout Board con...

  • Page 243

    Publication 1398-5.0 – October 1998Cable Diagrams, Schematics and ExamplesB-31Table B.4:9/230 to J1 Connector9/230 8520-ASM-4Drive ConnectionsPinSignalJ1 PinSignal11CHA_HI7Mtr Output Chnl A+10CHB_HI9Mtr Output Chnl B+39CHZ_HI11Mtr Output Chnl Index+41CHA_LO8Mtr Output Chnl A-40CHB_LO10Mtr Outpu...

  • Page 244

    Publication 1398-5.0 – October 1998B-32Cable Diagrams, Schematics and Examples

  • Page 245

    TouchPadCommand TreeVer12.10Allen-BradleyAllen-Bradley Headquarters1201 South Second StreetMilwaukee, WI 53204 USATel: (1) 414 382-2000Fax: (1) 414 382-4444Technical Support: (1) 216 646-6800Installation and Operation1. Power down the drive and remove all serial connections. 2. Install the TouchP...

  • Page 246

    CTLPANELSTATUSDrvStatDrive Statussee TableInpFlagsInput Flagssee TableOutFlagsOutput Flagssee TableDRVINFOFW VerFirmware VersionRelease LevelReg RevRegulator BoardRevision LevelPwr RevPower BoardRevision LevelAssy RevAssemblyRevision LevelDISPLAYI CmdCurrent CommandAmpsI AvgCurrent AverageAmpsI P...

  • Page 247

    Publication 1398-5.0 – October 1998Appendix CTouchPad InstructionsAppendix CThe optional TouchPad is a compact and rugged device for interfacing with ULTRA 200 Series drives. It provides the operator with a convenient device for accessing status information, program variables, and control funct...

  • Page 248

    Publication 1398-5.0 – October 1998C-2TouchPad Instructions5. After self-test is completed, the TouchPad display defaults to the branch title DRVSETUP. 6. Horizontal and vertical movement through the TouchPad Com-mand Tree and parameter modification is explained below. The 250,“TouchPad Comm...

  • Page 249

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-3TouchPad CommandsCommands are entered by pressing a single key or combination of keys. Two modes of operation are available. Parameter mode allows you to move through the TouchPad Command Tree to each parameter. Modify mode allows you t...

  • Page 250

    Publication 1398-5.0 – October 1998C-4TouchPad InstructionsFigure C.3TouchPad Command Tree (sheet 1 of 2)IntroFolRatioGear RatioNumericSlewEnabSlew EnableSelectionSlewRateSlew Raterpm/secMastrRotMaster Rotationnormal or reverseDRVSETUPMotorSelMotor Selectionsee TableDrv NameDrive Name<32 cha...

  • Page 251

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-5IntroFigure C.3TouchPad Command Tree (sheet 2 of 2)CTLPANELSTATUSDrvStatDrive Statussee TableInpFlagsInput Flagssee TableOutFlagsOutput Flagssee TableDRVINFOFW VerFirmware VersionRelease LevelReg RevRegulator BoardRevision LevelPwr RevP...

  • Page 252

    Publication 1398-5.0 – October 1998C-6TouchPad InstructionsSupplemental InstructionsMotor SelectionEnter a Motor Identification number to load the correct motor parameters into the drive. 256, Table 256,C.2 and 257, Table 257,C.3 list the motors available in the motor table directory. Displa...

  • Page 253

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-7For example: If the SpeedWin setting is 5000 rpm and the Maximum Speed in the motor table is 5200, pressing the key increases the parameter to 5200 (the upper limit), but pressing the key decrements the parameter to 4000. The most sig...

  • Page 254

    Publication 1398-5.0 – October 1998C-8TouchPad InstructionsRatioA FolRatio (gear ratio) longer than eight characters may require scrolling with the and keys. The ratios are numeric values that increment or decrement by 1 each time the , or , key is pressed. The method of display is dependent ...

  • Page 255

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-9Fault/Error/Warning 255,Table 255,C.1 lists the possible fault, error and warning messages that may appear on the TouchPad. The items below describe the different types of messages. qThe TouchPad displays Fault and a description. A Fau...

  • Page 256

    Publication 1398-5.0 – October 1998C-10TouchPad InstructionsMotor Table Table C.2:TouchPad Motor Table Identification by Motor SeriesMotorIDMotorIDMotorIDMotorIDB14H1050551B14H1056558B14H1060560B14H1066562B14J1050559B14J1050559B14J1060563B18H1070564B18H1076566B18H1080568B18H1086570B18J1070567B...

  • Page 257

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-11 N-2302-1-F335N-2304-1-F336N-3406-2-H81N-3406-2-K849N-3412-2-H82N-3412-2-K850N-4214-2-H83N-4214-2-K851N-4220-2-H84N-4220-2-K852N-5630-2-H85N-5630-2-K853N-5637-2-H86N-5637-2-K854N-5647-2-H87N-5647-2-K855Y-1002-169Y-1002-268Y-1003-171Y-...

  • Page 258

    Publication 1398-5.0 – October 1998C-12TouchPad InstructionsTouchPad Options 785 F-6100-R-K786 F-6200-R-K787 F-6300-R-K788 H-2005-K-K789 H-3007-N-K790 H-3016-N-K791 H-4030-P-K792 H-4030-M-K793 H-4050-P-K794 H-4075-R-K795 H-6100-Q-K796 H-6200-Q-K797 H-6300-Q-K798 H-8350-S-K799 H-8500-S-K849 N-3...

  • Page 259

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-13TouchPad Lists Table C.5:Drive Communications Parameter List for the TouchPadDisplayParameter007 Data Bits, 1 Stop Bit, Even Parity017 Data Bits, 1 Stop Bit, Odd Parity028 Data Bits, 1 Stop Bit, No Parity038 Data Bits,...

  • Page 260

    Publication 1398-5.0 – October 1998C-14TouchPad Instructions Table C.9:Index Pointer Parameter List for TouchPadDisplayParametera00Index 001Index 102Index 203Index 304Index 405Index 506Index 607Index 708RAM Indexa. Parameters available only if the drive supports Indexing. Table C...

  • Page 261

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-15 Table C.13:Reverse Enable for HomingDisplayParameteraInactiveNo reversing if started on SensorActiveReverse if started on Sensora. Parameters available only if the drive supports Indexing. Table C.14:Digital Input Parameter...

  • Page 262

    Publication 1398-5.0 – October 1998C-16TouchPad Instructions Table C.16:Analog Output Parameter List for TouchPadDisplayParameterI CmdCurrent CommandI AvgAverage Current CommandIPeak+Positive Current PeakIPeak-Negative Current PeakILimit+Positive Current LimitILimit-Negative Current LimitVel...

  • Page 263

    Publication 1398-5.0 – October 1998TouchPad InstructionsC-17 PersWrtPersonality Write ErrorServWrtService Write ErrorCPUCommCPU Communications ErrorMtrOvtMotor OvertemperatureIPMFaltIPM FaultExsVErrExcess Velocity ErrorComutatCommutation Angle ErrorNot HomdAxis Not HomedNOTE:The Drive St...

  • Page 264

    Publication 1398-5.0 – October 1998C-18TouchPad Instructions

  • Page 265

    Publication 1398-5.0 – October 1998Appendix DCreating Custom Motor FilesAppendix DEach motor controlled by a ULTRA 200 Series drive requires a unique parameter set. The parameter set provides the drive with information about the motor necessary for proper commutation, precise control and protec...

  • Page 266

    Publication 1398-5.0 – October 1998D-2Creating Custom Motor FilesDrive and Motor File Configuration with ULTRA MasterAt startup ULTRA Master examines the contents of the /MOTORDIR subdirectory to determine the list of motors it will display. If a custom motor file is to appear, it must be copie...

  • Page 267

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-3The text string translates the table ID into a real motor model number for display. For example, the user can select the text string “H-4030-P-H” rather than entering the table ID #2 267,3. Figure 267,D.1 defines the text str...

  • Page 268

    Publication 1398-5.0 – October 1998D-4Creating Custom Motor FilesMany motor manufacturers include drawings in their data sheets that identify the phasing of the back-EMF and Hall feedback signals, or an application engineer may have access to an internal document listing the information. As a l...

  • Page 269

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-5Motor Parameter DefinitionsThe parameters to configure in a custom motor file are defined below. ULTRA Master arranges motor parameters in an index card format. The groupings are:qGeneral, qFeedback, qCurrent Loop, qElectrical, an...

  • Page 270

    Publication 1398-5.0 – October 1998D-6Creating Custom Motor FilesSynchronous/InductionThis field identifies whether the motor is a synchronous (permanent magnet) motor or an induction motor. The motor type informs ULTRA Master which fields are valid for a particular motor, and which fields are ...

  • Page 271

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-7If a motor operates with trap drives, the torque constant is specified as a “square wave” torque constant. However, ULTRA 200 Series drives are sinusoidal drives and the torque constant must be specified as a “sine wave” t...

  • Page 272

    Publication 1398-5.0 – October 1998D-8Creating Custom Motor FilesFeedback ParametersLinecountThe encoder linecount, or size, specifies the number of encoder lines per mechanical revolution of the motor, and is required in units of lines/mechanical revolution. The linecount value can be in the r...

  • Page 273

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-9The Hall signals, as well as the line-to-line back-EMF voltages, must sequence according to the Allen-Bradley standard (refer to 268, Figure 268,D.2 and the 267,“Motor Phasing” on page 267,D-3). The Hall offset value is the...

  • Page 274

    Publication 1398-5.0 – October 1998D-10Creating Custom Motor FilesIf the drive is set up for Hall/Hall startup commutation, the initial commutation angle is determined by the state of the three Hall feedback inputs: 001, 010, 011, 100, 101, or 110. When the motor begins moving, a transition fro...

  • Page 275

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-11InductanceThe inductance value is the measured phase-to-phase inductance in milliHenries of the stator winding. The inductance is used to set the current regulator gains, and is critical to current loop performance. The inductanc...

  • Page 276

    Publication 1398-5.0 – October 1998D-12Creating Custom Motor FilesPeak TorqueThe peak or maximum torque specifies the maximum current capability of the motor in peak Amps. (Note: This is peak Amps, rather than rms.) The drive uses the maximum torque value to limit the current applied to the mot...

  • Page 277

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-13The thermal time constant of the motor is measured by stabilizing the motor temperature at its rated condition, disabling the drive, and measuring the time for the hottest part of the motor winding to drop 63% of the difference f...

  • Page 278

    Publication 1398-5.0 – October 1998D-14Creating Custom Motor FilesExample of Custom Motor File CreationThe following is an example of a custom motor. A 50:1 gear is included inside this motor. The example illustrates how to configure a custom motor. Manufacturer’s DataThe following specificat...

  • Page 279

    Publication 1398-5.0 – October 1998Creating Custom Motor FilesD-15Parameter Conversions The 1:50 gearing makes this motor an unusual case. The motor file must be generated as if the motor and gear are two separate devices. The inertia, torque, speed, etc., must be computed based on the motor si...

  • Page 280

    Publication 1398-5.0 – October 1998D-16Creating Custom Motor FilesCustom Motor FileThe custom motor file parameters are as follows: Troubleshooting Custom Motor Files GENERALCURRENT LOOPMotor Model:A_CUSTOMCurrent Feedforward:0 degrees / kRPMTable ID:-1Motor File:CUSTOM21.MTRELECTRICALMotor T...

  • Page 281

    Publication 1398-5.0 – October 1998Appendix EElectromagnetic Compatibility Guidelines for Machine DesignAppendix EThis appendix provides background information about Electromagnetic Interference (EMI) and machine design guidelines for Electromagnetic Compatibility (EMC). The ULTRA 200 Series i...

  • Page 282

    Publication 1398-5.0 – October 1998E-2Electromagnetic Compatibility Guidelines for Machine DesignThe EMI model provides only three options for eliminating the EMC problem:qreduce the EMI at the source,qincrease the victim’s immunity to EMI (harden the victim), orqreduce or eliminate the coupl...

  • Page 283

    Publication 1398-5.0 – October 1998Electromagnetic Compatibility Guidelines for Machine DesignE-3One method to improve the EMC characteristics of a drive is to use an isolation AC power transformer to feed the amplifier its input power. This minimizes inrush currents on power-up and provides el...

  • Page 284

    Publication 1398-5.0 – October 1998E-4Electromagnetic Compatibility Guidelines for Machine Design The only reasonable filtering at the drive output terminals is the use of inductance. Capacitors would slow the output switching and deteriorate the drive performance. A common mode choke, as is ...

  • Page 285

    Publication 1398-5.0 – October 1998Electromagnetic Compatibility Guidelines for Machine DesignE-5GroundingHigh frequency (HF) grounding is different from safety grounding. A long wire is sufficient for a safety ground, but is completely ineffective as an HF ground due to the wire inductance. As...

  • Page 286

    Publication 1398-5.0 – October 1998E-6Electromagnetic Compatibility Guidelines for Machine DesignShielding and SegregationThe EMI radiating from the drive enclosure drops off very quickly over distance. Mounting the drive in an enclosure, such as an industrial cabinet, further reduces the radia...

  • Page 287

    Publication 1398-5.0 – October 1998Appendix FDynamic Braking Resistor SelectionAppendix FThis appendix provides equations to assist in sizing resistors for dynamic braking. A properly sized resistive load may be required to dynamically brake the system by dissipating the energy stored in a moto...

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    Publication 1398-5.0 – October 1998F-2Dynamic Braking Resistor SelectionFor this type of response, 98% of the energy will be dissipated in 4 time constants. Therefore the average power for each dynamic braking event can be calculated as: Equation 1 is used in equation 2 and 3 to put the power...

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    Publication 1398-5.0 – October 1998Dynamic Braking Resistor SelectionF-3Sample CalculationsThe following example uses an H4075 motor with a 10 times inertia mismatch and dynamic braking resistors sized at four times the motor winding resistance. The average power of the motor is 1116 Watts for ...

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    Publication 1398-5.0 – October 1998F-4Dynamic Braking Resistor SelectionCurrent Calculation (Amps): Instantaneous Power Calculation (Watts): Average Power (Watts): Introit()KEωoet–τ----⋅⋅0.866 R2 RL⋅+()-------------------------------------------=:IntroP( )t.R.2R Le00.050.10.150.2...

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    Publication 1398-5.0 – October 1998Appendix GSpecifications Appendix GItemSpecificationAgency ApprovalsUL and cUL UL508C File E145959CE markLow Voltage Directive andElectromagnetic Compatibility Directive Certificate of Conformity from TUV Product ServiceEnvironmentalOperating Temperature1398...

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    Publication 1398-5.0 – October 1998G-2SpecificationsSelectable (5)24 Volt, Optically Isolated, Single ended, Active High, Current Sinking, 4.5 mA nominalENABLE24 Volt, Optically Isolated, Single ended, Active High, Current Sinking, 4.5 mA nominalDigital OutputsSelectable (4)24 Volt, Optically I...

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    Publication 1398-5.0 – October 1998SpecificationsG-3Update Rate5 kHz-3dB Bandwidth150 Hz-45° Bandwidth50 HzRipple±2 RPM @ 1000 RPMResolution16-bitPosition RegulationTypeDigital, PID with FeedforwardFiltersLow PassDigital, 0 - 1000 Hz, -3 dB Bandwidth, SelectableSoftware ControlsData Collectio...

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    Publication 1398-5.0 – October 1998G-4SpecificationsRun-Time FaultsMotor OvertemperatureBus OvervoltageIPM FaultOverspeedExcess ErrorEncoder State ChangeEncoder Line BreakFuseIllegal Hall StateSelectable Digital InputsDrive Mode SelectIntegrator InhibitFollower EnableForward EnableReverse Enabl...

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    Publication 1398-5.0 – October 1998SpecificationsG-5Power Table G.1:ULTRA 200 Series Power Ratings 1398-DDM-010,1398-DDM-010X1398-DDM-020,1398-DDM-020X1398-DDM-030,1398-DDM-030X1398-DDM-075,1398-DDM-075X1398-DDM-150,1398-DDM-150XAuxiliary AC Input Voltage (rms Volts nominal)Frequency(Hz)Curren...

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    Publication 1398-5.0 – October 1998G-6SpecificationsBus Capacitance(µF)11701950273042907520Peak Power Outputb(kWatts @ 120 Vrms)(kWatts @ 240 Vrms)1.25 2.5 2.5 5 3.75 7.5 14, 1∅20, 3∅36 Continuous Power Output2(kWatts @ 120 Vrms)(kWatts @ 240 Vrms)0.6 1.0 1.22.0 1.8 3 3.5 7.5, 3∅15, 3...

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    Publication 1398-5.0 – October 1998SpecificationsG-7Power DissipationThe ULTRA 200 Series controller dissipates power that results in cabinet heating. The following table lists power dissipation values for the ULTRA 200 Series drives. Calculate the cabinet cooling requirements using the power d...

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    Publication 1398-5.0 – October 1998G-8Specifications

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    Publication 1398-5.0 – October 1998IndexHelpIndexAABS Input G-1Absolute Indexing 8-39ACBus 7-7Line Filters 57, 5-7Power 7-7see also PowerAccessories A-1Address Switch G-1Agency Approvals G-1Allen-Bradley 9/Series B-30Altitude G-1AM Line 11-8Analog 108, 6-44Connections 108, 6-44Cont...

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    Publication 1398-5.0 – October 1998Index-2DriveAddressingSerial Communications 100, 100, 6-36TouchPad Defaults C-1Default Parameters G-7InstallationInterface Connections 55, 5-5Mechanical Requirements 51, 5-1Storage 49, 4-7Dynamic Braking Resistors F-1EEEPROM G-2Electromagnetic Compatib...

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    Publication 1398-5.0 – October 1998Index-3J1 65, 65, 6-1J2 91, 91, 6-27J3 95, 95, 6-31J4 and J5 98, 6-34Motor Encoder Signal 81, 6-17Output Circuit Examples 75, 6-11Power 67, 67, 6-3Selectable Outputs 73, 6-9Wiring 56, 5-6see also TroubleshootingI/O ConnectorsAuxiliary Port 95, 6-31Co...

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    Publication 1398-5.0 – October 1998Index-4ProcedurePosition Loop 9-9Velocity Loop 9-8Velocity Loop Examples 9-10Mechanical Installation 51, 5-1Mechanical ResonancePossible Causes 9-2Tuning Guidelines 9-2Microcontroller Type G-2Modifying User Units, see User UnitsMotorCabling 7-3, B-21...

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    Publication 1398-5.0 – October 1998Index-5Communication Test 11-11Single Axis Set-up 102, 102, 6-38RS-485 Multiple Axes Set-up 105, 6-41Run-TimeError Codes 10-2Faults G-4SSafety Guidelines 27, 27, 1-1Sample Application, see ExampleSelectable I/ODigital Inputs G-4Digital Outputs G-4Selec...

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    Publication 1398-5.0 – October 1998Index-6Serial Protocol G-3Shock G-1Shunt PowerContinuous G-5Peak G-5Speed Control Command G-4Speed RegulationBandwidth G-3Resolution G-3Ripple G-3Update Rate G-3Status Display G-1Storage Temperature G-1Thermostat Inputs G-1Vibration G-1Weight G-1...

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    Publication 1398-5.0 – October 1998Index-7UUnpacking the Drive 43, 4-1Update Rate, see SpecificationsUser Units 8-45VVelocity Loop Diagram 9-3Version LevelFirmware 42, 42, 3-4Software 41, 3-3Version Level, TouchPad C-1Vibration G-1WWarningClassifications 22, 22, Intro-20Defined 22, 22,...

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    Publication 1398-5.0 – October 1998Index-8

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    Publication 1398-5.0 – October 1998PN 0013-1042-002 Rev ACopyright 1997 Allen-Bradley Company, Inc.Printed in USA

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