Allen-Bradley 2098-DSD-005, 2098-DSD-150, 2098-DSD-75, 2098-DSD-005X, 2098-DSD-010X Installation Manual

...

Ultra3000 Digital Servo Drives

(Catalog Numbers 2098-DSD-005, -010, and -020 2098-DSD-xxxX 2098-DSD-xxx-SE 2098-DSD-xxx-DN 2098-DSD-xxxX-DN

2098-DSD-030, -075, and -150 2098-DSD-xxxX 2098-DSD-xxx-SE 2098-DSD-xxx-DN 2098-DSD-xxxX-DN

2098-DSD-HV030, -HV050, -HV100, -HV150, and -HV220 2098-DSD-HVxxxX 2098-DSD-HVxxx-SE 2098-DSD-HVxxx-DN 2098-DSD-HVxxxX-DN)

Installation Manual

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any

particular installation, Allen-Bradley

does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the

Application, Installation and Maintenance of Solid-State Control

(available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation

is prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, A-B, ControlLogix, and Rockwell Automation are registered trademarks of Rockwell Automation. RSLogix, RSLogix 5000, SoftLogix, and Ultra3000 are trademarks of Rockwell Automation. DeviceNet is a trademark of the Open DeviceNet Vendor Association. SERCOS interface is a trademark of the Interests Group SERCOS interface e.V. (IGS). Windows is a registered trademark of Microsoft Corporation. UL is a registered trademark of Underwriters Laboratories, Inc. Bussmann is a registered trademark of Cooper Industries, Inc. LittelFuse is a registered trademark of LittelFuse.

Summary of Changes

The Ultra3000 Digital Servo Drive Installation Manual Document Update, publication 2098-DU003B-EN-P, includes important information about changes and updates to this Ultra3000 Digital Servo Drive Installation Manual.

The document update used to be provided as a separate document, but is now incorporated into this installation manual, in the section immediately following this Summary of Changes section, and before the Table of Contents.

Before using this installation manual, read and understand the changes and updates identified in the document update section.

No engineering or editorial changes have been made to either the document update or the installation manual; therefore, the publication dates and revisions of each respective manual did not change. The publication date of this Summary of Changes section indicates the date that the combined manuals were released.

Rockwell Automation Publication 2098-IN003E-EN-P - March 2012 I

Summary of Changes

Notes:

II Rockwell Automation Publication 2098-IN003E-EN-P - March 2012

Document Update

Ultra3000 Digital Servo Drive Installation Manual

Catalog Numbers 2098-DSD-005, -010, and -020 2098-DSD-xxxX 2098-DSD-xxxSE 2098-DSD-xxx-DN 2098-DSD-xxxX-DN

2098-DSD-030, -075, and -150 2098-DSD-xxxX

About This Publication

2098-DSD-xxxSE 2098-DSD-xxx-DN 2098-DSD-xxxX-DN

2098-DSD-HV030, -HV050, -HV100, -HV150, and -HV220 2098-DSD-xxxX 2098-DSD-xxxSE 2098-DSD-xxx-DN 2098-DSD-xxxX-DN

This document updates information about the Ultra3000 digital servo drive products. Use this document in conjunction with the Ultra3000 Digital Servo Drive Installation Manual, publication 2098-IN003E-EN-P. To obtain a copy, contact your local Rockwell Automation sales office, distributor, or online at http://

literature.rockwellautomation.com

Publication 2098-DU003B-EN-P — September 2006

2 Ultra3000 Digital Servo Drive Installation Manual

Page 2-52

+12V dc

RS-232 Interface

COM

RCV

XMT

Note: Pin-outs vary by manufacturer.

This example uses a B&B 485 adapter.

232 to 485

Replace Figure 2.57 on page 2-52 with the one shown below. The new figure correctly identifies the drive connector as CN3.

Figure 2.57 RS-232 to RS-485 Connection Diagram

Common

Adapter

COM

RCV-

RCV+

XMT-

XMT+

RCV+

RCV- XMT+

CN3

Drive 1

XMT-

RCV+

RCV- XMT+

CN3

Drive 2

XMT-

RCV+

RCV- XMT+

CN3

Drive n

XMT-

Page 4-3

Error Code

E02 Velocity exceeds position rollover /2

E03 Absolute feedback range exceeded

E44

Problem or Symptom Possible Cause Action/Solution

Lost motion fault (only applies to applications with Stegmann feedback devices)

Update the Error Codes table beginning on page 4-3 with the following entries:

• Replace the error code entry for E02. In the new entry, the reference to firmware revisions prior to 1.10 is removed.

• Replace the error code entry for E03. In the new entry, the reference to firmware revisions prior to 1.10 is added.

• Add the lost motion fault (E44).

Error Codes

The velocity command or feedback exceeds half the machine cycle length per millisecond (applies only when the machine cycle position rollover is enabled).

The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback).

Detection occurs during a fault reset. Absolute position in the drive is incorrect and the motion has been lost due to line loss condition.

Increase machine cycle size or reduce velocity profile.

• Decrease application range of motion.

• Upgrade firmware.

This error only applies to firmware revisions prior to 1.10.

• Cycle power.

• Cycle power and re-home drive if drive

was homed in the same power cycle that the lost motion fault occurred.

Publication 2098-DU003B-EN-P — September 2006

Ultra3000 Digital Servo Drive Installation Manual 3

Page A-2

Specification

AC input voltage

AC input frequency 47...63 Hz

AC input current

Continuous output current (0-pk) 2.5 A 5 A 10 A

Intermittent output current (0-pk) 7.5 A 15 A 30 A

Bus capacitance 1410 μF 1880 μF 1880 μF

Internal shunt resistance N/A N/A N/A

Shunt on N/A N/A N/A

Shunt off N/A N/A N/A

Bus overvoltage 400V dc 400V dc 400V dc

Energy absorption capability

Continuous power output

(1)

(2)

(3)

(4)

Replace the Ultra3000 (230V) Power Specifications table on page A-2 with the one shown below. The new table includes inrush current specifications configured as Series A, B, or C.

• Ultra3000 drive firmware revision 1.45 is required to support the Series C hardware.

• Ultraware software, version 1.63, is required to download firmware to Series C drives containing the new power board.

Ultra3000 Drive (230V) Power Specifications 2098-DSD-005x-xx, 2098-DSD-010x-xx, and 2098-DSD-020x-xx

Description

2098-DSD-005 2098-DSD-010 2098-DSD-020

(1)

(2) (3)

Nom (rms) 230V ac (0-pk) max inrush

115V ac input 230V ac input

Specification is for nominal voltage. The absolute limits are ±10%, or 88...265V rms.

The 2098-DSD-005x-xx, -010x-xx, and -020x-xx (230V) drives are limited to: Series A or B - one contactor cycle every two minutes. Series C - one contactor cycle every 10 s for up to two minutes, not to exceed 12 cycles in five minutes.

Power initialization requires a short period of inrush current. Dual-element time delay (slow blow) fuses are recommended.

Inrush current-limiting circuitry is enabled within 3 s after removal of ac line power.

(4)

100...240V rms single-phase

5 A 100 A - Series A or B

20 A - Series C

93 J 38 J

0.25 kW

0.5 kW

9 A 100 A - Series A or B

20 A - Series C

125 J 51 J

0.5 kW

1.0 kW

18 A 100 A - Series A or B

20 A - Series C

1.0 kW

2.0 kW

ATTENTION

The inrush current-limiting circuitry is limited in the number of power cycles it can withstand within a set period of time. If you exceed these limitations, the circuitry will be damaged.

Publication 2098-DU003B-EN-P — September 2006

4 Ultra3000 Digital Servo Drive Installation Manual

Page A-3

Replace the Ultra3000 (230V) Power Specifications table on page A-3 with the one shown below. The new table includes an updated value in the bus capacitance field for 2098-DSD-030 drives.

Ultra3000 Drive (230V) Power Specifications 2098-DSD-030x-xx, 2098-DSD-075x-xx, and 2098-DSD-150x-xx

Specification

AC input voltage

(1)

2098-DSD-030 2098-DSD-075 2098-DSD-150

100...240V rms Single-phase

AC input frequency 47...63 Hz

Main ac input current

Nom (rms) 230V ac (0-pk) Max inrush

(2) (3)

28 A 50 A

Auxiliary ac Input current

115V ac (rms) Nom 230V ac (rms) Nom 115V ac (0-pk) Max inrush 230V ac (0-pk) Max inrush

(4) (4)

1.0 A

0.5 A 47 A 95 A

Continuous output current (0-pk) 15 A 35 A 65 A

Intermittent output current (0-pk) 30 A 75 A 150 A

Bus capacitance 2820 μF 4290 μF 7520 μF

Internal shunt resistance 35 Ω 16.5 Ω 9.1 Ω

Shunt on 420V dc 420V dc 420V dc

Shunt off 402V dc 402V dc 402V dc

Bus overvoltage 452V dc 452V dc 452V dc

Internal shunt

Continuous power Peak power

50 W

4.5 kW

External shunt

Resistance Continuous power Peak power

30 Ω (-0/+5%)

2.4 kW 6 kW

Energy absorption capability

115V ac input 230V ac input

211 J 117 J

Continuous power output

115V ac input 230V ac input

(1)

Specification is for nominal voltage. The absolute limits are ±10%, or 88...265V rms.

(2)

The 2098-DSD-030x-xx, -075x-xx, and -150x-xx (230V) drives are limited to one contactor cycles per two minutes.

(3)

Power initialization requires a short period of inrush current. Dual-element time delay (slow blow) fuses are recommended.

(4)

400 μs half wave sine.

1.5 kW 3 kW

Description

100...240V rms Three-phase

30 A 50 A

1.0 A

0.5 A 47 A 95 A

50 W 10 kW

16.5 Ω (-0/+5%) 4 kW 10 kW

381 J 211 J

3.75 kW

7.5 kW

46 A 68 A

1.0 A

0.5 A 47 A 95 A

180 W 18 kW

9 Ω (-0/+5%) 8 kW 19 kW

669 J 370 J

7.5 kW 15 kW

Publication 2098-DU003B-EN-P — September 2006

ATTENTION

The inrush current-limiting circuitry is limited in the number of power cycles it can withstand within a set period of time. If you exceed these limitations, the circuitry will be damaged.

Ultra3000 Digital Servo Drive Installation Manual 5

Page A-4

Add the attention statement (below) to the Ultra3000 (460V) Power Specifications table on page A-4. The table didn’t change, however, the warning applies to all Ultra3000 drives.

Ultra3000 Drive (460V) Power Specifications 2098-DSD-HV030x-xx, -HV050x-xx, -HV100x-xx, -HV150x-xx, and -HV220x-xx

Specification

AC Input Voltage

AC Input Frequency 47...63 Hz

Main AC Input Current

460V ac (rms) Nom 460V ac (rms) Max inrush

Auxiliary AC Input Current

230V ac (rms) Nom 360V ac (rms) Nom 480V ac (rms) Nom 230V ac (0-pk) Max inrush 480V ac (0-pk) Max inrush

Continuous Output Current (0-pk) 7 A 11 A 23 A 34 A 47 A

Intermittent Output Current (0-pk) 14 A 22 A 46 A 68 A 94 A

Bus Capacitance 470 μF 705 μF 940 μF 1880 μF

Internal Shunt Resistance 120 Ω 40 Ω 25 Ω 20 Ω

Shunt On 800V dc

Shunt Off 750V dc

Bus Overvoltage 810V dc

Internal Shunt

Continuous power Peak power

External Shunt

Resistance (-0/+5%) Continuous power Peak power

Energy Absorption Capability

230V ac input with 230V motor 230V ac input with 460V motor 460V ac input

Continuous Power Output

230V ac input 460V ac input

(1)

Specification is for nominal voltage. The absolute limits are ±10%, or 207...528V rms.

(2)

The 2098-DSD-HVxxx-xx drives can be powered with 230-240 V rms in order to be used in conjunction with motors designed for 230V operation. In such cases, the voltage levels used for shunting and DC bus overvoltage limits are adjusted to be compatible with the voltage limit of the motor.

(3)

The 2098-DSD-HVxxx -xx (460V) drives are limited to three contactor cycles per minute.

(4)

Power initialization requires a short period of inrush current (processor controlled via soft start circuitry). Dual element time delay (slow blow) fuses are recommended (refer to Fuse Specifications on page 6-8).

(5)

400 μs half wave sine.

(1) (2)

(3) (4)

(5) (5)

2098-DSD-HV030 2098-DSD-HV050 2098-DSD-HV100 2098-DSD-HV150 2098-DSD-HV220

230...480V rms Three-phase

4 A 6 A

0.55 A

0.35 A

0.25 A 47 A 68 A

100 W

5.3 kW

120 Ω 3 kW

5.3 kW

15 J 129 J 55 J

1.5 kW

3.0 kW

7 A 6 A

2.5 kW

5.0 kW

Description

14 A 6 A

200 W 16 kW

40 Ω 10 kW 16 kW

22 J 194 J 82 J

5.0 kW 10 kW

20 A 6 A

200 W

25.6 kW

25 Ω 15 kW

25.6 kW

29 J 259 J 109 J

7.5 kW 15 kW

28 A 6 A

400 W 32 kW

20 Ω 22 kW 32 kW

59 J 517 J 219 J

11 kW 22 kW

ATTENTION

The inrush current-limiting circuitry is limited in the number of power cycles it can withstand within a set period of time. If you exceed these limitations, the circuitry will be damaged.

Publication 2098-DU003B-EN-P — September 2006

6 Ultra3000 Digital Servo Drive Installation Manual

Page B-2

Note: Information:

May be used to maintain power to logic section of drive and status LED indicators when main ac input power is removed. A separate ac line

source may be used if voltage is between 88-265V ac (rms) on 2098-DSD-xxx (230V drives) or 207-528V ac (rms) on 2098-DSD-HVxxx (460V drives). In this configuration, a separate line filter for logic power may be required.

Place the ac (EMC) line filter as close to the drive as possible and do not route very dirty wires in wireway (refer to Establishing Noise Zones, on

page 1-13). If routing in wireway is unavoidable, use shielded cable with shields grounded to the drive chassis and filter case. For ac line filter specifications, refer to AC Line Filter Specifications in Appendix A.

Page B-4

Replace notes 6 and 7 in the Ultra3000 Interconnect Diagram Notes with the ones shown below. The new versions include information regarding the placement of ac line filters and routing of wires.

Replace the interconnect diagram on page B-4 with the one shown below. The new diagram changes the recommended wiring of input fusing, ac line filter, and contactor.

Figure B.2 Typical Power Wiring of Ultra3000 System (2098-DSD-030x-xx)

Ultra3000

Digital Servo Drive

2098-DSD-030x-xx

Note 13

Fused Disconnect

or Circuit Breaker *

Note 1

Isolation

Transformer *

Note 2

Single-phase Input

100-240V ac (rms)

Single-phase AC Line

50/60 Hz

L2/N

Chassis

Ter min al Blocks *

Note 3

Input Fusing *

Note 4, 5

Bonded Cabinet

Ground Bus *

Single-phase AC Line Filter

Note 7

To additional

Ultra3000 drive.

Three-phase

Motor Power

Connections

Note 12

Note 6

Input Fusing *

CN1

M1 *

Note 8

Note 4, 5

TB1

DC+

DC-

L2/N

L1 AUX

L2/N AUX

START *

CR1 *

Motor Power Connections

AC Input Power Connections

Cable Shield Clamp Note 9

STOP *

CR1 *

TB2

CN1

External Passive Shunt Connections

N.O. Relay Output+

N.O. Relay Output-

CR1 *

M1 *

Note 20

24V dc

* Indicates User Supplied Component

Publication 2098-DU003B-EN-P — September 2006

Refer to Attention statement (Notes 10, 11)

Ultra3000 Digital Servo Drive Installation Manual 7

Page B-5

Fused Disconnect

or Circuit Breaker *

Note 1

Isolation

Tra nsfo rme r *

Note 2

Three-phase AC Line

50/60 Hz

Neutral

Chassis

Replace the interconnect diagram on page B-5 with the one shown below. The new diagram changes the recommended wiring of input fusing, ac line filter, and contactor.

Figure B.3 Typical Power Wiring of Ultra3000 System (2098-DSD-075x-xx and -150x-xx)

Ultra3000

Digital Servo Drives

2098-DSD-075x-xx and

-150x-xx

Note 13

TB2

CN1

External Passive Shunt Connections

N.O. Relay Output+

N.O. Relay Output-

Note 20

Input Fusing *

Note 4, 5

Three-phase

AC Line Filter

Note 7

Three-Phase

Motor Power

Connections

Note 6

Bonded Cabinet Ground Bus *

Note 12

M1 *

Note 8

Input Fusing *

Note 4, 5

TB1

DC+

DC-

L1 AUX

L2/N AUX

Motor Power Connections

AC Input Power Connections

Cable Shield Clamp Note 9

Three-phase Input 100-240V ac (rms)

* Indicates User Supplied Component

Terminal Blocks *

Note 3

To additional

Ultra3000 drive.

CN1

CR1 *

STOP *

CR1 *

M1 *

START *

Refer to Attention statement (Notes 10, 11)

24V dc

Publication 2098-DU003B-EN-P — September 2006

8 Ultra3000 Digital Servo Drive Installation Manual

Page B-6

Fused Disconnect

or Circuit Breaker *

Note 1

Isolation

Transformer *

Note 2

Three-phase AC Line

50/60 Hz

Neutral

Chassis

Replace the interconnect diagram on page B-6 with the one shown below. The new diagram changes the recommended wiring of input fusing, ac line filter, and contactor.

Figure B.4 Typical Power Wiring of Ultra3000 System (2098-DSD-HVxxx-xx and -HVxxxX-xx)

Ultra3000

Digital Servo Drives

2098-DSD-HVxxx-xx and

-HVxxxX-xx

Note 14

TB2

CN1

External Passive Shunt Connections

N.O. Relay Output+

N.O. Relay Output-

Input Fusing * Notes 4 and 5

Three-phase

AC Line Filter

Note 7

Note 6

Three-phase

Motor Power

Connections

Input Fusing* Notes 4 and 5

Bonded Cabinet Ground Bus *

Note 12

M1 *

Note 8

TB1

DC+

DC-

L1 AUX

L2/N AUX

Motor Power Connections

AC Input Power Connections

Cable Shield Clamp Note 9

Note 20

Three-phase Input

230-480V ac (rms)

Terminal Blocks *

Note 3

* Indicates User Supplied Component

Publication 2098-DU003B-EN-P — September 2006

To additional

Ultra3000 drive.

CN1

CR1 *

STOP *

CR1 *

M1 *

START *

Refer to Attention statement (Notes 10, 11)

24V dc

Ultra3000 Digital Servo Drive Installation Manual 9

Page B-12

Ultra3000 Drive

BRN

BLK

BLU

GN/YL

Notes 13, 14

Motor Feedback

(15-pin) Connector

Control Interface

(44-pin) Connector

CN2

CN1

Note 19

Replace Figure B.12 on page B-12 with the one shown below. The new figure includes MP-Series food grade (MPF), stainless steel (MPS) and low inertia (MPL-A/B15xx and MPL-A/B2xx) motors. Also included is an illustration of grounding the feedback cable shield.

Figure B.12 Ultra3000 Drive to MP-Series (MPL-A/B, MPF-A/B, and MPS-A/B) Motors

MPL-A/B15xx and -A/B2xx,

MPF-A/Bxxx and MPS-A/Bxxx

Servo Motors with

High Resolution Feedback

Green/Yellow

Blue

Black

Brown

2090-XXNPMF-xxSxx

Motor Power Cable

Note 12

Black

White

C/W B/V

A/U

G/-

F/+

Three-Phase

Motor Power

Motor Feedback

BR-

BR+

Thermostat

GND

Motor Brake

1 2

3 4

5 6

10 11

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

BLUE

Motor Feedback (CN2) Connector

SIN+ SIN-

COS+ COS-

DATA+ DATA-

+5VDC ECOM

+9VDC

TS+

TS-

1 2

3 4

10 14

6 7

Motor Power

TB1

Grounding Technique for

Feedback Cable Shield

Exposed shield secured

under clamp.

Motor Feedback Breakout Board

Cable Shield Clamp

Note 9

+24V dc Power Supply

(2090-UXBB-DM15)

COM

User Supplied

(1.0 A max)

Cable Tie

+24V

MPL-A/B15xx and -A/B2xx

Servo Motors with

Incremental Feedback

D/ C/W

B/V

A/U

Three-Phase

Motor Power

Motor Feedback

Thermostat

G/-

F/+

BR-

BR+

GND

Motor Brake

Refer to illustration (lower left)

for proper grounding technique.

2090-XXNFMF-Sxx

(flying-lead) Feedback Cable

Notes 12, 16, 18

COM

Motor Feedback (CN2) Connector

1 2

3 4

5 6

9 10 11 13

14 15 16 17 12

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

BLUE

WHT/BLUE

YELLOW

WHT/YELLOW

AM+ AM-

BM+ BM-

IM+ IM-

+5VDC

ECOM

–

TS+

TS-

S1 S2

COM

1 2

3 4

10 14

Refer to illustration (lower left)

for proper grounding technique .

2090-XXNFMF-Sxx Feedback Cable

Note 12, 16

Publication 2098-DU003B-EN-P — September 2006

10 Ultra3000 Digital Servo Drive Installation Manual

Page B-13

2090-XXNPH/HF-xxSxx or -UXNPBH/HF-xxSxx

Ultra3000 230V Drive

BRN

BLK

BLU

GN/YL

Motor

Power

TB1

Motor Power Cable

Note 12

Note 13

Motor Feedback

(15-pin) Connector

Control Interface

(44-pin) Connector

Cable Shield Clamp

Note 9

CN2

9101-0330 Brake Cable Connector Kit

CN1

User Supplied

+24V dc Power Supply

Replace Figure B.13 on page B-13 with the one shown below. The new figure correctly identifies the motor brake-connector pins as A and B. Also included is an illustration of grounding the feedback cable shield.

Figure B.13 Ultra3000 Drive to H- and F-Series (230V) Motors

H- or F-Series (230V)

Servo Motors with

Incremental Feedback

Green/Yellow

Brown

Note 12

Note 19

+24V

COM

(1.0 A max)

Blue

Black

White

BR-

BR+

GND

Three-Phase Motor Power

Motor Feedback

Motor Brake

Thermostat

A B

C D

E F

R P

K J

N T

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

WHT/BROWN

BROWN

GRAY

WHT/GRAY

BLUE

WHT/BLUE

VIOLET

WHT/VIOLET

Motor Feedback

(CN2) Connector

AM+ AM-

BM+ BM-

IM+

IM-

TS+

+5VDC

ECOM

S2 S1

–

TS-

1 2

3 4

10 11

13 12

Grounding Technique for

Feedback Cable Shield

Exposed shield secured

under clamp.

Motor Feedback Breakout Board

(2090-UXBB-DM15)

Cable Tie

Refer to illustration (lower left)

for proper grounding technique.

2090-XXNFHF-Sxx (flying lead)

or 2090-UXNFBHF-Sxx (with drive-end con nector)

Feedback Cable Notes 12, 15, 16

Publication 2098-DU003B-EN-P — September 2006

Ultra3000 Digital Servo Drive Installation Manual 11

Page B-15

Ultra3000 230V Drive

1-BLK

2-BLK

3-BLK

GN/YL

Motor Power

TB1

Grounding Technique for

Feedback Cable Shield

Note 13

Motor Feedback

(15-pin) Connector

CN2

Control Interface

(44-pin) Connector

CN1

Cable Shield Clamp

Note 9

Replace Figure B.15 on page B-15 with the one shown below. The new figure correctly identifies the motor power-cable pins as 1, 2, 3, and 5. Also included is an illustration of grounding the feedback cable shield.

Figure B.15 Ultra3000 Drive to Y-Series (230V) Motors

Green/Yellow

3/Black

2/Black

1/Black

2090-XXNPY-16Sxx Motor Power Cable

Note 12

Note 19

COM

+24V dc Power Supply

+24V

User Supplied

(1.0 A max)

BLK

Y-Series (230V)

Servo Motors with

Incremental Feedback

Pigtail

Three-Phase

Motor Power

BR-

BR+

GND

Motor

Feedback

Motor Brake

Pigtail

11 12

13 14

15 17

–

22 23

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

WHT/BLUE

BLUE

BROWN

WHT/BROWN

GRAY

WHT/GRAY

3 2

Refer to illustration (lower left)

for proper grounding techniq ue.

2090-XXNFY-Sxx (flying lead)

or 2090-UXNFBY-Sxx (with drive-end connector)

Feedback Cable Notes 12, 15, 16

AM+

AM-

BM+

BM-

IM+

IM-

S1 S2

–

+5VDC

ECOM

DRAIN

Motor Feedback

(CN2) Connector

1 2

3 4

10 12

Exposed shield secured

under clamp.

Cable Tie

Motor Feedback Breakout Board

(2090-UXBB-DM15)

Publication 2098-DU003B-EN-P — September 2006

Page B-19

Replace the table on page B-19 with the one shown below. The new table includes the MPL-x15xx, MPL-x2xx, and TL-Series motors.

Compatible Brake Motors Coil Current Compatible Brake Motors Coil Current

MPL-x15xx

MPL-x2xx

MPL/MPF/MPS-x310, -x320, -x330

(1)

MPL-x420, -x430, -x4520, -x4530, -x4540

MPF-x430, -x4530, -x4540

MPG-x004

MPG-x010

MPG-x025

MPG-x050

MPG-x110

(1)

Applies to 230V and 460V motors.

(1)

0.48 A 1326AB-B4xxx 0.88 A

0.51 A F-4030, -4050, and -4075 0.69 A

0.50 A Y-1002 and -1003 0.26 A

(1)

0.64 A

Y-2006 and -2012 0.31 A

Y-3023 0.37 A

0.33 A TL-A110P-H, -A120P-H, and -A130P-H 0.208 A

0.45 A

TL-A220P-H and -A230P-H 0.375 A

TL-A2530P-H and -A2540P-H 0.396 A

0.50 A TL-A410P-H 0.746 A

1.0 A

Replace Figure B.19 with the one shown below. The new figure correctly identifies the relay output pins as CN1-43 and CN1-44.

Figure B.19 Example Configuration Controlling a Motor Brake

Power Supply

Ultra3000 Drive

N.O. Relay Output +

CN1

(1)

Flyback diode (1N4004 rated 1.0 A @ 400V dc) or MOV suppresses the collapsing field of the brake coil.

(2)

For non-SERCOS drive, the relay output (CN1-43 and -44) must be configured as a brake.

IMPORTANT

N.O. Relay Output +

Electrical arcing may occur at the relay contacts until the brake

3 A @ 24V dc

(2)

(1)

CR1

(1)

CR1

Brake

Feedback

Power

Servo

Motor

power dissipates. A customer-supplied diode or metal oxide varistor (MOV) is recommended to prevent arcing. Use of an MOV can also reduce the time to mechanically engage the brake.

Allen-Bradley, Rockwell Automation, and Ultra3000 are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication 2098-DU003B-EN-P — September 200612 PN 0013-2069-002

Table of Contents

Preface

Installing Your Ultra3000

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . P-1

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Product Receiving and Storage Responsibility . . . . . . . . . . . P-2

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . P-4

Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-4

Comments Regarding this Manual . . . . . . . . . . . . . . . . . P-4

Chapter 1

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Complying with European Union Directives . . . . . . . . . . . . 1-2

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Meeting CE Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-2

Low Voltage Directive. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Ultra3000 System Component Overview . . . . . . . . . . . . . . . 1-3

Before Mounting Your System . . . . . . . . . . . . . . . . . . . . . . 1-5

Unpacking Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

System Mounting Requirements. . . . . . . . . . . . . . . . . . . 1-6

Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sizing an Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Transformer Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Fuse Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

HF Bonding Your System . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . 1-12

Planning Your Panel Layout . . . . . . . . . . . . . . . . . . . . . . . 1-12

Establishing Noise Zones . . . . . . . . . . . . . . . . . . . . . . 1-13

Cable Categories for the Ultra3000. . . . . . . . . . . . . . . . 1-14

Mounting Guidelines to Reduce Electrical Noise . . . . . 1-15

Mounting Your Ultra3000 Drive . . . . . . . . . . . . . . . . . . . . 1-18

Ultra3000 Connector Data

i Publication 2098-IN003E-EN-P — April 2004

Chapter 2

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Understanding Ultra3000 Connectors . . . . . . . . . . . . . . . . . 2-1

Ultra3000 Front Panel Connections . . . . . . . . . . . . . . . . 2-2

Ultra3000 (with SERCOS) Front Panel Connections. . . . 2-10

Ultra3000 (with DeviceNet) Front Panel Connections . . 2-18

Understanding Ultra3000 I/O Specifications . . . . . . . . . . . 2-26

Digital I/O Power Supply . . . . . . . . . . . . . . . . . . . . . . 2-26

Auxiliary 5V Logic Supply . . . . . . . . . . . . . . . . . . . . . . 2-26

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Analog COMMAND Input . . . . . . . . . . . . . . . . . . . . . . 2-37

ii Table of Contents

Analog ILIMIT Input . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Understanding Motor Encoder Feedback Specifications . . . 2-40

AM, BM, and IM Inputs . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Hall Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Thermostat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

+ Limit and - Limit Inputs . . . . . . . . . . . . . . . . . . . . . . 2-43

Encoder Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Motor Encoder Connection Diagram . . . . . . . . . . . . . . 2-45

Understanding Motor Feedback Signals and Outputs . . . . . 2-46

Unbuffered Encoder Outputs. . . . . . . . . . . . . . . . . . . . 2-46

Incremental Encoder Output . . . . . . . . . . . . . . . . . . . . 2-47

High Resolution Encoder Output . . . . . . . . . . . . . . . . . 2-48

Understanding Auxiliary Encoder Feedback Specifications . 2-49

5V Auxiliary Encoder Power Supply . . . . . . . . . . . . . . 2-51

Understanding the Serial Interface. . . . . . . . . . . . . . . . . . . 2-51

Default Serial Interface Settings . . . . . . . . . . . . . . . . . . 2-52

Multiple Axes RS-232 Communications. . . . . . . . . . . . . 2-52

Four-Wire RS-485 Connections . . . . . . . . . . . . . . . . . . 2-53

Restoring Drive Communications. . . . . . . . . . . . . . . . . 2-54

Connecting Your Ultra3000

Chapter 3

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Understanding Basic Wiring Requirements . . . . . . . . . . . . . 3-1

Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . 3-2

Routing Power and Signal Wiring . . . . . . . . . . . . . . . . . 3-2

Determining Your Type of Input Power . . . . . . . . . . . . . . . 3-3

Three-Phase Power Wired to Three-Phase Drives . . . . . . 3-3

Single-Phase Power Wired to Single-Phase Drives . . . . . 3-5

Three-Phase Power Wired to Single-Phase Drives. . . . . . 3-6

Grounding Your Ultra3000 . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Grounding Your System to the Subpanel . . . . . . . . . . . . 3-9

Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . 3-10

Motor Power Cable Shield Termination . . . . . . . . . . . . 3-10

Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . 3-13

Connecting Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Connecting Motor Power and Brakes . . . . . . . . . . . . . . . . 3-18

Applying the Motor Cable Shield Clamp. . . . . . . . . . . . 3-18

Wiring Motor Power . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Understanding Motor Brake Connections . . . . . . . . . . . 3-21

Understanding Shunt Connections . . . . . . . . . . . . . . . . . . 3-22

Understanding Feedback and I/O Cable Connections . . . . 3-23

Motor Feedback Connector Pin-outs . . . . . . . . . . . . . . 3-24

Connecting Your SERCOS Fiber-Optic Cables . . . . . . . . . . 3-26

Connecting to a DeviceNet Network . . . . . . . . . . . . . . . . . 3-29

Connecting Your DeviceNet Cable. . . . . . . . . . . . . . . . 3-30

Publication 2098-IN003E-EN-P — April 2004

Troubleshooting Status Indicators

Specifications and Dimensions

Table of Contents iii

Chapter 4

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Troubleshooting for SERCOS Drives . . . . . . . . . . . . . . . . . . 4-9

SERCOS Module Status LED . . . . . . . . . . . . . . . . . . . . . 4-9

SERCOS Network Status LED. . . . . . . . . . . . . . . . . . . . . 4-9

Troubleshooting for DeviceNet Drives . . . . . . . . . . . . . . . 4-10

DeviceNet Module Status LED . . . . . . . . . . . . . . . . . . . 4-10

DeviceNet Network Status LED . . . . . . . . . . . . . . . . . . 4-10

Appendix A

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Ultra3000 Power Specifications. . . . . . . . . . . . . . . . . . . . . . A-2

Ultra3000 (230V) Power Specifications. . . . . . . . . . . . . . A-2

Ultra3000 (460V) Power Specifications. . . . . . . . . . . . . . A-4

Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Circuit Breaker Specifications . . . . . . . . . . . . . . . . . . . . A-6

Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Power Dissipation Specifications . . . . . . . . . . . . . . . . . . A-7

Ultra3000 General Specifications. . . . . . . . . . . . . . . . . . . . . A-8

Physical and Environmental Specifications . . . . . . . . . . . A-8

Control Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Inputs and Outputs Specifications . . . . . . . . . . . . . . . . . A-9

Communication Specifications. . . . . . . . . . . . . . . . . . . . A-9

Motor Feedback Specifications . . . . . . . . . . . . . . . . . . A-10

Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . A-10

Connector Specifications. . . . . . . . . . . . . . . . . . . . . . . A-10

AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . A-11

Ultra Family External Shunt Module Specifications . . . . A-12

Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . A-13

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

Ultra3000 (230V) Dimensions . . . . . . . . . . . . . . . . . . . A-14

Ultra3000 (460V) Dimensions . . . . . . . . . . . . . . . . . . . A-16

Interconnect Diagrams

Appendix B

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Ultra3000 Interconnect Diagram Notes . . . . . . . . . . . . . . . . B-2

Power Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . B-3

Shunt Module Interconnect Diagrams . . . . . . . . . . . . . . . . . B-7

Active Shunt Module Diagrams . . . . . . . . . . . . . . . . . . . B-7

Passive Shunt Module Diagrams . . . . . . . . . . . . . . . . . . B-7

Ultra3000/Motor Interconnect Diagrams . . . . . . . . . . . . . . B-10

Control String Examples (120V ac) . . . . . . . . . . . . . . . . . . B-16

Publication 2098-IN003E-EN-P — April 2004

iv Table of Contents

Catalog Numbers and Accessories

Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . B-19

Ultra3000 to Logix Cable and Interconnect Diagrams . . . . . B-20

Ultra3000 to IMC-S Compact Cable and

Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . B-23

Appendix C

Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Ultra3000 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

External Shunt Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Motor Feedback Cables. . . . . . . . . . . . . . . . . . . . . . . . . C-5

MP-Series Motor Brake Cable . . . . . . . . . . . . . . . . . . . . C-5

Ultra3000 Interface Cables . . . . . . . . . . . . . . . . . . . . . . . C-5

SERCOS Interface Fiber-Optic Cables . . . . . . . . . . . . . . . C-6

Drive End Connector Kits . . . . . . . . . . . . . . . . . . . . . . . C-6

Motor End Connector Kits . . . . . . . . . . . . . . . . . . . . . . . C-7

Breakout Board Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Breakout Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Breakout Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Publication 2098-IN003E-EN-P — April 2004

Preface

Introduction

Who Should Use this Manual

Read this preface to familiarize yourself with the rest of the manual. This preface contains the following topics:

• Who Should Use this Manual

• Purpose of this Manual

• Contents of this Manual

• Product Receiving and Storage Responsibility

• Related Documentation

• Conventions Used in this Manual

• Allen-Bradley Support

Use this manual for designing, installing, and wiring your Ultra™3000 Digital Servo Drive (DSD). The manual is intended for engineers or technicians directly involved in the installation and wiring of the Ultra3000.

If you do not have a basic understanding of the Ultra3000, contact your local Allen-Bradley representative for information on available training courses before using this product.

Purpose of this Manual

1 Publication 2098-IN003E-EN-P — April 2004

This manual provides the mounting, wiring, and connecting procedures for the Ultra3000 and standard Rockwell Automation/ Allen-Bradley motors recommended for use with the Ultra3000.

For power up procedures, troubleshooting tables, and system integration with Ultraware or the ControlLogix modules/PCI cards (see table below) refer to the Ultra3000 Digital Servo Drives Integration Manual (publication 2098-IN005x-EN-P). Manuals are available electronically (as a .pdf) or in hardcopy from www.theautomationbookstore.com.

Interface

SERCOS interface™ 1756-MxxSE 1784-PM16SE

Analog interface 1756-M02AE 1784-PM02AE

ControlLogix Motion Module

SoftLogix PCI Card

and SoftLogix™

P-2 Preface

Contents of this Manual

Refer to the following listing for the descriptive contents of this installation manual.

Chapter Title Contents

Preface

1 Installing Your Ultra3000 Provides mounting information for the Ultra3000.

2 Ultra3000 Connector Data

3 Connecting Your Ultra3000

Appendix A Specifications and Dimensions

Appendix B Interconnect Diagrams

Appendix C

Troubleshooting Status Indicators

Catalog Numbers and Accessories

Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended.

Provides I/O, encoder, and serial interface connector locations and signal descriptions.

Provides connection and wiring information for the Ultra3000.

Provides troubleshooting tables that define the Ultra3000 status LED error codes.

Provides physical, electrical, environmental, and functional specifications for the Ultra3000.

Provides interconnect diagrams for the Ultra3000.

Provides catalog numbers and descriptions of the Ultra3000 and related products.

Product Receiving and Storage Responsibility

You, the customer, are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company. Check the item(s) you receive against your purchase order. If any items are obviously damaged, it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill. Should you discover any concealed damage during unpacking, you are responsible for notifying the freight agent. Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment.

Store the product in its shipping container prior to installation. If you are not going to use the equipment for a period of time, store using the following guidelines.

• Use a clean, dry location

• Maintain an ambient temperature range of -40 to 70° C

(-40 to 158° F)

• Maintain a relative humidity range of 5% to 95%, non-condensing

• Store it where it cannot be exposed to a corrosive atmosphere

• Store it in a non-construction area

Publication 2098-IN003E-EN-P — April 2004

Preface P-3

Related Documentation

For: Read This Document: Catalog Number:

Information on configuring and troubleshooting your Ultra3000

Ultraware Installation Instructions Ultraware CD Installation Instructions 2098-IN002x-EN-P

Information on configuring your Ultra3000 using Ultraware

Information on communicating with the Ultra3000 using DeviceNet™

Information on attaching Ultra3000 drives to a DeviceNet network

A description and specifications for the Ultra Family including motors and motor accessories

Application sizing and configuration information

More detailed information on the use of ControlLogix motion features and application examples

ControlLogix SERCOS interface module installation instructions

ControlLogix Analog Encoder Servo module installation instructions

SoftLogix SERCOS interface PCI card installation instructions

SoftLogix Analog Encoder PCI card installation instructions

The instructions needed to program a motion application

Information on configuring and troubleshooting your ControlLogix motion module

Information on configuring and troubleshooting your SoftLogix PCI card

Information on proper handling, installing, testing, and troubleshooting fiber-optic cables

Information, examples, and techniques designed to minimize system failures caused by electrical noise

For declarations of conformity (DoC) currently available from Rockwell Automation

An article on wire sizes and types for grounding electrical equipment

A glossary of industrial automation terms and abbreviations

The following documents contain additional information concerning related Allen-Bradley products. To obtain a copy, contact your local Allen-Bradley office, distributor, or download them from www.theautomationbookstore.com

Ultra3000 Digital Servo Drives Integration Manual 2098-IN005x-EN-P

Ultraware User Manual 2098-UM001x-EN-P

Ultra3000 DeviceNet Reference Manual 2098-RM001x-EN-P

DeviceNet Cable System Planning and Installation Manual

Motion Control Selection Guide GMC-SG001x-EN-P

Motion Book Servo Sizing CD

(v4.0 service pack 4 or above)

ControlLogix Motion Module Programming Manual 1756-RM086x-EN-P

3, 8, or 16 Axis SERCOS interface Module Installation Instructions

Analog Encoder (AE) Servo Module Installation Instructions

16 Axis PCI SERCOS interface Card Installation Instructions

PCI 2 Axis Servo Card Installation Instructions 1784-IN005x-EN-P

Logix Controller Motion Instruction Set Reference Manual

ControlLogix Motion Module Setup and Configuration Manual

SoftLogix Motion Card Setup and Configuration Manual

Fiber-Optic Cable Installation and Handling Instructions

System Design for Control of Electrical Noise Reference Manual

Rockwell Automation Product Certification website

National Electrical Code

Allen-Bradley Industrial Automation Glossary AG-7.1

DN-6.7.2

Motion Book-mmmyy

1756-IN572x-EN-P

1756-IN047x-EN-P

1784-IN041x-EN-P

1756-RM007x-EN-P

1756-UM006x-EN-P

1784-UM003x-EN-P

2090-IN010x-EN-P

GMC-RM001x-EN-P

www.ab.com/ certification/ce/docs

Published by the National Fire Protection Association of Boston, MA.

Publication 2098-IN003E-EN-P — April 2004

P-4 Preface

Conventions Used in this Manual

Allen-Bradley Support

The following conventions are used throughout this manual.

• Bulleted lists such as this one provide information, not procedural steps

• Numbered lists provide sequential steps or hierarchical information

• Words that you type or select appear in bold

• When we refer you to another location, the section or chapter

name appears in italics

• Abbreviations for the Ultra3000 drives, shown in the table below, are used throughout this manual

Ultra3000 Drive Abbreviation

Ultra3000 with SERCOS interface

Ultra3000 with DeviceNet interface Ultra3000-DN

Allen-Bradley offers support services worldwide, with over 75 Sales/ Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world.

Ultra3000-SE

Local Product Support

Contact your local Allen-Bradley representative for:

• Sales and order support

• Product technical training

• Warranty support

• Support service agreements

Technical Product Assistance

If you need technical assistance, contact your local Allen-Bradley representative or Rockwell Automation Technical Support at (440) 646-5800 / www.ab.com/support. Please have the catalog numbers of your products available when you call.

Comments Regarding this Manual

To offer comments regarding the contents of this manual, go to www.ab.com/manuals/gmc and download the Motion Control Problem Report form. Mail or fax your comments to the address/fax number given on the form.

Publication 2098-IN003E-EN-P — April 2004

Installing Your Ultra3000

Chapter

Chapter Objectives

This chapter provides system installation guidelines and procedures for mounting your Ultra3000. This chapter covers the following topics:

• Complying with European Union Directives

• Ultra3000 System Component Overview

• Before Mounting Your System

• HF Bonding Your System

• Planning Your Panel Layout

• Mounting Your Ultra3000 Drive

ATTENTION

The following information is a guideline for proper installation. The National Electrical Code and any other governing regional or local codes overrule this information. The Allen-Bradley Company cannot assume responsibility for the compliance or the noncompliance with any code, national, local or otherwise, for the proper installation of this system or associated equipment. If you ignore codes during installation, hazard of personal injury and/or equipment damage exists.

1 Publication 2098-IN003E-EN-P — April 2004

1-2 Installing Your Ultra3000

Complying with European Union Directives

If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply.

Note: Declarations of Conformity (DOCs) to European Union

Directives are available on-line at www.ab.com/certification/ce/ docs. The web site is the authoritative source for verifying compliance and suitability for use of this and other Rockwell Automation/Allen-Bradley products.

EMC Directive

This unit is tested to meet Council Directive 89/336/EEC Electromagnetic Compatibility (EMC) using a technical construction file and the following standards, in whole or in part:

• EN 50081-2 EMC - Emission Standard, Part 2 - Industrial Environment

• EN 50082-2 EMC - Immunity Standard, Part 2 - Industrial Environment

• EN 61800-3 - Adjustable Speed Electrical Power Drive Systems, Part 3 - EMC Product Standard including specific test methods

The product described in this manual is intended for use in an industrial environment.

Meeting CE Requirements

To meet CE requirements the following components are required:

• Install an AC line filter (2090-UXLF-xxx or -HVxxx) between the AC power source and the drive input, and as close to the drive as possible (refer to Appendix C for available AC line filters). The supply must be grounded for the filter to operate properly.

• Connect auxiliary input power (if required) from the load side of the AC line filter to the drive.

• Use 2090 series motor power and feedback cables and terminate the motor power cable shields to the chassis clamp provided (refer to Chapter 3 for wiring instructions).

Publication 2098-IN003E-EN-P — April 2004

• When installing the Ultra3000 system inside an enclosure, run input power wiring (grounded to the enclosure) in conduit outside of the enclosure.

• Separate signal and power cables as shown in Planning Your Panel Layout of this chapter.

Installing Your Ultra3000 1-3

Low Voltage Directive

These units are tested to meet Council Directive 73/23/EEC Low Voltage Directive. The EN 60204-1 Safety of Machinery-Electrical Equipment of Machines, Part 1-Specification for General Requirements standard applies in whole or in part. Additionally, the standard EN 50178 Electronic Equipment for use in Power Installations applies in whole or in part.

Refer to Appendix B for interconnect information.

Ultra3000 System

This section provides an overview of the Ultra3000 system components and a typical installation.

Component Overview

Ultra3000 System Component

Ultra3000 Drives

Ultra3000-SE SERCOS interface Drives

Ultra3000-DN DeviceNet Drives

ControlLogix/ SoftLogix Platforms

RSLogix™ 5000 software

Ultraware Software 2098-UWCPRG The Ultra3000 Analog and DeviceNet drives are configured using Ultraware software.

Servo Motors

Cables

AC Line Filters

External Shunt Modules

Catalog Numbers Description

2098-DSD-xxx and -xxxX

2098-DSD-HVxxx, and

-HVxxxX

2098-DSD-xxx-SE

2098-DSD-HVxxx-SE

2098-DSD-xxx-DN and

-xxxX-DN

2098-DSD-HVxxx-DN and

-HVxxxX-DN

1756-MxxSE module 1784-PM16SE PCI card

9324-RLD300ENE

MP-Series, 1326AB, F-, H-, N-, and Y-Series

Motor Power, Feedback, and Brake cables

Fiber-Optic cables

2090-UXLF-xxx AC line filters with 6, 10, 23, 32, 36, and 50A are available for Ultra3000 (230V) drive systems.

2090-UXLF-HVxxx AC line filters with 23, 30, and 50A are available for Ultra3000 (460V) drive systems.

2090-UCSR-xxxx, 9101-1183, and 2090-SRxxx-xx

Ultra3000 and Ultra3000 with indexing available with 500W, 1, 2, 3, 7.5 and 15 kW continuous output and 230V input power.

Ultra3000 and Ultra3000 with indexing available with 3, 5, 10, 15, and 22 kW continuous output and 460V input power.

Ultra3000 with SERCOS interface available with 500W, 1, 2, 3, 7.5 and 15 kW continuous output and 230V input power.

Ultra3000 with SERCOS interface available with 3, 5, 10, 15, and 22 kW continuous output and 460V input power.

Ultra3000 with DeviceNet and Ultra3000 with indexing DeviceNet available with 500W, 1, 2, 3, 7.5 and 15 kW continuous output with 230V input power.

Ultra3000 with DeviceNet and Ultra3000 with indexing DeviceNet available with 3, 5, 10, 15, and 22 kW continuous output with 460V input power.

The SERCOS interface module/PCI card serves as a link between the ControlLogix/SoftLogix platform and Ultra3000 system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (SERCOS) protocol over a fiber-optic cable.

RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of controllers.

The MP-Series (Low Inertia, Integrated Gear, and Food Grade) 230 and 460V, 1326AB (M2L/S2L) 460V, and F-, H-, N-, and Y-Series 230V motors are available for use with the Ultra3000 drives.

Motor power, feedback, and brake cables include integral molded, bayonet style, quick connect/ quick-release connectors at the motor. Power and brake cables have flying leads on the drive end and straight connectors that connect to servo motors. Standard feedback cables have angled connectors (45º) on the drive end and straight connectors that connect to servo motors.

SERCOS fiber-optic cables are available in enclosure only, PVC, nylon, and glass with connectors at both ends.

External shunt modules are available when the Ultra3000 internal shunt capability is exceeded.

Note: Refer to Appendix C for a complete list of catalog numbers for

the Ultra3000 system components listed above.

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1-4 Installing Your Ultra3000

The typical Ultra3000 system installation includes the following, as shown in the figures below.

Figure 1.1 Ultra3000-SE (SERCOS) Digital Servo Drive System Overview

Ultra3000-SE

ControlLogix

Encoder Feedback

Motor Power

Input

Controller

Commissioning and Communications

Output

1756-MxxSE SERCOS Interface Module

ControlLogix Chassis

SERCOS Fiber-Optic Ring

Ultra3000-SE

Encoder Feedback

Motor Power

MP-Series Servo Motor

SERCOS Fiber-Optic Ring

RSLogix 5000

Ultra3000-SE

MP-Series Servo Motor

Figure 1.2 Ultra3000 Digital Servo Drive System Overview

Encoder Feedback

Motor Power

MP-Series Servo Motor

Ultra3000

Encoder Feedback

Motor Power

Commissioning and Communications

Input

ControlLogix Controller

I/O and Commands

MP-Series Servo Motor

PC-Powered Ultraware

Output

1756-M02AE Servo Module

ControlLogix Chassis

Publication 2098-IN003E-EN-P — April 2004

Installing Your Ultra3000 1-5

Figure 1.3 Ultra3000-DN (DeviceNet) Digital Servo Drive System Overview

Ultra3000-DN

Encoder Feedback

Motor Power

Before Mounting Your System

Commissioning and Communications

ControlLogix Controller

I/O and Commands

DeviceNet Network

MP-Series Servo Motor

Input

Output

DeviceNet Network Card

ControlLogix Chassis

PC-Powered Ultraware

Before you mount your Ultra3000 system make sure you understand the following:

• how to unpack the system

• the minimum mounting requirements

Unpacking Modules

Each Ultra3000 ships with the following:

• One Ultra3000 drive

• One installation manual (publication 2098-IN003x-EN-P)

Remove all packing material, wedges, and braces from within and around the components. After unpacking, check the item(s) name plate catalog number against the purchase order.

Publication 2098-IN003E-EN-P — April 2004

1-6 Installing Your Ultra3000

System Mounting Requirements

There are several things that you need to take into account when preparing to mount the Ultra3000:

• The Ultra3000 must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP22 such that they are not accessible to an operator or unskilled person, in order to comply with UL requirements. A NEMA 4X enclosure exceeds these requirements providing protection to IP66.

• The ambient temperature of the location in which you will install the Ultra3000 must not exceed 55° C (131° F).

• You must install the Ultra3000 vertically on the panel (refer to Figure 1.4 for mounting orientation).

• You must install the panel on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors.

and CE

• You need to maintain minimum clearances (refer to Figure 1.4) for proper airflow, easy module access, and proper cable bend radius.

• The Ultra3000 can operate at elevations to 1000 m (3280 ft)

without derating, however, the continuous current rating must be de-rated by 3% for each additional 300 m (984 ft) up to 3000 m (9842 ft). Consult your local Allen-Bradley representative prior to operating above 3000 m (9842 ft).

ATTENTION

Refer to Appendix A for mounting dimensions, power dissipation, and environmental specifications for the Ultra3000.

Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

Publication 2098-IN003E-EN-P — April 2004

Ventilation Requirements

This section provides information to assist you in sizing your cabinet and locating your Ultra3000 drive(s) inside the cabinet.

Figure 1.4 Minimum Clearance Requirements

Ultra3000 mounted

vertically on the panel

Installing Your Ultra3000 1-7

50.8 mm (2.0 in.) clearance for airflow and installation

Do not mount drive on its side.

Allow 12.7 mm (0.5 in.)

side clearance

Allow 12.7 mm (0.5 in.)

side clearance

Minimum cabinet depth = 243.8 mm (9.6 in.) Minimum front clearance = 76.2 mm (3.0 in.)

Motor cable entry area for ground clamp

50.8 mm (2.0 in.) clearance for airflow and installation

IMPORTANT

If the cabinet is ventilated, use filtered or conditioned air to prevent the accumulation of dust and dirt on electronic components. The air should be free of oil, corrosives, or electrically conductive contaminates.

Refer to Appendix A for Ultra3000 power dissipation specifications.

Publication 2098-IN003E-EN-P — April 2004

1-8 Installing Your Ultra3000

Sizing an Enclosure

As an additional aid in sizing an enclosure, with no active method of heat dissipation, either of the following approximate equations can be used:

Metric Standard English

0.38Q

------------------------= A

1.8T 1.1–

Where T is temperature difference between inside air and outside ambient (°C), Q is heat generated in enclosure (Watts), and A is

enclosure surface area (m of all six sides of an enclosure is calculated as

A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144

Where d (depth), w (width), and h (height) are in meters.

). The exterior surface

Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in enclosure (Watts), and A is enclosure surface area (ft²). The exterior surface of all six sides of an enclosure is calculated as

Where d (depth), w (width), and h (height) are in inches.

4.08Q

----------------= T 1.1–

Transformer Sizing

The Ultra3000 does not require isolation transformers. However, a transformer may be required to match the voltage requirements of the controller to the available service. To size a transformer for the main AC power inputs, the power output (KVA) of each axis must be known. This can be derived by calculating the horsepower for each axis and converting that horsepower into units of watts. If you are supplying power to more than one motor and an Ultra3000, simply add the kW ratings together from each calculation to get a system kW total.

Publication 2098-IN003E-EN-P — April 2004

IMPORTANT

If using an autotransformer, ensure that the phase to neutral/ground voltages do not exceed the input voltage ratings of the drive.

Definitions:

kW = power or real power KVA = apparent power

Transformer KVA rating = (Sum of average output power of each axis) x 2.0.

Installing Your Ultra3000 1-9

IMPORTANT

If you are using the Rockwell Automation/ Allen-Bradley system sizing program, the average speed and average torque data has already been calculated and can be used in the above equation. If you are not sure of the exact speed and torque in your application, another approach is to look at the speed/torque curve for your Ultra3000/motor combination and use the values for the worst case continuous speed and torque.

IMPORTANT

Calculations are multiplied by a factor to compensate for the power and loss elements within a power system. A factor of 2.0 is used with a single phase system and a factor of 1.5 is used with a three phase system. This factor should minimize the effects of the secondary line voltage sagging in the transformer during peak current periods.

Example: sizing a transformer to the voltage requirements of an 2098-DSD-020 and MPL-A320P motor:

Intro

KVA

Speed RPM()xTorque lb in–()

-------------------------------------------------------------------------------------x

5 000 RP M(),()X17.7 lb in–()

--------------------------------------------------------------------------------=

63 025,

42 250,

746Watts

--------------------------- x HP

KVA

------------------------------ x 2 . 0= 1000W atts

Transformer Size 2.1 KVA=

Intro

The speed/torque curve information for 230V motors is based upon an Ultra3000 input voltage of 230V ac. For a 115V ac input voltage, the maximum speed can be reduced up to one half.

Intro Intro Intro Intro Intro Intro Intro Intro Intro

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1-10 Installing Your Ultra3000

Fuse Sizing

In the United States, the National Electric Code (NEC) specifies that fuses must be selected based on the motor full load amperage (FLA). The typical fuse size should be 300% of the motor FLA for non-time delay fuses (and time-delay class CC fuses) or 175% of motor FLA for time delay fuses. If these ratings are not high enough for starting currents, the NEC allows non-time delay fuses (and time-delay class CC fuses) to be sized up to 400% of the motor FLA and time-delay fuses to be sized up to 225% of the motor FLA.

In most cases, fuses selected to match the drive input current rating will meet the NEC requirements and provide the full drive capabilities. Dual element, time delay (slow acting) fuses should be used to avoid nuisance trips during the inrush current of power initialization. Refer to the section Ultra3000 Power Specifications in Appendix A for input current and inrush current specifications.

The Ultra3000 utilizes solid state motor short circuit protection rated as shown in the table below.

Drive Models: Input Power Type

2098-DSD-xxx-xx or xxxX-xx

Input Power and Auxiliary Input

2098-DSD-HVxxx-xx or HVxxxX-xx

Power

HF Bonding Your System

Short Circuit Current Rating with No Fuse Restrictions:

Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, 240V maximum.

Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, 480V maximum.

Short Circuit Current Rating with Fuse Restrictions:

Suitable for use on a circuit capable of delivering not more than 200,000 rms symmetrical amperes, 240V maximum, when protected by high interrupting capacity, current limiting fuses meeting UL 198C (Class CC, G, J, L, R, T).

Suitable for use on a circuit capable of delivering not more than 200,000 rms symmetrical amperes, 480V maximum, when protected by high interrupting capacity, current limiting fuses meeting UL 198C (Class CC, G, J, L, R, T).

Wiring to the auxiliary power terminals (L1 AUX and L2/N AUX) of

the drive should be 2.5 mm

(14 AWG) minimum and fusing for the auxiliary power should be selected to properly protect the wire. For example, if 60° C (140° F) wire is used, the fuse should not exceed 8A. If 75° C (167° F) wire is used, the fuse should not exceed 13A. Refer to Fuse Specifications in Appendix A for fuse examples.

Bonding is the practice of connecting metal chassis, assemblies, frames, shields and enclosures to reduce the effects of electromagnetic interference (EMI). For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual (publication GMC-RM001x-EN-P).

Publication 2098-IN003E-EN-P — April 2004

Installing Your Ultra3000 1-11

Bonding Modules

Unless specified, most paints are not conductive and they act as insulators. To achieve a good bond between modules and the subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance exit path for high-frequency energy.

IMPORTANT

To improve the bond between the drive and subpanel, construct your subpanel out of zinc plated (paint-free) steel.

Improper bonding blocks that direct exit path and allows high-frequency energy to travel elsewhere in the cabinet. Excessive high-frequency energy can effect the operation of other microprocessor controlled equipment. The illustrations that follow (refer to Figure 1.5) show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Figure 1.5 Recommended Bonding Practices

Stud-mounting the subpanel

to the enclosure back wall

Back wall of enclosure

Subpanel Welded stud

Star washer

Nut

Use a wire brush to remove paint from threads to maximize ground connection.

Use plated panels or scrape paint on front of panel.

Welded stud

Mounting bracket or

Flat washer

Nut

Stud-mounting a ground bus

or chassis to the subpanel

ground bus

Flat washer

If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material

Star washer

around the mounting hole.

Subpanel

Scrape paint

Ground bus or

mounting bracket

Flat washer

Nut

Bolt-mounting a ground bus or chassis to the back-panel

Subpanel

Tapped hole

Nut

Star washer

Scrape paint on both sides of panel and use star washers.

Star washer

Flat washer

If the mounting bracket is coated with

Star washer

a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole.

Bolt

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1-12 Installing Your Ultra3000

Bonding Multiple Subpanels

Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels. Refer to the figure below for recommended bonding practices.

Figure 1.6 Multiple Subpanels and Cabinet

Recommended:

Bond the top and bottom of each subpanel to the cabinet using

25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.

Planning Your Panel Layout

Bonded cabinet

ground bus to

subpanel

Scrape the paint around each fastener to maximize metal to metal contact.

This section outlines the practices which minimize the possibility of noise-related failures as they apply specifically to Ultra3000 installations. For more information on the concept of electrical noise reduction, refer to System Design for Control of Electrical Noise (publication GMC-RM001x-EN-P).

Publication 2098-IN003E-EN-P — April 2004

Installing Your Ultra3000 1-13

Establishing Noise Zones

Observe the following guidelines when laying out your panel (refer to Figure 1.7 for zone locations).

• The clean zone (C) is above and beneath the Ultra3000 and includes CN1, CN2, CN3, and the DC filter (grey wireways).

• The dirty zone (D) is left of the Ultra3000 (black wireways) and includes the circuit breakers, transformer, AC line filter, contactors, 24V dc power supply, and motor power cables.

• The very dirty zone (VD) is limited to where the AC line (EMC) filter AC output jumpers over to the Ultra3000. Shielded cable is required only if the very dirty cables enter a wireway.

• The SERCOS fiber-optic cables are immune to electrical noise.

Figure 1.7 Establishing Noise Zones

Dirty Wireway Clean Wireway

(1)

Contactors

Filter

Mount AC line

filter as close

to the drive as

possible

Line Filter

Motor Power Cables

Route Encoder/Analog/Registration

Shielded Cable

Ultra3000

CN3

CN2

CN1 I/O Cable

Circuit

Breaker

XFMR

Route Motor Power Shielded Cable

If I/O cable contains (dirty) relay wires, route cable with motor power wires in dirty wireway.

This is a clean 24V dc available for CN1 I/O power supply. The 24V enters the clean wireway and exits to the right.

This is a dirty 24V dc available for motor brakes and contactors. The 24V enters the dirty wireway and exits to the left.

24V

Power Supply

Very dirty EMC filter connections

segregated (not in wireway)

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1-14 Installing Your Ultra3000

Observe the following guidelines when installing your 1756-MxxSE SERCOS interface module (refer to Figure 1.8 for zone locations).

• The clean zone (C) is beneath the less noisy modules (I/O, analog, encoder, registration, etc. (grey wireway).

• The dirty zone (D) is above and below the power supply and noisy modules (black wireway).

• The SERCOS fiber-optic cables are immune to electrical noise.

Figure 1.8 Establishing Noise Zones (ControlLogix)

Dirty Wireway

(1)

EMC Filter

EMC filter/power supply connections segregated (not in wireway)

Route dirty wireways directly above the ControlLogix rack

(shielded by the chassis)

Dirty I/O

(24V dc I/O, AC I/O)

Spare Slot(s)

(Analog, Encoder

Registration, etc.)

Clean I/O

Clean Wireway

Cable Categories for the Ultra3000

The table below indicates the zoning requirements of cables connecting to the Ultra3000.

Wire/Cable Connector

DC-/DC+

L1, L2, L3 (shielded cable) X X

L1, L2, L3 (unshielded cable) X

U, V, W (motor power) X X

Registration Wiring CN1 X X

Other 24V Wiring CN1 X

Motor Feedback CN2 X X

Serial Communications CN3 X X

Fiber-Optic Rx and Tx No Restrictions

Publication 2098-IN003E-EN-P — April 2004

TB1

Very Dirty

Zone Method

Dirty Clean

Ferrite Sleeve

Shielded Cable

Installing Your Ultra3000 1-15

The table below indicates the zoning requirements of cables connecting to the External Shunt Resistor Kit.

Zone Method

Wire/Cable Connector

Shunt Connections (shielded option)

Shunt Connections (unshielded option) X

Fan (if present) N/A X

TB2

Very Dirty

Dirty Clean

Mounting Guidelines to Reduce Electrical Noise

When mounting an AC line (EMC) filter or external shunt resistor refer to the sections below for guidelines designed to reduce system failures caused by excessive electrical noise.

Ferrite Sleeve

Shielded Cable

ATTENTION

High voltage exists in AC line filters. The filter must be grounded properly before applying power. Filter capacitors retain high voltages after power removal. Before handling the equipment, voltages should be measured to determine safe levels. Failure to observe this precaution could result in personal injury.

AC Line Filters

Observe the following guidelines when mounting your AC line (EMC) filter (refer to Figure 1.7 for an example).

• Mount the AC line filter and bonded cabinet ground bus on the same panel as the Ultra3000, and as close to the Ultra3000 as possible.

• Good HF bonding to the panel is critical. For painted panels, refer to Figure 1.5.

• Segregate input and output wiring as far as possible.

IMPORTANT

CE test certification applies only to AC line filter and single drive. Multiple drive loads may perform satisfactorily, but the user takes legal responsibility.

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1-16 Installing Your Ultra3000

External Shunt Resistor

Observe the following guidelines when mounting your external shunt resistor (refer to Figure 1.9 and for an example).

• Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI.

• Mount resistors (other than metal-clad) in a shielded and ventilated enclosure outside the cabinet.

• Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.

Figure 1.9 External Shunt Resistor Outside the Enclosure

Customer-supplied

metal enclosure

150 mm (6.0 in.) of

clearance on all sides

of the shunt module

minimum

Dirty Wireway

Very dirty shunt connections

segregated (not in wireway).

Maximum Length: 3.05 m (10 ft).

Circuit

Breaker

XFMR

24V

Power Supply

1394 Digital Servo Controller

300W Shunt Module

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC

FOR FUSE REPLACEMENT USE:

BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

Metal conduit (where required by local code)

Shunt Wiring Methods:

Twisted pair in conduit (1st choice). Shielded twisted pair (2nd choice). Twisted pair, 2 twists per foot min. (3rd choice).

Contactors

Filter

Line Filter

Internal

External

Shunt

Motor

DC Bus

100-240 VAC

50/60 Hz

TB2

L2/N

L1 AUX

L2/N AUX

TB1

Clean Wireway

Ultra3000

Publication 2098-IN003E-EN-P — April 2004

Route Motor Power Shielded Cable

Very dirty power connections

segregated (not in wireway)

Motor Power Cable

Route Encoder/Analog/Registration

Enclosure

Shielded Cables

Installing Your Ultra3000 1-17

When mounting your shunt module inside the enclosure, follow these additional guidelines (refer to Figure 1.10 and for an example).

• Metal-clad modules can be mounted anywhere in the dirty zone, but as close to the Ultra3000 as possible.

• Shunt power wires can be run with motor power cables.

• Keep unshielded wiring as short as possible. Keep shunt wiring as

flat to the cabinet as possible.

• Separate shunt power cables from other sensitive, low voltage signal cables.

Figure 1.10 External Shunt Resistor Inside the Enclosure

Dirty Wireway

Very dirty shunt connections

segregated (not in wireway).

Maximum Length: 3.05 m (10 ft).

Circuit

Breaker

XFMR

Power Supply

24V

150 mm (6.0 in.) of clearance on all sides of the shunt module minimum

1394 Digital Servo Controller

300W Shunt Module

ALLEN-BRADLEY

BULLETIN 1394 300W SHUNT MODULE

CAT. PART SER.

INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

Shunt Wiring Methods:

Twisted pair in conduit (1st choice). Shielded twisted pair (2nd choice). Twisted pair, 2 twists per foot min. (3rd choice).

Contactors

Filter

Line Filter

Internal

External

Shunt

Motor

DC Bus

100-240 VAC

50/60 Hz

TB2

L2/N

AUX

L2/N AUX

TB1

Clean Wireway

Ultra3000

Route Motor Power Shielded Cable

Very dirty power connections

segregated (not in wireway)

Motor Power Cable

Route Encoder/Analog/Registration

Enclosure

Shielded Cables

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1-18 Installing Your Ultra3000

Mounting Your Ultra3000 Drive

The procedures in this section assume you have prepared your panel and understand how to bond your system. For installation instructions regarding other equipment and accessories, refer to the instructions that came with each of the accessories for their specific requirements.

ATTENTION

To mount your Ultra3000 drive:

1. Layout the position for the Ultra3000 and accessories in the

enclosure (refer to Establishing Noise Zones for panel layout recommendations). Mounting hole dimensions for the Ultra3000 are shown in Appendix A.

This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook.

2. Attach the Ultra3000 to the cabinet, first using the upper mounting

slots of the drive and then the lower. The recommended mounting hardware is M5 metric (1/4-20) or #10 MS bolts. Observe bonding techniques as described in HF Bonding Your System.

IMPORTANT

3. Tighten all mounting fasteners.

To improve the bond between the Ultra3000 and subpanel, construct your subpanel out of zinc plated (paint-free) steel.

Publication 2098-IN003E-EN-P — April 2004

Ultra3000 Connector Data

Chapter

Chapter Objectives

Understanding Ultra3000 Connectors

Designator Description Connector

CN1 User Input/Output 44-pin high-density D-shell

CN2 Motor Feedback 15-pin high-density D-shell

CN3 Serial Port 9-pin standard D-shell

TB1

TB2 Shunt

This chapter provides I/O, encoder, and serial interface connector locations and signal descriptions for your Ultra3000. This chapter includes:

• Understanding Ultra3000 Connectors

• Understanding Ultra3000 I/O Specifications

• Understanding Motor Encoder Feedback Specifications

• Understanding Auxiliary Encoder Feedback Specifications

• Understanding the Serial Interface

Switch and LED locations are shown, however for switch and LED configuration, refer to the Ultra3000 Digital Servo Drives Integration Manual (publication 2098-IN005x-EN-P).

The following table provides a brief description of the Ultra3000 front panel connectors and describes the connector type.

DC bus, Motor and AC power

DC bus, Motor, AC power, and auxiliary AC power

9-position screw style barrier terminal strip (2098-DSD-005x-xx, -010x-xx, and -020x-xx)

11- or 12-position screw style barrier terminal strip (2098-DSD-030x-xx, -075x-xx, -150x-xx, HVxxx-xx, and HVxxxX-xx)

3-position screw style barrier terminal strip (2098-DSD-030x-xx, -075x-xx, -150x-xx, HVxxx-xx, and HVxxxX-xx)

For connector pin-outs and the location of connectors, switches, and status LEDs on:

2098-DSD-xxx and -HVxxx Ultra3000 drives Figures 2.1-2.4 and the tables that follow on pages 2-2 through 2-9.

2098-DSD-xxx and -HVxxx Ultra3000 drives with SERCOS interface Figures 2.5-2.8 and the tables that follow on pages 2-10 through 2-17.

2098-DSD-xxx and -HVxxx Ultra3000 drives with DeviceNet interface Figures 2.9-2.12 and the tables that follow on pages 2-18 through 2-25.

1 Publication 2098-IN003E-EN-P — April 2004

All signal connections on the Ultra3000 use commonly available D-shell type connectors.

Refer to:

2-2 Ultra3000 Connector Data

Ultra3000 Front Panel Connections

Use the figure below to locate the front panel connections on the Ultra3000 230V drives (500W, 1 kW, and 2 kW).

Figure 2.1 Ultra3000 Front Panel Connections for 2098-DSD-005, -005X, -010, -010X, -020, and -020X

9-pin CN3

Serial Connector

Seven Segment

Status LED

DC Bus Connections for

Active Shunt Resistor Kit

AC Input Power

Connections

Motor Power

Connections

Motor Power

Cable Shield Clamp

Logic Power LED

CN3 9-pin Serial Port Connector

CN2 15-pin Motor Feedback Connector

CN1 44-pin User I/O Connector

Pin 9

Pin 6

15-pin CN2

Feedback Connector

Pin 15

Pin 11 Pin 6

44-pin CN1

I/O Connector

Pin 44

Pin 31

Pin 16

Pin 5

Pin 1

Pin 10

Pin 5

Pin 1

Pin 30

Pin 15

Pin 1

Serial Port Connector

The following table provides the signal descriptions and pin-outs for the CN3 serial port (9-pin) connector.

Publication 2098-IN003E-EN-P — April 2004

CN3 Pin Description Signal

1 RS-422/RS-485 Input+ RCV+

2 RS-232 Input RCV

3 RS-232 Output XMT

4 RS-422/RS-485 Output+ XMT+

5 Common COM

6Reserved –

7 RS-422/RS-485 Input- RCV-

8 RS-422/RS-485 Output- XMT-

9 Reserved –

Ultra3000 Connector Data 2-3

I/O Connector

The following table provides the signal descriptions and pin-outs for the CN1 I/O (44-pin) connector.

CN1 Pin Description Signal CN1 Pin Description Signal

1 Auxiliary Encoder Power Out (+5V) EPWR 23 Programmable Analog Output AOUT

2 Common ECOM 24 Analog Current Limit Input ILIMIT

3 Auxiliary Logic Power In (+5V) AUXPWR 25 Command + COMMAND+

4 Auxiliary A+/Step+/CW+ AX+ 26 Command - COMMAND-

5 Auxiliary A-/Step-/CW- AX- 27 I/O Common IOCOM

6 Auxiliary B+/Dir+/CCW+ BX+ 28 I/O Common IOCOM

7 Auxiliary B-/Dir-/CCW- BX- 29 I/O Power IOPWR

8 Auxiliary Encoder Ch I+ IX+ 30 I/O Power IOPWR

9 Auxiliary Encoder Ch I- IX- 31 Digital Input 1 INPUT1

10 Unbuffered Motor Encoder Ch A+ AM+ 32 Digital Input 2 INPUT2

11 Unbuffered Motor Encoder Ch A- AM- 33 Digital Input 3 INPUT3

12 Unbuffered Motor Encoder Ch B+ BM+ 34 Digital Input 4 INPUT4

13 Unbuffered Motor Encoder Ch B- BM- 35 Digital Input 5 INPUT5

14 Unbuffered Motor Encoder Ch I+ IM+ 36 Digital Input 6 INPUT6

15 Unbuffered Motor Encoder Ch I- IM- 37 Digital Input 7 INPUT7

16 Buffered Motor Encoder Ch A+ AMOUT+ 38 Digital Input 8 INPUT8

17 Buffered Motor Encoder Ch A- AMOUT- 39 Digital Output 1 OUTPUT1

18 Buffered Motor Encoder Ch B+ BMOUT+ 40 Digital Output 2 OUTPUT2

19 Buffered Motor Encoder Ch B- BMOUT- 41 Digital Output 3 OUTPUT3

20 Buffered Motor Encoder Ch I+ IMOUT+ 42 Digital Output 4 OUTPUT4

21 Buffered Motor Encoder Ch I- IMOUT- 43 Normally Open Relay Output+ RELAY+

22 Common ACOM 44 Normally Open Relay Output- RELAY-

CN2 Pin Description Signal CN2 Pin Description Signal

1 Channel A+/Sine Differential Input+ AM+ 9 Positive Overtravel Limit +LIMIT

2 Channel A-/Sine Differential Input- AM- 10 Channel I-/Index Pulse- IM-

3 Channel B+/Cosine Differential Input+ BM+ 11 Thermostat TS

4 Channel B-/Cosine Differential Input- BM- 12 Commutation Channel S1 S1

5 Channel I+/Index Pulse+ IM+ 13 Commutation Channel S2 S2

6 Common ECOM 14 Encoder Power (+5V) EPWR_5V

7 Reserved – 15 Negative Overtravel Limit -LIMIT

8 Commutation Channel S3 S3

Motor Encoder Connector

The following table provides the signal descriptions and pin-outs for the CN2 motor encoder (15-pin) connector.

Publication 2098-IN003E-EN-P — April 2004

2-4 Ultra3000 Connector Data

Use the figure below to locate the front panel connections on the Ultra3000 230V drives (3 kW).

Figure 2.2 Ultra3000 Front Panel Connections for 2098-DSD-030 and -030X

Passive Shunt

Resistor Connections

Motor Power

Connections

AC Input Power

Connections

Motor Power

Cable Shield Clamp

External

Shunt

100-240 VAC

50/60 Hz

Internal

DC Bus

Seven Segment

TB2

Status LED

Logic Power LED

9-pin CN3

Serial Connector

Pin 9

Pin 6

Pin 5

Pin 1

15-pin CN2

Feedback Connector

CN3 9-pin Serial Port

Motor

Connector

CN2 15-pin Motor Feedback Connector

L2/N

AUX

L2/N

AUX

TB1

CN1 44-pin User I/O Connector

Pin 15

Pin 11

Pin 6

44-pin CN1

I/O Connector

Pin 44

Pin 31

Pin 10

Pin 5

Pin 1

Pin 30

Pin 15

Pin 1

Pin 16

Publication 2098-IN003E-EN-P — April 2004

Serial Port Connector

The following table provides the signal descriptions and pin-outs for the CN3 serial port (9-pin) connector.

CN3 Pin Description Signal

1 RS-422/RS-485 Input+ RCV+

2 RS-232 Input RCV

3 RS-232 Output XMT

4 RS-422/RS-485 Output+ XMT+

5 Common COM

6Reserved –

7 RS-422/RS-485 Input- RCV-

8 RS-422/RS-485 Output- XMT-

9 Reserved –

Ultra3000 Connector Data 2-5

I/O Connector

The following table provides the signal descriptions and pin-outs for the CN1 I/O (44-pin) connector.

CN1 Pin Description Signal CN1 Pin Description Signal

1 Auxiliary Encoder Power Out (+5V) EPWR 23 Programmable Analog Output AOUT

2 Common ECOM 24 Analog Current Limit Input ILIMIT

3 Reserved – 25 Command + COMMAND+