Rockwell Automation 1398-DDM-xxx User Manual
Allen-Bradley
ULTRA
200 Series
User
Digital Servo
Drives
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, chart s, sample programs and la yout 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 intell ectual proper ty liabili ty) 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 cont ents of t his copyrigh ted public ation, in whole
or in part, without written permission of Allen-Bradley Company,
Inc., is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations. For example:
Intro
ATTENTION: This symbol identifies inf ormation about
practices or circumst ances tha t can lead t o personal injury
or death, property damage or economic loss.
Attention statements help you to:
● identify a hazard
● avoid the hazard
● recognize the consequences
Note: This symbol iden tifies in formation that is critical for succes sful
application and understanding of the product.
Mathcad is a registered tradem ark of MathSoft, Inc.
Microsoft, MS-DOS and Window s ar e trademarks of Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.
Table of Contents
IntroTable of Contents
Table of Contents Intro-1
List of Figures Intro-7
List of Tables Intro-11
Preface Intro-15
About This Manual .........................Intro-16
Additional Instructions and Manuals ...............Intro-17
Host Commands and ULTRA Master .............Intro-17
TouchPad .............................Intro-18
Symbols and Conventions .....................Intro-19
Typographical and Wording Conventions ...........Intro-19
Graphical Symbols and Warning Classifications .......Intro-20
Pictorial Index ............................Intro-21
Chapter 1
Chapter 2
Safety
Installing and Using the ULTRA 200 Series .............1-1
Potential Hazards...........................1-1
Safety Guidelines ............................1-3
Selecting Other System Components
ULTRA 200 Series Overview .....................2-1
Drive Power Ratings .........................2-1
Interface Cables............................2-2
ULTRA 200 Series Features ......................2-2
Stand-alone Design..........................2-2
High Performance Microcontroller Technology .........2-2
IPM Technology ...........................2-2
Analog and Digital Interfaces ....................2-2
Encoder Control ...........................2-2
Encoder Output ............................2-3
Digital I/O ...............................2-3
Analog I/O...............................2-3
AC Input Power............................2-3
Personality Module..........................2-3
Multiple Protection Circuits.....................2-4
ULTRA Master Softw are ......................2-4
Publication 1398-5.0 – October 1998
Intro-2 Table of Contents
Communications............................2-4
Autotuning ...............................2-5
Agency Approvals...........................2-5
Options .................................2-5
Motors ...................................2-6
European Union Requirements .....................2-7
Chapter 3
Chapter 4
Chapter 5
ULTRA Master Installation
Hardware and Software Requirements .................3-1
Installing ULTRA Master ........................3-2
Starting a nd Quitting ULTRA Master .................3-3
Version Level .............................3-3
The ULTRA Master Start-Up Screen ................3-3
The readme File ............................3-4
Firmware Files .............................3-4
Unpacking, Inspecting and Storing
Unpacking the Drive ...........................4-1
Inspection Procedure...........................4-1
Testing the Unit..............................4-2
Hardware Setup ............................4-3
Drive Checkout Test .........................4-4
Storing the Unit..............................4-7
Installation
Mechanical Installation Requirements .................5-1
Interface Connections ..........................5-5
Wiring .................................5-6
Electromagnetic Compatibility ...................5-6
Qualified AC Line Filters.......................5-6
Allen-Bradley AC Line Filters....................5-7
Chapter 6
Publication 1398-5.0 – October 1998
Interfaces
J1 – Controller ..............................6-1
Digital I/O Power ...........................6-3
Digital Inputs..............................6-4
Digital Outputs.............................6-9
Analog Inputs ............................6-14
Analog Outputs ...........................6-16
Motor Encoder Output Signals ..................6-17
Auxiliary Encoder Inputs .....................6-19
Interface C able Examples .....................6-21
J1 Terminal Strip/Breakout Board.................6-26
J2 – Encoder ..............................6-27
Table of Contents Intro-3
J2 Terminal Strip/Breakout Board ................ 6-30
J3 – Auxiliary Port ..........................6-31
J4 and J5 – Serial Port ........................ 6-34
Serial Communications Overview ................ 6-36
RS-232 Connections ........................ 6-38
Four Wire RS-485 Connections.................. 6-40
A1, A2, and COM – Analog Outputs ................ 6-44
Interface Connections ......................... 6-45
Chapter 7
Chapter 8
Power Connections
TB1 – DC Bus and AC Power .....................7-1
Motor Power Cabling ........................7-3
Motor Over load Protection .....................7-5
Emergency Stop Wiring .......................7-6
DC Bus.................................7-6
AC Power Cabling ..........................7-7
Auxiliary Power .......................... 7-10
TB2 – Shunt Regulator ........................ 7-11
External Shunt Connection .................... 7-14
Application and Configuration Examples
Analog Control..............................8-1
Hardware Setup............................8-1
Connection Diagram .........................8-2
Configuration .............................8-3
Tuning ................................8-4
Operation ...............................8-5
Preset Controller .............................8-6
Hardware Setup............................8-6
Connection Diagram .........................8-8
Configuration .............................8-8
Tuning ............................... 8-10
Operation .............................. 8-11
Position Follower (Master Encode r) ................. 8-12
Hardware Setup........................... 8-12
Connection Diagram ....................... 8-13
Configuration ............................ 8-13
Tuning ................................ 8-15
Operation .............................. 8-16
Position Follower (Step/Direction) ................. 8-17
Hardware Setup........................... 8-17
Connection Diagram ........................ 8-18
Configuration ............................ 8-18
Tuning ................................ 8-20
Publication 1398-5.0 – October 1998
Intro-4 Table of Contents
Operation...............................8-21
Position Follower (Step Up/Step Down) ...............8-22
Hardware Setup ...........................8-22
Connection Diagram ........................8-23
Configuration ............................8-23
Tuning ................................8-25
Operation...............................8-26
Incremental Indexing .........................8-27
Hardware Setup ...........................8-28
Connection Diagram ........................8-29
Configuration ............................8-29
Tuning ................................8-31
Operation...............................8-32
Registration Indexing .........................8-33
Hardware Setup ...........................8-34
Connection Diagram ........................8-35
Configuration ............................8-35
Tuning ................................8-37
Operation...............................8-38
Absolute Indexing ...........................8-39
Hardware Setup ...........................8-39
Connection Diagram ........................8-40
Configuration ............................8-41
Tuning ................................8-43
Operation...............................8-44
Modifying User Units .........................8-45
Changing the Display Units Settings ...............8-45
Chapter 9
Chapter 10
Publication 1398-5.0 – October 1998
Tuning
Tuning Guidelines ............................9-1
General Tuning Rules .........................9-1
High Inertia Loads...........................9-1
Mechanical Resonance ........................9-2
Backlash ................................9-3
Auto Tune Mode .............................9-4
Auto Tuning ..............................9-4
Manual Tune Mode............................9-6
Gains ..................................9-6
Filters ..................................9-7
Manual Tuning.............................9-8
Velocity Loop Tuning Examples .................9-10
Status Display
Operating Messages ..........................10-1
Table of Contents Intro-5
Error Messages............................. 10-2
Run-Time Error Codes....................... 10-2
Power-Up Error Codes....................... 10-3
Chapter 11
Appendix A
Maintenance and Troubleshooting
Maintenance .............................. 11-1
Periodic Maintenance ....................... 11-1
Fuse Replacement ......................... 11-1
EEPROM Personality Module .................. 11-2
Firmware Upgrading ......................... 11-5
Firmware Upgrade Procedure using ULTRA Master...... 11-5
Troubleshooting ............................ 11-6
Error Codes ............................. 11-6
RS-232 Communication Test ...................11-11
Testing Digital Outputs ......................11-12
Testing Digital Inputs .......................11-14
Testing Analog Outputs ......................11-14
Testing Positive and Negative Current Limits..........11-15
Testing Encoder Inputs.......................11-17
Options and Accessories
ULTRA 200 Series Drives .......................A-1
Fuses ...................................A-2
Options and Accessories ........................A-2
Publications................................A-3
Interface Cables .............................A-3
Serial Inte rface Cables .........................A-3
Encoder Feedback Cables........................A-4
Motor Power Cables...........................A-5
Connector Kits ..............................A-6
Mating Connectors............................A-6
Appendix B
Appendix C
Cable Diagrams, Schematics and Examples
Interface Cables .............................B-3
Serial Inte rface Cables ........................B-11
Encoder Feedback Cables.......................B-14
Motor Power Cables .........................B-21
Cabling Examples ...........................B-26
Allen-Bradley 9/Series CNC Family Connections.........B-30
TouchPad Instructions
Installation and Operation........................C-1
TouchPad Commands ..........................C-3
Supplemental Instructions .......................C-6
Publication 1398-5.0 – October 1998
Intro-6 Table of Contents
Motor Selection ............................C-6
Displays ................................C-6
Motor Table...............................C-10
TouchPad Options ...........................C-12
TouchPad Lists .............................C-13
Appendix D
Appendix E
Creating Custom Motor Files
Drive and Motor File Config uration with U LTRA Ma ster .... D-2
Motor Parameter Set ........................ D-2
General Parameters ......................... D-5
Feedback Parameters ........................ D-8
Electrical Parameters ........................D-10
Rating Parameters ..........................D-11
Example of Custom Motor File Creation ..............D-14
Manufacturer’s Data.........................D-14
Parameter Conversions .......................D-15
Custom Motor File .........................D-16
Troubleshooting Custom Motor Files ................D-16
Electromagnetic Compatibility Guidelines
for Machine Design
Filtering ..................................E-2
AC Line Filter Selection .......................E-3
Grounding .................................E-5
Shielding and Segregation........................E-6
Appendix F
Appendix G
Publication 1398-5.0 – October 1998
Dynamic Braking Resistor Selection
Dynamic Braking Equations.......................F-1
Sample Calculations..........................F-3
Specifications
Power .................................. G-5
Power Dissipation ........................... G-7
Index Index-1
List of Figures
IntroList of Figures
Product Parts Explained .....................Intro-21
Chapter 1
Chapter 2 Selecting Other System Components
Chapter 3 ULTRA Master Installation
Chapter 4 Unpacking, Inspecting and Storing
Chapter 5
Chapter 6
Safety
Connection Diagram
...........................4-4
Installation
1398-DDM Mounting Dimensions (sheet 1 of 2)
MDF AC Line Filter Mounting Diagrams
MIF Single Phase AC Line Filter Mounting Diagram
Power Wiring Diagrams
(sheet 1 of 3)
..............5-8
................5-11
Interfaces
Digital Input Circuit
Drive Input Connected to a Switch/Relay Contact
Drive Input Connected to an Opto-Isolator
Drive Input Connected to an Active High Sourcing Transistor
Drive Input Connected to Active Low Output using
a Switch/Relay
Drive Input Connected to Active Low Output using
an Opto-Isolator
Drive Input Connected to Sourcing Output
READY and BRAKE Circuits
Digital Output Circuit
Drive Output Connected to an Opto-Isolator
Drive Output Connected to an LED Indicator
Drive Output Connected to a Resistive Load
Drive Output Connected to a Switch/Relay
Drive Output Connected to Active Low Input using
a Switch/Relay ...........................6-13
Drive Output Connected to Active Low Input using
an Opto-Isolator ..........................6-13
Drive Output Connected to Active High (Sinking) Input .....6-13
Positive and Negative Current Limit Circuits ...........6-14
Analog COMMAND Input Circuit .................6-15
ANALOG 1 and ANALOG 2 Output Circuits ...........6-16
Output Encoder Interface Circuit ..................6-17
Auxiliary Encoder Input Types ...................6-19
Auxiliary Encoder Input Circuit ...................6-19
...........................6-4
..............6-7
............................6-7
...........................6-8
.............6-8
......................6-9
.........................6-10
............6-11
............6-12
............6-12
...........5-3
.......5-10
.........6-7
..6-7
...........6-12
Publication 1398-5.0 – October 1998
Intro-8 List of Figures
External Encoder Interface via TTL Differential Line Drivers
Complementary Encoder Interface via 7406 Line Drivers
with Pull-up Resistors
Complementary Encoder Interface via Standard TTL Logic
Single-Ended Encoder Interface via Open Collector
Transistor without Pull-up (not recommended)
Single-Ended Encoder Interface via Standard TTL Signals
(not recommended)
Single-Ended Encoder Interface via Open Collector Transistor
with 5 VDC to 12 VDC Pull-up (not recommended)
Single-Ended Encoder Interface via Open Collector
Transistor with 24 VDC Pull-up (not recommended)
External Step/Direction Interface via TTL Differential
Line Drivers
External Step/Direction Interface via Single-Ended
TTL Line Drivers (not recommended)
External CW/CCW (Step Up/Step Down) Interface via TTL
Differential Line Drivers
External CW/CCW (Step Up/Step Down) Interface via
Single-Ended Line Drivers (not recommended)
Motor Encoder Interface Circuit
Hall Effect Sensor Circuit
ULTRA 200 Series Motor Encoder Connections
RS-232/485 Interface Circuit
Sixteen Position Rotary Addressing Switch
RS-232 Connection Diagrams
RS-485/RS-422 Communication Comparison
Four Wire RS-485 Daisy Chain Connection Diagram
RS-232 to RS-485 Multi-Drop Connection Diagram
ANALOG 1 and ANALOG 2 Output Circuits
1398-DDM Interface Connection Diagram
.............................6-25
........................6-21
....6-22
.........6-22
.........................6-23
......6-23
......6-24
..............6-25
......................6-25
.........6-26
...................6-28
.......................6-28
...........6-30
.....................6-34
.............6-36
.....................6-38
...........6-40
........6-42
.........6-43
...........6-44
..............6-45
...6-21
Chapter 7
Chapter 8
Publication 1398-5.0 – October 1998
Power Connections
Motor Power EMC Shield Connection
Pigtail Ground
Emergency Stop Contactor Wiring
External Shunt Wiring Examples
External Shunt Mounting Diagram ..................7-14
............................. 7-4
................ 7-3
.................. 7-7
...................7-13
Application and Configuration Examples
Analog Controller Connection Diagram ............... 8-2
Preset Controller Connection Diagram ................ 8-8
Master Encoder Connection Diagram ................8-13
Step/Direction Controller Connection Diagram ..........8-18
Step Up/Step Down Controller Connection Diagram .......8-23
Incremental Indexing Examples ...................8-27
Incremental Indexing Connection Diagram .............8-29
Registration Indexing Examples ...................8-33
List of Figures Intro-9
Registration Indexing Connection Diagram
Absolute Indexing Examples
Absolute Indexing Connection Diagram
PC Display Units – Default Dialog
Chapter 9
Chapter 10
Chapter 11 Maintenance and Troubleshooting
Appendix A
Appendix B Cable Diagrams, Schematics and Examples
Tuning
Velocity Loop Structure
Torque Current Conditioning Structure
Signal Nomenclature
Underdamped Signal
Overdamped Signal
Critically Damped Signal (Ideal Tuning)
..........................9-11
Status Display
Fuse and Jumper Locations
Options and Accessories
J1 to J3 Interface Cable (P/N 9101-1367) ................B-3
J1 to No Connector Interface Cable (P/N 9101-1370) . . . . . . . . B-4
J3 to J3 Interface Cable (P/N 9101-1463) ................B-5
J3 to No Connector Interface Cable (P/N 9101-1368) . . . . . . . . B-6
J1 to 50-pin Terminal Block Kit Diagram
(P/N 9101-1391 and 9101-1560) ....... ...........B-7
J1 to 50-pin D-Connector Cable (P/N 9101-1369) . . . . . . . . . . B-8
J2 to 25-pin Terminal Block Kit Diagram (P/N 9101-1392) . . . . .B-9
J2 to 25-pin D-Connector Cable (P/N 9101-1371) . . . . . . . . . B-10
J5 to 9-pin D-Shell Interface Diagram (P/N 9101-1372) . . . . . . B-11
J5 to J5 Serial Interface Cable (P/N 9101-1374) . . . . . . . . . . . B-12
J5 to No Connector Serial Interface Cable (P/N 9101-1379) . . . . B-13
F- or H-Series Motors to No Connector Encoder Cable
(P/N 9101-1365) ..........................B-14
J2 to F- or H-Series Encoder Cable (P/N 9101-1366) . . . . . . . . B-15
J2 to Y-Series Encoder Cable (P/N 9101-1375) . . . . . . . . . . . B-16
No Connector to Y-Series Encoder Cable (P/N 9101-1373) . . . . B-17
J2 to No Connector Encoder Cable (P/N 9101-1380) . . . . . . . . B-18
J2 to N-Series Encoder Cable (P/N 9101-1468) . . . . . . . . . . . B-19
No Connector to N-Series Encoder Cable (P/N 9101-1469) . . . . B-20
2000 or 3000 F- or H-Series Power Cable (P/N 9101-1381) . . . . B-21
4000 F- or H-Series Power Cable (P/N 9101-1382) . . . . . . . . . B-22
6100 or 6200 F- or H-Series Power Cable (P/N 9101-1383) . . . . B-22
6300 H-Series Power Cable (P/N 9101-1399) ............B-23
8000 H-Series Power Cable (P/N 9101-1384) ............B-23
Y-Series Power Cable (P/N 9101-1385) ...............B-24
.....................8-39
..................8-45
.........................9-3
.........................9-10
.........................9-11
.....................11-4
............8-35
..............8-40
................9-3
..............9-12
Publication 1398-5.0 – October 1998
Intro-10 List of Figures
N-Series Power Cable (P/N 9101-1467) ...............B-25
F or H-Series Motors to ULTRA 200 Series Drive . . . . . . . .B-26
F- or H-Series Motors to ULTRA 200 Series Drive
using P2 Terminal Strip .......................B-27
Y-Series Motors to ULTRA 200 Series Drive . . . . . . . . . . . . .B-28
Y-Series Motors to ULTRA 200 Series Drive
usingP2TerminalStrip ........... ............B-29
Appendix C
Appendix D
Appendix E
Appendix F
TouchPad Instructions
TouchPad Connection and Pinouts ... ...............C-2
TouchPad Version Number Display .................C-2
TouchPad Command Tree
(sheet 1 of 2) ...............C-4
Creating Custom Motor Files
Allen-Bradley Motor Naming Convention .............D-3
Required Back-EMF and Hall Signal Phasing
for Clockwise Rotation .......................D-4
Phasing of the Encoder Signals for Clockwise Rotation . . . . . . D-4
Index Offsets ..............................D-8
Hall Offsets ...............................D-9
Motor Thermal Protection Software Method . . . . . . . . . . . D-13
Back-EMF and Hall Signals, Clockwise Rotation . . . . . . . . . D-14
Electromagnetic Compatibility Guidelines
for Machine Design
EMI Source-Victim Model ......................E-2
Single Point Ground Types ......................E-5
Dynamic Braking Resistor Selection
Appendix G Specifications
Publication 1398-5.0 – October 1998
IntroList of Tables
Chapter 1 Safety
Chapter 2 Selecting Other System Components
Chapter 3 ULTRA Master Installation
Chapter 4 Unpacking, Inspecting and Storing
Chapter 5 Installation
Qualified AC Line Filters
MDF AC Line Filter Dimensions
MIF AC Line Filter Dimensions
........................5-7
....................5-9
....................5-10
List of Tables
Chapter 6
Interfaces
24 Volt Power Supply Specifications
5 Volt Power Supply Spe c ifications
General and Dedicated Inputs
INPUT1, INPUT2, INPUT3, INPUT4
and FAULT RESET Functions
Digital Input Specifications
.......................6-6
READY Output Specifications
BRAKE Output Specifications
.....................6-10
General and Dedicated Outputs
OUTPUT1, OUTPUT2, OUTPUT3 and OUTPUT4 Functions
Transistor Output Specifications
Analog Inputs +I LIMIT and -I LIMIT
Positive and Negative Current Limit Imput Specification
Analog Command Input
........................6-15
Analog Command Input Specifications
Analog Outputs: ANALOG 1 and ANALOG 2
Analog Output Specifications
Motor Encoder Output Signal
.....................6-17
.....................6-18
Motor Encoder Output Specifications ................6-18
Auxiliary Encoder/Step and Diection/CW & CCW
(Step Up & Down) Signals .....................6-20
Quadrature Interface Specifications .................6-20
Step/Direction and CW/CCW (Step Up/Step Down)
Interface Specifications .......................6-24
J2- Motor Encoder Connector Pin-Outs ...............6-28
J3 – Auxiliary Connector Pin-Outs ..................6-32
J4 and J5 – Serial Port Connector Pin-Outs .............6-35
Drive Addressing ...........................6-36
Analog outputs ANALOG 1 and ANALOG 2 ...........6-44
..................6-3
..................6-4
.....................6-5
....................6-5
.....................6-9
...................6-10
...6-10
...................6-11
................6-14
.....6-14
...............6-15
...........6-16
Publication 1398-5.0 – October 1998
Intro-12 List of Tables
Chapter 7 Power Connections
TB1 – Motor Power Terminals
Motor Power Contact and Wire Sizing Recommendations
TB1 – DC Bus Terminals
TB1 – AC Power Terminals
AC Input Power Sizing Requirements
Auxiliary Power Terminals
Auxiliary Power Sizing Requirements
TB2 – Shunt Regulator Terminals
Internal Shunt Power Ratings for Drive Models
Maximum External Shunt Power Ratings for Drive Models
Minimum Ratings for Customer Supplied External
Shunt Resistor
............................7-13
..................... 7-3
.....7-5
........................ 7-7
....................... 7-8
................ 7-9
.......................7-10
................7-10
...................7-12
..........7-12
....7-12
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Appendix A
Appendix B Cable Diagrams, Schematics and Examples
Application and Configuration Examples
Preset Binary Inputs
.......................... 8-6
Tuning
Velocity Loop Gains
Position Loop Gains
.......................... 9-6
.......................... 9-7
Status Display
Run-Time Error Codes
Power-Up Error Codes
.........................10-2
.........................10-4
Maintenance and Troubleshooting
Troubleshooting Guide
........................11-6
Options and Accessories
9/260 or 9/290 to Breakout Board
9/260 or 9/290 to J1 Connector
9/230 to Breakout Board
9/230 to J1 Connector
........................B-30
..........................B-31
...................B-30
....................B-30
Appendix C
Publication 1398-5.0 – October 1998
TouchPad Instructions
TouchPad Fault/Error/Warning Displays .............C-9
TouchPad Motor Table Identification by Motor Series .......C-10
TouchPad Motor Table Identification by Motor ID .........C-11
Option Selections for the TouchPad .................C-12
Drive Communications Parameter List for the TouchPad .....C-13
Baud Rate Parameter List for TouchPad ...............C-13
Encoder Output Parameter List for TouchPad ...........C-13
IO Mode Parameter List for TouchPad ................C-13
Index Pointer Parameter List for TouchPad .............C-14
Index Termination Parameter List for TouchPad ..........C-14
List of Tables Intro-13
Home Type Parameter List for TouchPad
Homing Auto-Start Parameter List for TouchPad
Reverse Enable for Homing
Digital Input Parameter List for TouchPad
Digital Output Parameter List for TouchPad
Analog Output Parameter List for TouchPad
Drive Status List for TouchPad
Input Flags Parameter List for TouchPad
Output Flags Parameter List for TouchPad
Appendix D
Appendix E Electromagnetic Compatibility Guidelines
Creating Custom Motor Files
......................C-15
....................C-16
..............C-14
.........C-14
.............C-15
............C-15
...........C-16
..............C-17
.............C-17
for Machine Design
Appendix F
Appendix G
AC Line Filter Installation
Dynamic Braking Resistor Selection
Dynamic Braking Resistor Parameters
Specifications
ULTRA 200 Series Power Ratings
........................E-4
................F-1
...................G-5
Publication 1398-5.0 – October 1998
Intro-14 List of Tables
Publication 1398-5.0 – October 1998
Preface
IntroPreface
This 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 specif ic pha ses of t he sy stem des ign proc ess ; from
ordering comp onents that will complement the performance of t he
ULTRA 200 Series drive, to recei ving, installing and ver ifying the
drive’s functionality.
Chapters and appendices in the manual include:
● Safety
● Selecting O ther System Components
● ULTRA Master Installation
● Unpacking, Inspecting and Storing
● Installation
● Interfaces
● Power Connections
● Application and Configuratio n Examp les
● Tuning
● Status Display
● Maintenance and Troubleshooting
● Options and Accessories
● Cable Diagrams, Schematics and Examples
● TouchPad Instructions
● Creating Custom Motor Files
● Electromag netic Compatibility Guidelines for Machine Design
● Dynamic Braking Resistor Selection
● Specifications
The intent of the manual is to assemble a high-performance servo
system in a methodical manner. By making correct decisions and
taking appropriat e actions a servo syst em that performs “as de signed”
can be assured.
Publication 1398-5.0 – October 1998
Intro-16 Preface
About This Manual This manual provides instructions on how to setup and connect the
ULTRA 200 Series drive to a controlling device and a motor. A
ULTRA 200 Series drive may operate in one of several different
functional modes. The hardware connections necessary to run the
drive are explained and basic software instructions are provided for
common set up procedures. For detailed explanation of software
instructions, refer to the comprehensive on-line instructions available
in the ULTRA Master software.
This manual explains how to install your ULTRA 200 Series drive
using ULTRA Master software with a personal computer. If you are
using a T o uchPad device, abbreviated command titles are displ aye d
but the setup steps remain the same.
This manual is organized into chapters and appendixes. The topics
covered in each chapter and section are briefly described.
Typographical conventions, warning and cautions specific to the
drive, and complementary manuals are also described.
Title Description
Safety Lists general safety requirements that must be followed when installing
or servicing the drive.
Selecting Other System
Components
ULTRA Master Installation Explains how to install, access and exit ULTRA Master.
Unpacking, Inspecting and
Storing
Installation Instructs you on how to physically install your ULTRA 200 Series drive.
Interfaces Provides comprehensive information about the signals available on
Reviews the major features of the ULTRA 200 Series drives and identifies motors and signal types that are compatible.
Lists what should be included with your ULTRA 200 Series drive and
instructs you on how to perform a basic functional test before installi ng
or storing the drive.
each connector. Each signal or set of signals is identified by:
• Power requirements for driving the signal.
• Functions performed by the signal.
• Specifications, including ON and OFF states.
• Schematic depictions of the circuit design for each signal type.
The signals are grouped under the following connectors.
• J1 – Controller
Diagrams show cable connections needed for common interfaces.
• J2 – Encoder
Details information ab out the enco der sign als, Hal l Eff ect switche s and
thermostat connections available through this connector.
• J3– Auxiliary Port
Provides a secon d con troller conne ction that du plica tes th e first 26 pins
on J1, the Controller connector
• J4 and J5 – Serial Port
Diagrams and instructions detail how to connect one or more drives
using RS-232 communications in a single or daisy-chain connection, or
to connect several drives using Multi-Drop RS-485.
• A1, A2, and COM – Analog Outputs
Describes the connections that allow monitoring of the analog command signals with external equipment.
Publication 1398-5.0 – October 1998
Preface Intro-17
Title Description
Power Connections Provides information on making motor power, DC bus and AC Power
connections.
Application and Conf iguration
Examples
Tuning Provides instructions on how to tune a drive and motor combination
Status Display Discusses the operator indicators available on the front panel. Operat-
Maintenance and Troubleshooting
Options and Accessories Lists the optional equipment available for the ULTRA 200 Series drives.
Cable Diagrams, Schemat-
ics and Examples
T ou chPad Instructions Describes how to progra m a ULTRA 200 Series dri ve using the o ptional
Creating Custom Motor Files Describes how to create a custom motor file for use with an ULTRA 200
Electromagnetic Compatibility Guidelines for Machine
Design
Dynamic Braking Resistor
Selection
Specifications Details the design and operational specifications for the ULTRA 200
Describes the hardware and software set up necessary to install the
drive as one of the following types:
• Analog Control in velocity or torque mode
• Preset Controller in velocity or torque mode
• Position Follower (Master Encoder) in velocity mode
• Position Follower (Step/Direction) in velocity mode
• Position Follower (Step Up/Step Down) in velocity mode
• Incremental Indexing
• Registration Indexing
• Absolute Indexing
• Modifying User Units
using the autotuning or manual tuning features in ULTRA Master.
ing or Error Messages are explained.
Describes the minimal maintenance necessary with the ULTRA 200
Series drives and provides a comprehensive troubleshooting chart of
potential problems and their solutions.
Provides schematics and cabling examples.
TouchPad device. Tables reference the various motor types that are
programmed to work with the ULTRA 200 Series d rive. A TouchPad
Command Tree card for the current firmware version is bound into the
manual.
Series drive.
Describes commo n ele ct r ic al no is e pro blems and suggests me thods to
ensure ElectroMagnetic Compatibility.
Provides equations to assist in sizing resistors for dynamic braking.
Series drives in a tabular format.
Additional Instructions and Manuals
Host Commands and ULTRA Master
All ULTRA 200 Series drives are setup through serial Host
Commands. The drives may be configured directly through the Host
Command language or indirectly through the ULTRA Master
software. ULTRA Master is a graphical user interface that provides a
visual method of accessing the Host Command language through the
Microsoft Windows Operating System.
Publication 1398-5.0 – October 1998
Intro-18 Preface
All documentation for both the Host Commands and ULTRA Master
is on-line. Host Command information is available through a
comprehensive on-line r eference manua l. ULTRA Master inf ormation
is available through Help menus. The on-line documents provide indepth explanations of the Host Command language as well as the
menus, windows and dialog boxes that make ULTRA Master a
convenient method for programming ULTRA 200 Series drives.
● To access the Host Command Reference
Click on the Host Command Reference icon in the
ULTRA Master program group.
● To access ULTRA Master Help
Open ULTRA Master by clicking on the ULTRA Master icon in
the ULTRA Master group, and
Press the F1 key.
TouchPad
The optional TouchPad may be used to monitor and configure the
UL TRA 200 Series drive. The TouchPad command structure is similar
to the structure of ULTRA Master, but operates through an
abbreviated keypad interface. The card TouchPad Instructions is
provided with the TouchPad. It describes the installation and
operational instructions in a pocket-sized directory. The TouchPad
Command Tree Car d and additional instructions for the TouchPad are
included in the section titled, “TouchPad Instructions” which begins
on page C-1. The TouchPad Command Tree Card is a graphical
presentation of both the operational instructions and the command
structure for the ULTRA 200 Series drives. You may find it
convenient to refer to th e card when using the TouchPad with a drive.
Publication 1398-5.0 – October 1998
Symbols and Conventions Ty pographical and Wording Conventions
This manual uses the following typographical and wording
conventions:
Example Description
»
Drive Set Up Text shown in this font and underlined indicates a Hot Key (keystroke combina-
ULTRA Master Text shown in this font is information to enter in a window or dialog box. For
win Text in lower case bold is information to enter at a keyboard. For example,
ALT+F4
ALT, F, N Keys that should be pressed in sequence are shown with a comma (,) between
Choose The wording indicates tha t an icon or a comm and is to be sele cted from a win dow
Select The wording indicates that options are to be defined or selected from a list. For
Typ e The wording indicate s that comm ands are to be entered int o a comman d box. For
a
Text preceded by right guillemet explains how to access the particular function in
the preceding paragraph. For example,
To Start ULTRA Master in Windows
» Choose the icon ULTRA Master.
tion) to quickly access a command. For example,
Choose Drive Set Up.
indicates typing ALT+D followed by ENTER accesses this command.
example,
Choose the icon ULTRA Master.
To start Windows from the DOS prompt, type win and then
press ENTER.
Keys that should be pressed simultaneously are shown with a plus sign (+)
between the key names. This example closes the active window.
the key names. This example opens the File menu and then opens a new file.
or a command box . F or example, the ins truc tio n f or accessing the com ma nd ic on
Drive Set Up states:
Choose Drive Set Up.
example, the instruction for accessing or entering information states:
Select Drive Type and Motor Model from the respective list
box.
example, the instruction for loading ULTRA Master states:
Type a:setup and then press ENTER.
Tips provide hints or shortcuts that are useful to know. For example,
Preface Intro-19
Note: UL TRA Master always displays the Help menu – Quick Start – when
it is first accesse d. T o disable thi s automatic di splay, choose the menu item
Show Quick Start from the Help menu.
a. Microsoft® Windows™ reserves certain multiple keystroke combinations to a ct ivate Windows comman ds.
Publication 1398-5.0 – October 1998
Intro-20 Preface
!
Graphical Symbols and Warning Classifications
This manual uses the following graphical symbols and warning
classifications. The use of a symbol and signal word is based on an
estimation of the likeli hood of exp osure to the ha zardou s situat ion and
what could happen as a result of exposure to the hazard.
Example Description
Protective conductor terminal (Earth ground)
Chassis terminal (not a protective ground)
Symbol plus ATTENTION: These notices provide information
intended to prevent potential personal injury and equipment
damage.
Publication 1398-5.0 – October 1998
Preface Intro-21
Pictorial Index Shown here are face views of the product, with pointers to where
individual parts are discussed.
Product Parts Explained (sheet 1 of 3)
Intro
page 10-1, 11-6
page 7-11
page 7-6
page 7-3
page 7-6
page 7-7
WARNING:
HIGH VOLTAGE
MAY EXIST FOR UP TO FIVE MI NUTES
AFTER REMOVING POWER.
page 6-44
page 6-36
page 6-34
page 6-34
page 6-31
page 6-27
page 7-10
page 6-1
Models:
1398-DDM-010 and 1398-DDM-010X,
1398-DDM-020 and 1398- DDM -02 0X,
1398-DDM-030 and 1398-DDM-030X
Publication 1398-5.0 – October 1998
Intro-22 Preface
Intro
page 7-11
page 7-6
page 7-3
Product Parts Explained (sheet 2 of 3)
WARNING:
HIGH VOLTAGE
MAY EXIST FOR UP TO EIGHT MINUTES
AFTER REMOVING POWER.
page 10-1, 11-6
page 6-44
page 6-36
page 6-34
page 6-34
page 7-6
page 7-7
page 7-10
page 6-31
page 6-27
page 6-1
Models:
1398-DDM-075 and 1398-DDM-075X
Publication 1398-5.0 – October 1998
Intro
page 7-11
page 7-6
page 7-3
Product Parts Explained (sheet 3 of 3)
WARNING:
HIGH VOLTAGE
MAY EXIST FOR UP TO EIGHT MINUTES
AFTER REMOVING POWER.
Preface Intro-23
page 10-1, 11-6
page 6-44
page 6-36
page 6-34
page 6-34
page 7-6
page 7-7
page 7-10
page 6-31
page 6-27
page 6-1
Models:
1398-DDM-150 and 1398-DDM-150X
Publication 1398-5.0 – October 1998
Intro-24 Preface
Publication 1398-5.0 – October 1998
Chapter 1
Safety Chapter 1
Installing and Using the
ULTRA 200 Series
Read the complete manual before attempting to instal l or operate the
ULTRA 200 Series drive. By reading the manual you will become
familiar with practices and procedures that allow you to operate the
ULTRA 200 Series drive safely and effectively.
Potential Hazards
The equipment described in this manual is intended for use in
industrial drive systems. This equipment can endanger life through
rotating machinery and high voltages, therefore it is essential that
guards for both electrical and mechanical parts are not removed. The
main hazards which can be encountered in the use of this equipment
are:
● Electric shock hazards
● Electric fire hazards
● Mechanical hazards
● Stored energy hazards
These hazards must be controlled by suitable machine design, using
the safety guidelines which follow. There are no chemical or ionizing
radiation hazards.
Voltage Potentials
Intro
ATTENTION: DC bus capacitors may retain hazar dous
!
Voltage potentials for the internal drive cir cuitry vary fr om 325 Volts
above to 325 Volts below earth ground for a 240 Volt input. Voltages
can exceed 450 VDC or 240 VAC within the ULTRA 200 Series. All
circuits, including the connections on the front panel, should be
considered “hot” when main or auxiliary power is connected and for
the time specified in the warning on the front of the drive after power
is removed.
voltages for several minutes after input power has been
removed, but will normally discharge in several seconds.
Measure the DC bus voltage to verify it has rea ched a safe
level each time power is removed before working on the
drive; or wait for the t ime i ndi cat ed in the warning on the
front of the drive. Failure t o observe this precau tion could
result in severe bodily injury or loss of life.
Publication 1398-5.0 – October 1998
1-2 Safety
Your Responsibilities
As the user or person installing this drive, you are responsible for
determining the suita bilit y of the pro duct for the intende d applic ation.
Rockwell Automation is neither responsible nor liable for indirect or
consequential damage resulting from the inappropriate use of this
product.
A qualified person is someone who is familiar with all safety notes
and established safety practices, with the installation, operation and
maintenance of this equipment and the hazards involved. For more
detailed d efinitions , refer to IEC 364.
It is recommended t hat anyone who oper ates or main tains e lectr ical or
mechanical equipment shoul d have a basic kn owledge of Firs t Aid. As
a minimum, they should know where the First Aid equipment is kept
and the identity of the official First Aiders.
Publication 1398-5.0 – October 1998
Safety 1-3
Safety Guidelines Electrical shock and fire hazards are avoided by using normal
installation pr oce dur es for electrical p ower equipment in an industr ial
environment. Installation must be undertaken by suitably qualified
personnel. Note that this amplifier must be installed in an industrial
cabinet such that access is restricted to suitable qualified personnel.
Mechanical hazards are associated with potentially uncontrolled
movement of the motor shaft. If this imposes a risk in the machine,
then appropriate precautions must be made to electrically disconnect
the motor from the drive when perso nnel have access to moving parts
of the machine. Note also that the motor must be securely mounted at
all times.
Stored energy hazards are both electrical and mechanical.
● Electrical hazard s can be avoided by dis connecti ng the driv e from
its power source and measur ing the DC bus vol tage to verif y it has
reached a safe level or by waiting for the time indicated in the
warning on the front of the drive prior to removing the protective
covers or touching any connections.
● Mechanical hazard s requi re a ri sk a nalysi s on the ef f ects of stor ed
mechanical energy when the machine is running at speed, as well
as the potential for the conversion of electrical energy stored in
the drive being convert ed to mechanical energy. Electrical energy
may be stored in drive for the time indicated in the warning on the
front of the drive.
The following points should be observed for the safety of personnel.
These safety notes do not represent a complete list of the steps
necessary to ensure safe operation of the equipment. Contact your
nearest Allen-Bradley representative for additi onal informat ion.
● Only qualified personnel familiar with the equipment are
permitted to install, operate and maintain the device.
● System documentation must be available and observed at all
times.
● All non-qualified personnel are kept at a safe distance from the
equipment.
● The system must be i nstalled in accorda nce with local re gul at ion s.
● The equipment is intended for permanent connection to a main
power input. It is not intended for use with a portabl e power input.
● Do not power up the unit without the covers in place and the
protective conductor connected.
● Do not operate the unit wit hout connecting the motor conduct or to
the appropriate terminal on the drive.
● Always remove power before making or removing any
connection on the unit.
Publication 1398-5.0 – October 1998
1-4 Safety
● Before removing the cover of the unit, shut off the main and
auxiliary power and measure the DC bus voltage to verify it has
reached a safe level or wait for the time indicated in the warning
on the front of the drive.
● Do not make any connections to the internal circuitry.
Connections on the front panel are the only points where users
should make connections.
● Be careful of the DC bus and shunt terminals. High voltage is
present when power is applied to the ULTRA 200 Series.
● Never connect the DC- terminal to earth ground, the drive
requires a floating DC bus.
● Do not use the ENABLE input as a safety shutdown. Always
remove power to the ULTRA 200 Series before maintaining or
repairing the unit.
● When operating a 1398-DDM-075 or 1398-DDM-075X with a
single phase power input, the current limits must be set correctly.
● Motors without thermal prot ection dev ices re quire a valid thermal
time constant. Otherwise the motor overload protection will not
function properly.
Publication 1398-5.0 – October 1998
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