Rockwell Automation 2090 User 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 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.

does not assume responsibility

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.

Motor Feedback Breakout Board

Cable Tie

(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

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

Chapter 2

Ultra3000 Connector Data

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

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

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.

Publication 2098-IN003E-EN-P — April 2004

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

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