Rockwell Automation 2098-IPD-xxx User Manual
Ultra5000 Intelligent
Positioning Drives
(Catalog Numbers
2098-IPD-005, -005-DN
2098-IPD-010, -010-DN
2098-IPD-020, -020-DN
2098-IPD-030, -030-DN, -HV030, -HV030-DN
2098-IPD-HV050, -HV050-DN
2098-IPD-075, -075-DN,
2098-IPD-HV100, -HV100-DN
2098-IPD-150, -150-DN, -HV150, -HV150-DN
2098-IPD-HV220, -HV220-DN
Installation Manual
Important User Information
ATTENTION
!
IMPORTANT
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
responsibility or liability (to include intellectual property liability)
for actual use based upon the examples shown in this
publication.
does not assume
Allen-Bradley publication SGI-1.1
Application, Installation and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into
consideration when applying products such as those described
in this publication.
Reproduction of the contents of this copyrighted publication, in
whole or part, without written permission of Rockwell
Automation, is prohibited.
Throughout this manual we use notes to make you aware of
safety considerations:
Identifies information about practices or
circumstances that can lead to personal injury
or death, property damage or economic loss.
, Safety Guidelines for the
Attention statements help you to:
• identify a hazard
• avoid a hazard
• recognize the consequences
Identifies information that is critical for
successful application and understanding of the
product.
Allen-Bradley is a registered trademark of Rockwell Automation.
ControlLogix, RSLogix 5000, Ultra5000, and Ultraware are trademarks of Rockwell Automation.
CSA is a registered trademark of Canadian Standards Association.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
UL and C-UL are registered trademarks of Underwriters Laboratories, Inc.
Table of Contents
Preface Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . P-4
Product Receiving and Storage Responsibility . . . . . . . . . . . P-4
Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-5
Comments Regarding this Manual . . . . . . . . . . . . . . . . . P-5
Chapter 1
Installing Your Ultra5000
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Complying with European Union Directives . . . . . . . . . 1-1
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Low Voltage Directive. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Before Mounting Your System . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Store Your Ultra5000 Before Installation . . . . . . 1-3
How to Unpack the System. . . . . . . . . . . . . . . . . . . . . . 1-4
Minimum Mounting Requirements. . . . . . . . . . . . . . . . . 1-5
Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-6
Sizing an Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Transformer Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Calculating Transformer Size Based on Speed/Torque
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fuse Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Bonding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . 1-11
Mounting Your Ultra5000 Drive . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2
Ultra5000 Connector
Information
i Publication 2098-IN001E-EN-P — April 2002
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Understanding Ultra5000 Controller Functions. . . . . . . . . . . 2-2
Ultra5000 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 2-2
Understanding Ultra5000 Connectors . . . . . . . . . . . . . . . . . 2-3
230V Ultra5000 Front Panel Connections . . . . . . . . . . . . 2-4
500W, 1 kW, and 2 kW Ultra5000
(2098-IPD-005, -010, and -020). . . . . . . . . . . . . . . . . 2-4
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . . 2-6
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . . 2-7
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3 kW Ultra5000
(2098-IPD-030) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
ii Table of Contents
7.5 kW, and 15 kW Ultra5000
(2098-IPD-075, and -150) . . . . . . . . . . . . . . . . . . . . 2-10
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . 2-11
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . 2-11
Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
230V Ultra5000 with DeviceNet Front Panel Connections . . .
2-13
500W, 1 kW, and 2 kW Ultra5000 with DeviceNet
(2098-IPD-005-DN, -010-DN, and -020-DN). . . . . . . 2-13
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . 2-14
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . 2-14
DeviceNet Connector. . . . . . . . . . . . . . . . . . . . . . . 2-14
3 kW, 7.5 kW, and 15 kW Ultra5000
(2098-IPD-005-DN, -010-DN, and -020-DN). . . . . . . 2-15
460V Ultra5000 Front Panel Connections . . . . . . . . . . . 2-16
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . 2-17
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . 2-17
Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Understanding Ultra5000 I/O Specifications. . . . . . . . . . . . 2-19
Digital I/O Power Supply . . . . . . . . . . . . . . . . . . . . . . 2-19
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Understanding Motor Encoder Feedback Specifications . . . 2-25
AM, BM, and IM Inputs . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Hall Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Thermostat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
+ Limit and - Limit Inputs . . . . . . . . . . . . . . . . . . . . . . 2-28
Encoder Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Motor Encoder Connection Diagram . . . . . . . . . . . . . . 2-31
Unbuffered Motor Encoder Outputs . . . . . . . . . . . . . . 2-31
Buffered Motor Encoder Outputs . . . . . . . . . . . . . . . . 2-31
Understanding Auxiliary Encoder Feedback Specifications . 2-32
Auxiliary Encoder Interface . . . . . . . . . . . . . . . . . . . . . 2-32
Understanding the Serial Interface. . . . . . . . . . . . . . . . . . . 2-34
Default Serial Interface Settings . . . . . . . . . . . . . . . . . . 2-34
Publication 2098-IN001E-EN-P — April 2002
Connecting Your Ultra5000
Table of Contents iii
Chapter 3
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Powering the Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Accessing the Internal Digital I/O Power Supply . . . . . . 3-2
Understanding Basic Wiring Requirements . . . . . . . . . . . . . 3-4
Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . 3-4
Routing High and Low Voltage Cables. . . . . . . . . . . . . . 3-5
Grounding Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Grounding Your System to the Subpanel . . . . . . . . . . . . 3-6
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . 3-7
Motor Power Cable Shield Termination . . . . . . . . . . . . . 3-7
Wiring Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting Interface Cables . . . . . . . . . . . . . . . . . . . . . 3-9
Wiring I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting to a DeviceNet Network . . . . . . . . . . . . . . 3-10
Connecting Your DeviceNet Cable . . . . . . . . . . . . . . . 3-11
Assigning Your Ultra5000 DeviceNet Address . . . . . . . 3-12
Wiring Power Connections . . . . . . . . . . . . . . . . . . . . 3-14
Commissioning Your Ultra5000
Maintaining Your Ultra5000
Chapter 4
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Understanding Communication Switch Settings . . . . . . . . . . 4-2
Applying Power To Your System . . . . . . . . . . . . . . . . . . . . 4-3
Configuring Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Chapter 5
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintaining the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning the Drive . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Inspecting the Cables . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Troubleshooting for DeviceNet Drives . . . . . . . . . . . . . . . . 5-6
DeviceNet Module Status LED. . . . . . . . . . . . . . . . . . . . 5-6
DeviceNet Network Status LED . . . . . . . . . . . . . . . . . . . 5-7
Node Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Device Failure - LED Status Check. . . . . . . . . . . . . . . . . 5-8
Scanner Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Power Supply Problems . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cable Installation and Design Problems. . . . . . . . . . . . 5-10
Adjusting the Physical Network Configuration . . . . . . . 5-10
Publication 2098-IN001E-EN-P — April 2002
iv Table of Contents
Specifications and
Dimensions
Appendix A
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Ultra5000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General Power Specifications . . . . . . . . . . . . . . . . . . . . A-1
2098-IPD-005-xx, -010-xx, and -020-xx . . . . . . . . . . . A-1
2098-IPD-030-xx, -075-xx, and -150-xx . . . . . . . . . . . A-2
2098-IPD-HV030-xx, -HV050-xx, -HV100-xx, -HV150-xx,
and -HV220-xx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Physical and Environmental. . . . . . . . . . . . . . . . . . . . . . A-4
Power Dissipation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
User Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Motor Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Auxiliary Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Interconnect Diagrams
Appendix B
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ultra5000 and Motor Cable Diagrams . . . . . . . . . . . . . . . . . B-1
Ultra5000 Drive and Motor Cable Combinations . . . . . . . B-1
Ultra5000 to Motor Interconnect Diagrams . . . . . . . . . . . B-3
Ultra5000 Power Wiring Diagrams . . . . . . . . . . . . . . . . . . B-15
Using an Emergency Stop Contactor . . . . . . . . . . . . . . . . . B-20
Grounding for Ultra5000 CE Requirements . . . . . . . . . . . . B-22
Ultra5000 Shunt Module Information. . . . . . . . . . . . . . . . . B-23
300 Watt Active Shunt Module. . . . . . . . . . . . . . . . . . . B-23
200 Watt Passive Shunt Module . . . . . . . . . . . . . . . . . . B-23
900 Watt Passive Shunt Module . . . . . . . . . . . . . . . . . . B-24
2090 Passive Shunt Module . . . . . . . . . . . . . . . . . . . . . B-24
Publication 2098-IN001E-EN-P — April 2002
Catalog Numbers and
Accessories
Wiring Three Phase Power to a
Single Phase Ultra5000
Table of Contents v
Appendix C
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Ultra5000 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Ultraware Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
External Shunt Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
300 Watt Active Shunt Ferrites. . . . . . . . . . . . . . . . . . . . C-5
2090 Series Passive Shunts . . . . . . . . . . . . . . . . . . . . . . C-5
Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Motor Feedback Cables . . . . . . . . . . . . . . . . . . . . . . . . C-7
MP-Series Motor Brake Cable . . . . . . . . . . . . . . . . . . . . C-8
Ultra5000 Interface Cables. . . . . . . . . . . . . . . . . . . . . . . C-8
Break Out Boards, Cables, and Kits . . . . . . . . . . . . . . . . . . C-8
Mating Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Appendix D
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Applicable Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Mandatory Neutral Connection of Isolation Transformer . . . D-2
Adding a Safety Ground to the Isolation Transformer. . . D-3
Three Phase Line Filtering Requirements for EMC . . . . . . . . D-3
Voiding of CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Publication 2098-IN001E-EN-P — April 2002
vi Table of Contents
Publication 2098-IN001E-EN-P — April 2002
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
• Related Documentation
• Conventions Used in this Manual
• Product Receiving and Storage Responsibility
• Allen-Bradley Support
Use this manual for designing, installing, programming, and
troubleshooting the Ultra5000™ Intelligent Positioning Drive (IPD). If
you do not have a basic understanding of the Ultra5000, contact your
local Allen-Bradley representative for information on available training
courses before using this product.
Purpose of this Manual
1 Publication 2098-IN001E-EN-P — April 2002
This manual describes the function and installation of the Ultra5000
products and standard Rockwell Automation/Allen-Bradley motors
recommended for use with the Ultra5000. The manual is intended for
engineers or technicians directly involved in the installation,
operation, and field maintenance of the Ultra5000.
P-2 Preface
Contents of this Manual
Refer to the following listing for the descriptive contents of this
installation manual.
Chapter Title Contents
Preface Describes the purpose, background, and
scope of this manual. Also specifies the
audience for whom this manual is intended.
1 Installing Your Ultra5000 Provides mounting information for the
Ultra5000.
2 Ultra5000 Connector
Information
3 Connecting Your Ultra5000 Provides steps to follow when applying
4 Commissioning Your
Ultra5000
5 Maintaining Your Ultra5000
Appendix A Specifications and
Dimensions
Appendix B Interconnect Diagrams Provides interconnect diagrams for the
Provides connection and wiring information
for the Ultra5000.
power to the Ultra5000 for the first time.
Powering-up and configuring the Ultra5000
drive.
Provides diagnostic aids that help isolate
problems with a drive.
Provides physical, electrical, environmental,
and functional specifications for the
Ultra5000.
Ultra5000.
Appendix C Catalog Numbers and
Accessories
Appendix D Wiring Three Phase Power
to a Single Phase Ultra5000
Provides catalog numbers and descriptions
of the Ultra5000 and related products.
Discusses star (Y) connection of single
phase Ultra5000 drives to a three phase
power source.
Publication 2098-IN001E-EN-P — April 2002
Preface P-3
Related Documentation
For: Read This Document: Catalog Number:
Active shunt installation instructions for:
• 2098-IPD-005, -005-DN
• 2098-IPD-010, -010-DN
• 2098-IPD-020, -020-DN
Passive shunt installation instructions for:
• 2098-IPD-075, -075-DN
• 2098-IPD-150, -150-DN
Passive shunt installation instructions for:
• 2098-IPD-030, -030-DN
Passive shunt installation instructions for:
• 2098-IPD-HV030, -HV030-DN
• 2098-IPD-HV050, -HV050-DN
• 2098-IPD-HV100, -HV100-DN
• 2098-IPD-HV150, -HV150-DN
• 2098-IPD-HV220, -HV220-DN
Ultraware™ installation instructions Ultraware CD Installation Instructions 2098-IN002
The following documents contain additional information concerning
related Allen-Bradley products. To obtain a copy, contact your local
Rockwell Automation office or distributor, or access the documents
on-line at
www.theautomationbookstore.com
www.ab.com/manuals/gmc
300 Watt Active Shunt Regulator Installation
Instructions
900 Watt Passive Shunt Module Installation
Instructions
200 Watt Passive Shunt Module Installation
Instructions
2090 Series Passive Shunts Installation
Instructions
.
or
2090-IN001
2090-IN002
2090-IN003
2090-IN004
Information on how to add a DeviceNet™
Expansion Kit to a Ultra5000 drive
Information on programming the Ultra5000 using
the Motion Library
Information on communicating with the
Ultra5000 using DeviceNet
Information on configuring your Ultra5000 using
Ultraware
How to minimize and control system-level noise System Design for Control of Electrical Noise GMC-RM001
Information on attaching Ultra5000 drives to a
DeviceNet network
Ultra5000 DeviceNet Expansion Kit Installation
Instructions
Ultra5000 Motion Library C Programming
Manual
Ultra5000 DeviceNet Reference Manual 2098-RM002
Ultraware User Manual
DeviceNet Cable System Planning and
Installation Manual
2098-IN004
2098-PM001
2098-UM001
DNET-UM072
A copy of the DeviceNet Specification, Volumes I and II, Release 2.0
may be ordered from the web site http://www.odva.org of the Open
Device Vendor Association.
Publication 2098-IN001E-EN-P — April 2002
P-4 Preface
Conventions Used in this Manual
Product Receiving and Storage Responsibility
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.
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-IN001E-EN-P — April 2002
Preface P-5
Allen-Bradley Support
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.
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 to contact Allen-Bradley for technical assistance, please
review the information in the chapter
call your local Allen-Bradley representative. For the quickest possible
response, please have the catalog numbers of your products available
when you call.
Maintaining Your Ultra5000 first, then
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-IN001E-EN-P — April 2002
P-6 Preface
Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000
ATTENTION
!
Chapter
1
Chapter Objectives
This chapter provides system installation guidelines and procedures
for mounting your Ultra5000. This chapter covers the following topics:
• Complying with European Union Directives
• Before Mounting Your System
Bonding Your System
•
• Mounting Your Ultra5000 Drive
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, the hazard of personal injury and/or
equipment damage exists.
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 EU Directives are
available on-line at www.ab.com/certification for Motion
Control products. The web site is the authoritative source for
verifying compliance and suitability for use of this and other
Rockwell Automation/Allen-Bradley products.
The web site also provides links to other certification agencies
(UL, CSA, etc.).
1 Publication 2098-IN001E-EN-P — April 2002
1-2 Installing Your Ultra5000
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.
To meet CE requirements, the following additions are required:
• Install a power line filter between the AC power source and the
drive input, as close to the drive as possible. (Refer to
Filters on page C-3.)
AC Line
• Terminate the motor power cable shield to the chassis clamp
provided.
• To meet CE requirements, the following additions may also be
required:
– Run single-phase input wiring in conduit that is grounded to
the enclosure.
– Terminate the shields of the motor power cables and the
motor feedback cables to the enclosure at the point of entry.
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.
Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-3
Before Mounting Your System
Before you mount your Ultra5000 system make sure you understand
the following:
How to Store Your Ultra5000 Before Installation
•
• How to Unpack the System
• Minimum Mounting Requirements
How to Store Your Ultra5000 Before Installation
The Ultra5000 should remain in the shipping container prior to
installation. If the equipment is not to be used for a period of time,
store it as follows:
• 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-IN001E-EN-P — April 2002
1-4 Installing Your Ultra5000
IMPORTANT
How to Unpack the System
Each Ultra5000 ships with the following:
• One Ultra5000 drive
• One installation manual, publication 2098-IN001
• Two I/O connector plugs (28 pin CN1A and 14 pin CN1B)
• One screwdriver
• One clear plastic terminal strip cover
Do not discard the clear plastic terminal strip cover.
Installing the plastic strip on the power terminal strip
provides a physical barrier and protection.
Ultra5000 drives with DeviceNet (2098-IPD-xxx-DN and -HVxxx-DN
only) ship with the following additional items:
• One reference manual, publication 2098-RM002
, for Ultra5000
drives with DeviceNet
• One DeviceNet connector plug for Ultra5000 drives with DeviceNet
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-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-5
Minimum Mounting Requirements
There are several things that you need to take into account when
preparing to mount the Ultra5000:
• The Ultra5000 is classified as IEC controlgear, and must be housed
in an enclosure that meets IEC60529 requirements for electrical
enclosure of controlgear.
• The ambient temperature of the location in which you will install
the Ultra5000 must not exceed 55° C (131° F).
• You must install the enclosure on a flat, rigid, vertical surface that
will not be subjected to shock, vibration, moisture, oil mist, dust, or
corrosive vapors.
• You need to maintain minimum clearances (refer to Figure 1.1
within the enclosure for proper airflow, easy module access, and
proper cable bend radius.
Refer to Appendix
A for mounting dimensions, power dissipation, and
environmental specifications for the Ultra5000.
)
Publication 2098-IN001E-EN-P — April 2002
1-6 Installing Your Ultra5000
50.8 mm (2.0 in.) clearance
for airflow and installation
50.8 mm (2.0 in.) clearance
for airflow and installation
Allow 12.7 mm (0.5 in.)
side clearance
Allow 12.7 mm (0.5 in.)
side clearance
Motor cable entry area for ground
clamp
Minimum cabinet depth = 243.8 mm (9.6 in.)
Minimum front clearance = 76.2 mm (3.0 in.)
IMPORTANT
Ventilation Requirements
This section provides information to assist you in sizing your cabinet
and locating your Ultra5000 drive(s) inside the cabinet.
Figure 1.1
Minimum Clearance Requirements
If the cabinet is ventilated, use filtered or
conditioned air to prevent the accumulation of dust
and dirt on electronic components. The air should be
free of oil, corrosives, or electrically conductive
contaminates.
Refer to Power Dissipation on page A-5 for Ultra5000 power
dissipation specifications.
Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-7
IMPORTANT
A
0.38Q
1.8T 1.1–
------------------------=
A
4.08Q
T 1.1–
----------------=
Sizing an Enclosure
As an additional aid in sizing an enclosure, with no active method of
heat dissipation, either of the following approximate equations can be
used:
Metric Standard English
Where T is temperature difference between
inside air and outside ambient (°C), Q is
heat generated in enclosure (Watts), and A
is enclosure surface area (m
surface of all six sides of an enclosure is
calculated as
A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height)
are in meters.
2
). The exterior
Where T is temperature difference between
inside air and outside ambient (°F), Q is
heat generated in enclosure (Watts), and A
is enclosure surface area (ft²). The exterior
surface of all six sides of an enclosure is
calculated as
Where d (depth), w (width), and h (height)
are in inches.
Transformer Sizing
The Ultra5000 does not require isolation transformers. However, a
transformer may be required to match the voltage requirements of the
controller to the available service. To size a transformer for the main
AC power inputs, the power output (KVA) of each axis must be
known. This can be derived by calculating the horsepower for each
axis and converting that horsepower into units of watts. If you are
supplying power to more than one motor and an Ultra5000, simply
add the kW ratings together from each calculation to get a system kW
total.
If using an autotransformer, ensure that the phase to
neutral/ground voltages do not exceed the input
voltage rating of the drive referenced in General
Power Specifications on Page A-1.
Calculating Transformer Size Based on Speed/Torque Data
Base the transformer size on the operating point within the speed/
torque curve for the drive and motor application as shown in Figure
1.2. The operating point for this hypothetical 230V drive/motor
combination is 23 lb-in and 3200 rpm.
Publication 2098-IN001E-EN-P — April 2002
1-8 Installing Your Ultra5000
IMPORTANT
IMPORTANT
TORQUE (lb-in)
3200 rpm SPEED (RPM)
23.0 lb-in
Application
Operating Point
KVA
Speed RPM()Torque lb in–()×
63 025,
--------------------------------------------------------------------------------
746Watts
HP
----------------------- -
×
KVA
1000Watts
-------------------------- -
× 2.0×=
KVA
3200rpm 23.0lb in–×
42 250,
-------------------------------------------------------=
TransformerSize 1.75KVA=
Figure 1.2
Transformer Sizing Based on Speed/Torque Data for Single Phase System
The formula and calculation are:
Definitions:
kW = power or real power
KVA = apparent power
Transformer KVA rating = (Sum of average output power of each axis) x 2.0
.
Calculations are multiplied by a factor to compensate
for the power and loss elements within a power
system.
•A factor of 2.0 is used with a single phase system.
•A factor of 1.5 is used with a three phase system.
This factor minimizes the effects of the secondary
line voltage sagging in the transformer during peak
current periods.
If you are using the Rockwell Automation/
Allen-Bradley system sizing program, the average
speed and average torque data has already been
calculated and can be used in the equation. If you
are not sure of the exact speed and torque in your
application, another approach is to look at the
speed/torque curve for your Ultra5000/motor
combination and use the values for the worst case
continuous speed and torque.
Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-9
Fuse Sizing
The Ultra5000 is listed by Underwriters Laboratories, Inc. with fuses
sized as four times the continuous output current of the drives (FLA),
according to UL 508C.
In most cases, fuses selected to match the drive input current rating
will meet the NEC requirements and provide the full drive capabilities.
Dual element, time delay (slow acting) fuses should be used to avoid
nuisance trips during the inrush current of power initialization. Refer
to the section General Power Specifications
current and inrush current specifications.
The Ultra5000 utilizes solid state motor short circuit protection rated as
shown in the table below.
in Appendix A for input
Drive Models:
2098-IPD-xxx-xx Suitable for use on a circuit capable of
2098-IPD-HVxxx-xx Suitable for use on a circuit capable of
Short Circuit Current Rating with No
Fuse Restrictions:
delivering not more than 5000 rms
symmetrical amperes, 240V maximum.
delivering not more than 5000 rms
symmetrical amperes, 480V maximum.
Short Circuit Current Rating with Fuse
Restrictions:
Suitable for use on a circuit capable of
delivering not more than 200,000 rms
symmetrical amperes, 240V maximum,
when protected by high interrupting
capacity, current limiting fuses meeting UL
198C (Class CC, G, J, L, R, T).
Suitable for use on a circuit capable of
delivering not more than 200,000 rms
symmetrical amperes, 480V maximum,
when protected by high interrupting
capacity, current limiting fuses meeting UL
198C (Class CC, G, J, L, R, T).
Mains Input Fuses
Mains input fuses shall be dual element
time delay types class RK5, J or CC only.
Fuse current ratings shall be the following,
or the closest standard value to these
minimums:
2098-IPD-HV030-xx (3kW)
2098-IPD-HV050-xx (5kW)
2098-IPD-HV750-xx (10kW)
2098-IPD-HV100-xx (15kW)
2098-IPD-HV220-xx (22kW)
Auxiliary Input Fuses
Auxiliary input fuses shall be dual element
time delay types class RK5, J or CC only.
Fuse current rating shall be the following, or
the closest standard value to these
minimums.
All drive sizes 0.4 A
5 A
8 A
17 A
25 A
35 A
Publication 2098-IN001E-EN-P — April 2002
1-10 Installing Your Ultra5000
Stud-mounting the subpanel
to the enclosure back wall
Stud-mounting a ground bus
or chassis to the subpanel
Subpanel Welded stud
Scrape
Flat washer
If the mounting bracket is coated
with a non-conductive material
(anodized, painted, etc.), scrape
the material around the mounting
hole.
Star washer
Nut
Nut
Flat washer
Mounting bracket or
ground bus
Use a wire brush to remove paint
from threads to maximize ground
connection.
Back wall of
enclosure
Welded
stud
Subpanel
Star washer
Use plated panels or scrape
paint on front of panel.
Subpanel
Nut
Nut
Star washer
Flat washer
Star washer
Star washer
Scrape paint on both sides
of panel and use star
Tapped
Bolt
Flat washer
Ground bus or
mounting bracket
If the mounting bracket is coated
with a non-conductive material
(anodixed, painted, etc.), scrape
the material around the mounting
Bolt-mounting a ground bus or chassis to the back-panel
Bonding Your System
Bonding is the practice of connecting metal chassis, assemblies,
frames, shields and enclosures to reduce the effects of electromagnetic
interference (EMI).
Bonding Modules
Unless specified, most paints are not conductive and they act as
insulators. To achieve a good bond between modules and the
subpanel, surfaces need to be paint-free or plated. Bonding metal
surfaces creates a low-impedance exit path for high-frequency energy.
Improper bonding blocks that direct exit path and allows
high-frequency energy to travel elsewhere in the cabinet. Excessive
high-frequency energy can effect the operation of other
microprocessor controlled equipment. The illustrations that follow
(refer to Figure 1.3
for painted panels, enclosures, and mounting brackets.
Figure 1.3
Recommended Bonding Practices
) show details of recommended bonding practices
Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-11
Recommended:
Bond the top and bottom of each subpanel to the cabinet
using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Scrape the paint around each fastener
to maximize metal to metal contact.
Bonded cabinet
ground bus to
subpanel
Recommended:
Bond the top and bottom of each subpanel to the cabinet
using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Scrape the paint around each fastener
to maximize metal to metal contact.
Bonded cabinet
ground bus to
subpanel
Bonding Multiple Subpanels
Bonding multiple subpanels creates a common low impedance exit
path for the high frequency energy inside the cabinet. Subpanels that
are not bonded together may not share a common low impedance
path. This difference in impedance may affect networks and other
devices that span multiple panels. Refer to the figure below for
recommended bonding practices.
Figure 1.4
Multiple Subpanels and Cabinet
Publication 2098-IN001E-EN-P — April 2002
1-12 Installing Your Ultra5000
ATTENTION
!
Mounting Your Ultra5000 Drive
The procedures in this section assume you have prepared your panel
and understand how to bond your system. For installation instructions
regarding other equipment and accessories, refer to the instructions
that came with each of the accessories for their specific requirements.
This product contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Follow static control
precautions when you install, test, service, or repair
this assembly.
Refer to Allen-Bradley publication 8000-4.5.2
Guarding Against Electrostatic Damage or any other
applicable ESD Protection Handbook.
Failure to observe this precaution may result in
damage to the equipment.
To mount your Ultra5000 drive:
1. Layout the positions for the Ultra5000 and accessories in the
enclosure. Mounting hole dimensions for the Ultra5000 are shown
in Appendix A.
,
2. Attach the Ultra5000 to the cabinet, first using the upper mounting
slots of the drive and then the lower. The recommended mounting
hardware is M5 metric (1/4-20) or #10 MS bolts. Observe bonding
techniques as described in Bonding Your System
2. Tighten all mounting fasteners.
.
Publication 2098-IN001E-EN-P — April 2002
Ultra5000 Connector Information
Chapter
2
Chapter Objectives
This chapter provides connector information and procedures for
wiring your Ultra5000 and making cable connections. This chapter
includes:
• Understanding Ultra5000 Controller Functions
• Understanding Ultra5000 Connectors
• Understanding Ultra5000 I/O Specifications
• Understanding Motor Encoder Feedback Specifications
• Understanding Auxiliary Encoder Feedback Specifications
• Understanding the Serial Interface
1 Publication 2098-IN001E-EN-P — April 2002
2-2 Ultra5000 Connector Information
InterfaceInterface
InterfaceInterface
InterfaceInterface
InterfaceInterface
InterfaceInterface
InterfaceInterface
InterfaceInterface
InterfaceInterface
InterfaceInterface
Digital InputsDigital Inputs
Digital OutputsDigital Outputs
Auxiliary Encoder InputsAuxiliary Encoder Inputs
Motor Encoder OutputsMotor Encoder Outputs
Motor EncoderMotor Encoder
Analog InputsAnalog Inputs
Analog OutputsAnalog Outputs
Gate ArrayGate Array
QuadQuad
ADCADC
DualDual
DACDAC
QuadQuad
ADCADC
POWER MODULEPOWER MODULE
Bus VoltageBus Voltage
InputInput
CurrentCurrent
InputsInputs
PWMPWM
OutputsOutputs
I/O CARDI/O CARD
512Kx8512Kx8
Low SpeedLow Speed
FlashFlash
MemoryMemory
256Kx32256Kx32
System FlashSystem Flash
MemoryMemory
128Kx32128Kx32
High SpeedHigh Speed
SRAMSRAM
64Kx864Kx8
Non-VolatileNon-Volatile
SRAMSRAM
SerialSerial
InterfaceInterface
7-Segment7-Segment
LEDLED
DisplayDisplay
Rotary DIPRotary DIP
SwitchesSwitches
TMS320C32TMS320C32
DSPDSP
Serial Port 1Serial Port 1
Serial Port 2Serial Port 2
Option Card Port 1Option Card Port 1
Option Card Port 2Option Card Port 2
PROCESSOR CARDPROCESSOR CARD
Understanding Ultra5000 Controller Functions
This section provides a short overview of the Ultra5000.
Ultra5000 Block Diagram
The Ultra5000 uses a two-stage circuit card solution with the capability
of adding two additional option cards. The first stage is the processor
circuit board and the second stage handles I/O connections including
a power module interface. Figure 2.1
interfaces.
Figure 2.1
Block Diagram of Ultra5000 Controller Functions
depicts the stages and the
Publication 2098-IN001E-EN-P — April 2002
Ultra5000 Connector Information 2-3
Understanding Ultra5000 Connectors
The following table provides a brief description of the Ultra5000 front
panel connectors and describes the connector type.
Designator Description Connector
CN1A User Input/Output 28-pin, 3.5mm, double-row, plugable spring
clamp
CN1B User Input/Output 14-pin, 3.5mm, double-row, plugable spring
clamp
CN2 Motor Feedback 15-pin high-density D-shell
CN3A Main Serial Port 9-pin standard D-shell
CN3B Auxiliary Serial Port 9-pin standard D-shell
TB DC bus, Motor and
AC power
TB1 DC bus, Motor, AC
power, and Auxiliary
AC power
TB2 Shunt 3-position screw style barrier terminal strip
9-position screw style barrier terminal strip
(2098-IPD-005xx, -010-xx, and -020-xx)
11- or 12-position screw style barrier
terminal strip (2098-IPD-030-xx, -075-xx,
-150-xx, and HVxxx-xx)
(2098-IPD-030-xx, -075-xx, -150-xx, and
HVxxx-xx)
CN1A and CN1B signal connections on the Ultra5000 use plugable,
spring-clamp connectors with 3.5mm spacing. Mating connectors for
discrete user wiring are included with your Ultra5000.
CN2, CN3A and CN3B signal connections on the Ultra5000. Mating
connectors for these D-shell type connectors are commonly available.
DeviceNet signal connections on the Ultra5000 with DeviceNet
(2098-IPD-xxx-DN and -HVxxx-DN only) use a 5-pin DeviceNet
connector. The mating connector is included with your Ultra5000.
For connector pin-outs and
the location of connectors,
switches, and status LEDs
on:
2098-IPD-xxx Ultra5000 drives Figure 2.2
2098-IPD-xxx-DN Ultra5000
drives with DeviceNet interface
2098-IPD-HVxxx high voltage
(460VAC) Ultra5000 drives
For I/O, Motor
Feedback and Serial
Communications Port
Connections refer to:
on pages 2-5
Figure 2.5
on pages 2-13
2-15
.
Figure 2.7
on pages 2-5
2-17
.
and the tables
through 2-7.
and the tables
through
and the tables
through
For Terminal Block
(Power) Connections
refer to:
table on page 3-17
table on page 3-17
table on page 3-17
.
.
.
Publication 2098-IN001E-EN-P — April 2002
2-4 Ultra5000 Connector Information
PWR
Seven Segment
Status LED
Logic Power LED
CN3A 9-pin
Main Serial Port
CN2 15-pin
Motor Encoder
CN1A 28-pin
Digital I/O
Node Address
Selector Switche
CN1B 14-pin
Auxiliary Encoder
and Analog I/O
CN3B 9-pin
Auxiliary Serial P
230V Ultra5000 Front Panel Connections
This section describes and provides a visual reference to the drive’s
connectors.
500W, 1 kW, and 2 kW Ultra5000 (2098-IPD-005, -010, and -020)
Use the figure below to locate the front panel connections on the
Ultra5000 230V drives (500W, 1 kW, and 2 kW). Detailed descriptions
of the connections are provided.
Figure 2.2
Ultra5000 Front Panel Connections
for 2098-IPD-005, -010, and -020
Publication 2098-IN001E-EN-P — April 2002
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