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	Because of the variety of uses for the products described in this
	publication, those responsible for the application and use of this
	control equipment must satisfy themselves that all necessary
	steps have been taken to assure that each application and use
	meets all performance and safety requirements, including any
	applicable laws, regulations, codes and standards.
	The illustrations, charts, sample programs and layout examples
	shown in this guide are intended solely for purposes of example.
	Since there are many variables and requirements associated with
	any particular installation, Allen-Bradley® does not assume
	responsibility or liability (to include intellectual property liability)
	for actual use based upon the examples shown in this
	publication.
	Allen-Bradley publication SGI-1.1, Safety Guidelines for the
	Application, Installation and Maintenance of Solid-State Control
	(available from your local Allen-Bradley office), describes some
	important differences between solid-state equipment and
	electromechanical devices that should be taken into
	consideration when applying products such as those described
	in this publication.
	Reproduction of the contents of this copyrighted publication, in
	whole or part, without written permission of Rockwell
	Automation, is prohibited.
	Throughout this manual we use notes to make you aware of
	safety considerations:
		Identifies information about practices or
	ATTENTION
		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

		Identifies information that is critical for
	IMPORTANT
		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	Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-1
Information	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

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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

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Chapter 3

Connecting Your Ultra5000 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

Chapter 4

Commissioning Your Ultra5000 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

Maintaining Your Ultra5000 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

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iv	Table of Contents

Specifications and

Dimensions

Interconnect Diagrams

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

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

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Table of Contents	v

Catalog Numbers and

Accessories

WiringThreePhas ePowertoa

Single Phase Ultra5000

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

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vi	Table of Contents

Publication 2098-IN001E-EN-P — April 2002

Preface

Introduction

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

Who Should Use this Manual

Purpose of this Manual

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.

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.

Publication 2098-IN001E-EN-P — April 2002

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	Provides connection and wiring information
	Information	for the Ultra5000.
3	Connecting Your Ultra5000	Provides steps to follow when applying
		power to the Ultra5000 for the first time.
4	Commissioning Your	Powering-up and configuring the Ultra5000
	Ultra5000	drive.
5	Maintaining Your Ultra5000	Provides diagnostic aids that help isolate
		problems with a drive.
Appendix A	Specifications and	Provides physical, electrical, environmental,
	Dimensions	and functional specifications for the
		Ultra5000.
Appendix B	Interconnect Diagrams	Provides interconnect diagrams for the
		Ultra5000.
Appendix C	Catalog Numbers and	Provides catalog numbers and descriptions
	Accessories	of the Ultra5000 and related products.
Appendix D	Wiring Three Phase Power	Discusses star (Y) connection of single
	to a Single Phase Ultra5000	phase Ultra5000 drives to a three phase
		power source.

Publication 2098-IN001E-EN-P — April 2002

Preface	P-3

Related Documentation

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 or www.ab.com/manuals/gmc.

For:	Read This Document:	Catalog Number:
Active shunt installation instructions for:	300 Watt Active Shunt Regulator Installation	2090-IN001
• 2098-IPD-005, -005-DN	Instructions
• 2098-IPD-010, -010-DN
• 2098-IPD-020, -020-DN
Passive shunt installation instructions for:	900 Watt Passive Shunt Module Installation	2090-IN002
• 2098-IPD-075, -075-DN	Instructions
• 2098-IPD-150, -150-DN
Passive shunt installation instructions for:	200 Watt Passive Shunt Module Installation	2090-IN003
• 2098-IPD-030, -030-DN	Instructions
Passive shunt installation instructions for:	2090 Series Passive Shunts Installation	2090-IN004
• 2098-IPD-HV030, -HV030-DN	Instructions
• 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
Information on how to add a DeviceNet™	Ultra5000 DeviceNet Expansion Kit Installation	2098-IN004
Expansion Kit to a Ultra5000 drive	Instructions
Information on programming the Ultra5000 using	Ultra5000 Motion Library C Programming	2098-PM001
the Motion Library	Manual
Information on communicating with the	Ultra5000 DeviceNet Reference Manual	2098-RM002
Ultra5000 using DeviceNet
Information on configuring your Ultra5000 using	Ultraware User Manual	2098-UM001
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 Cable System Planning and	DNET-UM072
DeviceNet network	Installation Manual

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

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.

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-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 Maintaining Your Ultra5000 first, then call your local Allen-Bradley representative. For the quickest possible response, 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.

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P-6	Preface

Publication 2098-IN001E-EN-P — April 2002

Chapter 1

Installing Your Ultra5000

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

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, 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.).

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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 AC Line Filters on page C-3.)

•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.

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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

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1-4	Installing Your Ultra5000

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.
	IMPORTANT
		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.

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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.

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1-6	Installing Your Ultra5000

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

Allow 12.7 mm (0.5 in.) side clearance

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

Motor cable entry area for ground clamp

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

Allow 12.7 mm (0.5 in.) side clearance

Minimum cabinet depth = 243.8 mm (9.6 in.)

Minimum front clearance = 76.2 mm (3.0 in.)

		If the cabinet is ventilated, use filtered or
	IMPORTANT
		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.

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Installing Your Ultra5000	1-7

Sizing an Enclosure

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

Metric	Standard English
0.38Q	4.08Q
A = ------------------------	A = ----------------
1.8T – 1.1	T – 1.1
Where T is temperature difference between	Where T is temperature difference between
inside air and outside ambient (°C), Q is	inside air and outside ambient (°F), Q is
heat generated in enclosure (Watts), and A	heat generated in enclosure (Watts), and A
is enclosure surface area (m2). The exterior	is enclosure surface area (ft²). The exterior
surface of all six sides of an enclosure is	surface of all six sides of an enclosure is
calculated as	calculated as
A = 2dw + 2dh + 2wh	A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height)	Where d (depth), w (width), and h (height)
are in meters.	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
	IMPORTANT
		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.

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1-8	Installing Your Ultra5000

Figure 1.2

Transformer Sizing Based on Speed/Torque Data for Single Phase System

TORQUE (lb-in)

Application

Operating Point

23.0 lb-in

3200 rpm

SPEED (RPM)

The formula and calculation are:

Speed(RPM) × Torque(lb – in) ×

KVA = --------------------------------------------------------------------------------

63, 025

3200rpm × 23.0lb – in KVA = -------------------------------------------------------

42, 250

TransformerSize = 1.75KVA

746----------Watts-------------	×	--------KVA------------------	× 2.0
HP		1000Watts

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
	IMPORTANT
		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/
	IMPORTANT
		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.

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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 in Appendix A for input current and inrush current specifications.

The Ultra5000 utilizes solid state motor short circuit protection rated as shown in the table below.

Drive Models:	Short Circuit Current Rating with No	Short Circuit Current Rating with Fuse
	Fuse Restrictions:	Restrictions:
2098-IPD-xxx-xx	Suitable for use on a circuit capable of	Suitable for use on a circuit capable of
	delivering not more than 5000 rms	delivering not more than 200,000 rms
	symmetrical amperes, 240V maximum.	symmetrical amperes, 240V maximum,
		when protected by high interrupting
		capacity, current limiting fuses meeting UL
		198C (Class CC, G, J, L, R, T).
2098-IPD-HVxxx-xx	Suitable for use on a circuit capable of	Suitable for use on a circuit capable of
	delivering not more than 5000 rms	delivering not more than 200,000 rms
	symmetrical amperes, 480V maximum.	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)	5 A
		2098-IPD-HV050-xx (5kW)	8 A
		2098-IPD-HV750-xx (10kW)	17 A
		2098-IPD-HV100-xx (15kW)	25 A
		2098-IPD-HV220-xx (22kW)	35 A
		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

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1-10	Installing Your Ultra5000

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) show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Figure 1.3

Recommended Bonding Practices

Stud-mounting the subpanel to the enclosure back wall

Subpanel

Star washer Nut

Back wall of

enclosure

Welded stud

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

Use plated panels or scrape paint on front of panel.

Stud-mounting a ground bus or chassis to the subpanel

Mounting bracket or ground bus

Flat washer

Nut

Star washer

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.

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

	Ground bus or	Nut
	mounting bracket

Flat washer

Nut

Star washer

Subpanel

Bolt

Tapped

Star washer

Scrape paint on both sides

of panel and use star Star washer

Flat washer

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

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Installing Your Ultra5000	1-11

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

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.

Bonded cabinet

ground bus to

subpanel

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

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1-12	Installing Your Ultra5000

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.

ATTENTION

!

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

Chapter 2

Ultra5000 Connector Information

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

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2-2	Ultra5000 Connector Information

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 depicts the stages and the interfaces.

Figure 2.1

Block Diagram of Ultra5000 Controller Functions

		I/O CARD		PROCESSOR CARD		Option Card Port 1
				Interface		Option Card Port 2
Digital Inputs	Interface			512Kx8
		Gate Array				Serial Port 1
				Low Speed	Serial
Digital Outputs	Interface
				Flash	Interface	Serial Port 2
				Memory
Auxiliary Encoder Inputs	Interface			256Kx32	7-Segment
Motor Encoder Outputs					LED
				System Flash
					Display
				Memory
Motor Encoder
	Interface			128Kx32	Rotary DIP
		ADC
				High Speed	Switches
	Interface
Analog Inputs				SRAM
	Interface	Dual		64Kx8	TMS320C32
Analog Outputs				Non-Volatile	DSP
		DAC
				SRAM
	Interface		Quad
		Interface	ADC

				POWER MODULE
Bus Voltage		Current		PWM
Input		Inputs		Outputs

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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	9-position screw style barrier terminal strip
	AC power	(2098-IPD-005xx, -010-xx, and -020-xx)
TB1	DC bus, Motor, AC	11or 12-position screw style barrier
	power, and Auxiliary	terminal strip (2098-IPD-030-xx, -075-xx,
	AC power	-150-xx, and HVxxx-xx)
TB2	Shunt	3-position screw style barrier terminal strip
		(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	For I/O, Motor	For Terminal Block
the location of connectors,	Feedback and Serial	(Power) Connections
switches, and status LEDs	Communications Port	refer to:
on:	Connections refer to:
2098-IPD-xxx Ultra5000 drives	Figure 2.2 and the tables	table on page 3-17.
	on pages 2-5 through 2-7.
2098-IPD-xxx-DN Ultra5000	Figure 2.5 and the tables	table on page 3-17.
drives with DeviceNet interface	on pages 2-13 through
	2-15.
2098-IPD-HVxxx high voltage	Figure 2.7 and the tables	table on page 3-17.
(460VAC) Ultra5000 drives	on pages 2-5 through
	2-17.

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2-4	Ultra5000 Connector Information

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

CN1A 28-pin

Digital I/O

CN1B 14-pin

Auxiliary Encoder

and Analog I/O

DC Bus Terminals for

Active Shunt Resistor Kit

AC Input Power Terminals

otor Power Terminals

PWR

Seven Segment

Status LED

Logic Power LED

Node Address

Selector Switche

CN3A 9-pin

Main Serial Port

CN3B 9-pin

Auxiliary Serial P

CN2 15-pin

Motor Encoder

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