Allen-Bradley Ultra3000 DSD-005, DSD-010, DSD-020, DSD-xxxX, DSD-xxx-SE, DSD-xxx-DN, DSD-xxxX-DN, DSD-030, DSD-075, DSD-150, DSD-HV030, DSD-HV050, DSD-HV100, DSD-HV150, DSD-HV220, DSD-HVxxxX, DSD-HVxxx-SE, DSD-HVxxx-DN, DSD-HVxxxX-DN Integration Manual
Ultra3000 DSD-005, Ultra3000 DSD-010, Ultra3000 DSD-020, Ultra3000 DSD-xxxX, Ultra3000 DSD-xxx-SE, Ultra3000 DSD-xxx-DN, Ultra3000 DSD-xxxX-DN, Ultra3000 DSD-030, Ultra3000 DSD-075, Ultra3000 DSD-150, Ultra3000 DSD-HV030, Ultra3000 DSD-HV050, Ultra3000 DSD-HV100, Ultra3000 DSD-HV150, Ultra3000 DSD-HV220, Ultra3000 DSD-HVxxxX, Ultra3000 DSD-HVxxx-SE, Ultra3000 DSD-HVxxx-DN, Ultra3000 DSD-HVxxxX-DN configure the Ultra3000 drives in standalone mode using Ultraware or with a Logix controller using RSLogix 5000 software. The guide provides information on power up procedures, system integration, and troubleshooting tables. The information and steps provide direction on configuring the Ultra3000 drive in standalone mode or using Logix controllers with RSLogix 5000 software.
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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)
Integration Manual
Important User Information
Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example.
Since there are many variables and requirements associated with any particular installation, Allen-Bradley
does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation
, is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
ATTENTION
!
Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.
Attention statements help you to:
• identify a hazard
• avoid a hazard
• recognize the consequences
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, A-B, ControlLogix, Kinetix, 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).
Hiperface is a registered trademarks of Stegmann, Inc.
i
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
Product Receiving and Storage Responsibility . . . . . . . . . . . P-2
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . 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
Commissioning Your Ultra3000
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Configuring Your Ultra3000 and Ultra3000 with Indexing . . 1-2
Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Applying Power To Your Ultra3000 Drive . . . . . . . . . . . 1-7
Detecting Your Ultra3000 Drive. . . . . . . . . . . . . . . . . . . 1-8
Understanding the Workspace and Drive Branches . . . . 1-9
Selecting a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Tuning Your Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Testing Your Motor (Non-Indexing Move) . . . . . . . . . . 1-16
Testing Your Motor (Indexing Move). . . . . . . . . . . . . . 1-18
Indexing and Non-Indexing Move Examples . . . . . . . . 1-20
Configuring Your Ultra3000 Drive with Logix . . . . . . . . . . 1-34
Configuring Your Ultra3000 Drive . . . . . . . . . . . . . . . . 1-34
Configuring Your Logix Analog Motion Module . . . . . . 1-35
Downloading Your Program . . . . . . . . . . . . . . . . . . . . 1-40
Testing and Tuning Your Axis. . . . . . . . . . . . . . . . . . . 1-41
Configuring Your Ultra3000 with SERCOS interface Drive . 1-47
Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . 1-47
Configuring Your Ultra3000 Drive . . . . . . . . . . . . . . . . 1-52
Configuring Your Logix SERCOS interface Module . . . . 1-54
Downloading Your Program . . . . . . . . . . . . . . . . . . . . 1-61
Applying Power To Your Ultra3000 with SERCOS . . . . 1-61
Testing and Tuning Your Axis. . . . . . . . . . . . . . . . . . . 1-63
Configuring Your Ultra3000 with DeviceNet Drive . . . . . . 1-70
Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . 1-70
Configuring Your Ultra3000 with DeviceNet . . . . . . . . 1-74
Applying Power To Your Ultra3000 with DeviceNet . . . 1-75
Publication 2098-IN005B-EN-P — August 2004
ii Table of Contents
Troubleshooting Your
Ultra3000
Interconnect Diagrams
Chapter 2
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Troubleshooting for SERCOS Drives . . . . . . . . . . . . . . . . . . 2-8
SERCOS Module Status LED. . . . . . . . . . . . . . . . . . . . . . 2-8
SERCOS Network Status LED . . . . . . . . . . . . . . . . . . . . . 2-8
Understanding Logix/Drive Fault Behavior . . . . . . . . . . . 2-9
Troubleshooting for DeviceNet Drives . . . . . . . . . . . . . . . 2-12
DeviceNet Module Status LED . . . . . . . . . . . . . . . . . . . 2-12
DeviceNet Network Status LED . . . . . . . . . . . . . . . . . . 2-12
Node Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Device Failure - LED Status Check . . . . . . . . . . . . . . . . 2-13
Scanner Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Power Supply Problems . . . . . . . . . . . . . . . . . . . . . . . 2-14
Cable Installation and Design Problems . . . . . . . . . . . . 2-15
Adjusting the Physical Network Configuration . . . . . . . 2-15
Appendix A
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Ultra3000 Interconnect Diagram Notes . . . . . . . . . . . . . . . . A-2
Power Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . A-3
Shunt Module Interconnect Diagrams . . . . . . . . . . . . . . . . . A-7
Active Shunt Module Diagrams . . . . . . . . . . . . . . . . . . . A-7
Passive Shunt Module Diagrams . . . . . . . . . . . . . . . . . . A-7
Ultra3000/Motor Interconnect Diagrams . . . . . . . . . . . . . . A-10
Control String Examples (120V ac) . . . . . . . . . . . . . . . . . . A-16
Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . A-19
Ultra3000 to Logix Cable and Interconnect Diagrams . . . . . A-20
Ultra3000 to IMC-S Compact Cable and
Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . A-23
Understanding Motor
Feedback Signals and Outputs
Appendix B
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Unbuffered Encoder Outputs. . . . . . . . . . . . . . . . . . . . . B-2
Incremental Encoder Output . . . . . . . . . . . . . . . . . . . . . B-3
High Resolution Encoder Output . . . . . . . . . . . . . . . . . . B-4
Publication 2098-IN005B-EN-P — August 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
This manual is intended for engineers or programmers directly involved in the operation, field maintenance, and integration of the
Ultra
3000 Digital Servo Drives (DSD).
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.
1
Purpose of this Manual
This manual provides power up procedures, system integration, and troubleshooting tables for the Ultra3000. The purpose of this manual is to assist you in the integration of your Ultra3000 as a stand alone drive using Ultraware or with a Logix controller using RSLogix
5000 software as outlined in the table below.
Drive Type
SERCOS interface™ drive
Analog drive
Digital drive with
DeviceNet™
Indexing drive
Indexing DeviceNet drives
Catalog Numbers Command Interface
2098-DSD-xxx-SE and -HVxxx-SE
2098-DSD-xxx and -HVxxx-
Fiber-optic SERCOS ring
Analog command interface
2098-DSD-xxx-DN and -HVxxx-DN
2098-DSD-xxxX and -HVxxxX
2098-DSD-xxxX-DN and -HVxxxX-DN
DeviceNet communication interface
Stand alone control
Software
RSLogix 5000
Ultraware or
RSLogix 5000
Ultraware
Publication 2098-IN005B-EN-P — August 2004
P-2
Preface
Contents of this Manual
Refer to the following listing for the descriptive contents of this installation manual.
Chapter
1
2
Appendix A
Appendix B
Title
Preface
Commissioning Your Ultra3000
Troubleshooting Your Ultra3000
Interconnect Diagrams
Contents
Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended.
Provides steps to follow when configuring your
Ultra3000 and when applying power to the
Ultra3000 for the first time.
Provides diagnostic aids that help isolate problems with your drive.
Provides power and signal interconnect diagrams between the Ultra3000 and shunt modules, servo motors, and input power.
Provides motor encoder input signal information and drive encoder output information specific to the Ultra3000 drives.
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-IN005B-EN-P — August 2004
Preface P-3
Related Documentation
The following documents contain additional information concerning related Allen-Bradley products. To obtain a copy, contact your local
Allen-Bradley office or distributor.
For:
The instructions needed for the installation and wiring of the Ultra3000
Ultraware Installation Instructions
Information on configuring your Ultra3000 using
Ultraware
Information on communicating with the Ultra3000 using
DeviceNet
Information on attaching Ultra3000 drives to a
DeviceNet network
A description and specifications for the Ultra Family including motors and motor accessories
Drive and motor sizing with application analysis software
More detailed information on the use of ControlLogix
motion features and application examples
ControlLogix SERCOS interface module installation instructions
ControlLogix Analog Encoder Servo module installation instructions
SoftLogix SERCOS interface PCI card installation instructions
SoftLogix Analog Encoder PCI card installation instructions
The instructions needed to program a motion application
Information on configuring and troubleshooting your
ControlLogix motion module
Information on configuring and troubleshooting your
SoftLogix PCI card
Information on proper handling, installing, testing, and troubleshooting fiber-optic cables
Information, examples, and techniques designed to minimize system failures caused by electrical noise
For declarations of conformity (DoC) currently available from Rockwell Automation
An article on wire sizes and types for grounding electrical equipment
Read This Document:
Ultraware CD Installation Instructions
Ultraware User Manual
Ultra3000 DeviceNet Reference Manual
DeviceNet Cable System Planning and Installation
Manual
Kinetix
Motion Control Selection Guide
Motion Analyzer CD
(v4.1 or above)
3, 8 or 16 Axis SERCOS interface Module
Installation Instructions
Analog Encoder (AE) Servo Module Installation
Instructions
16 Axis PCI SERCOS interface Card Installation
Instructions
PCI 2 Axis Servo Card Installation Instructions
Logix Controller Motion Instruction Set Reference
Manual
ControlLogix Motion Module Setup and
Configuration Manual
SoftLogix Motion Card Setup and Configuration
Manual
Fiber Optic Cable Installation and Handling
Instructions
System Design for Control of Electrical Noise
Reference Manual
Rockwell Automation Product Certification website
National Electrical Code
Catalog Number:
Ultra3000 Digital Servo Drives Installation Manual
2098-IN003x-EN-P
2098-IN002x-EN-P
2098-UM001x-EN-P
2098-RM001x-EN-P
DN-6.7.2
GMC-SG001x-EN-P
PST-SG003x-EN-C
ControlLogix Motion Module Programming Manual
1756-RM086x-EN-P
1756-IN572x-EN-P
1756-IN047x-EN-P
1784-IN041x-EN-P
1784-IN005x-EN-P
1756-RM007x-EN-P
1756-UM006x-EN-P
1784-UM003x-EN-P
2090-IN010x-EN-P
GMC-RM001x-EN-P www.ab.com/certification/ ce/docs
Published by the National
Fire Protection Association of Boston, MA.
A glossary of industrial automation terms and abbreviations
Allen-Bradley Industrial Automation Glossary
AG-7.1
Publication 2098-IN005B-EN-P — August 2004
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
•
Abbreviations for the Ultra3000 drives, shown in the table below, are used throughout this manual
Ultra3000 Drive
Ultra3000 with SERCOS interface
Abbreviation
Ultra3000-SE
Ultra3000 with DeviceNet interface Ultra3000-DN
Publication 2098-IN005B-EN-P — August 2004
Allen-Bradley Support
Preface P-5
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 Troubleshooting Status
Indicators first, then call your local Allen-Bradley representative or
Rockwell Automation Technical Support at (440)-646-5800. 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.
Publication 2098-IN005B-EN-P — August 2004
P-6
Preface
Publication 2098-IN005B-EN-P — August 2004
1
Chapter Objectives
General Startup
Precautions
Chapter
1
Commissioning Your Ultra3000
This chapter provides you with information to apply power and configure your Ultra3000. This chapter includes these sections:
•
•
•
Configuring Your Ultra3000 and Ultra3000 with Indexing
•
Configuring Your Ultra3000 with SERCOS interface Drive
•
Configuring Your Ultra3000 with DeviceNet Drive
Note: Some of the procedures in this chapter include information regarding integration with other products.
The following precautions pertain to all of the procedures in this chapter. Be sure to read and thoroughly understand them before proceeding.
ATTENTION
!
This product contains stored energy devices. To avoid hazard of electrical shock, verify that all voltages on the system bus network have been discharged before attempting to service, repair or remove this unit. Only qualified personnel familiar with solid state control equipment and safety procedures in publication NFPA 70E or applicable local codes should attempt this procedure.
ATTENTION
!
This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Allen-Bradley publication
8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook.
Publication 2098-IN005B-EN-P — August 2004
1-2
Commissioning Your Ultra3000
Before You Begin
These procedures assume you have completed mounting, wiring, and connecting your Ultra3000 drive as described in the Ultra3000 Digital
Servo Drives Installation Manual (publication 2098-IN003x-EN-P).
Use the table below to determine where to begin configuring your
Ultra3000 drive.
If you are configuring this drive:
2098-DSD-xxx, -xxxX, -HVxxx, or -HVxxxX
2098-DSD-xxx-SE or -HVxxx-SE
2098-DSD-xxx-DN, -xxxX-DN, -HVxxx-DN, or
-HVxxxX-DN
Then:
Go to Configuring Your Ultra3000 and Ultra3000
Go to Configuring Your Ultra3000 Drive
Go to Configuring Your Ultra3000 with
Configuring Your Ultra3000 and Ultra3000 with
Indexing
The procedures in this section apply to Ultra3000 drives
(2098-DSD-xxx, -xxxX, -HVxxx, or -HVxxxX) and describe how to:
•
Apply power to your Ultra3000 drive
•
Detect your Ultra3000 drive
•
Understand the workspace and drive branches in Ultraware
•
Select your motor
•
Tune your motor
•
Test your motor (non-indexing move)
•
Test your motor (indexing move)
•
Make indexing and non-indexing moves
•
Configure your Ultra3000 drive with the Logix servo module
Publication 2098-IN005B-EN-P — August 2004
Seven Segment
Status LED
DC Bus Connections for
Active Shunt Resistor Kit
AC Input Power
Connections
Commissioning Your Ultra3000 1-3
Front Panel Connections
This section provides front panel connection information for your
Ultra3000 and Ultra3000 with indexing drive.
Use the figure below to locate the front panel connections on the
Ultra3000 230V drives (500W, 1 kW, and 2 kW).
Figure 1.1
Ultra3000 Front Panel Connections for 2098-DSD-005, -005X, -010, -010X, -020, and -020X
9-pin CN3
Serial Connector
Pin 9
Pin 6
Pin 5
Pin 1
Logic Power LED
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
Pin 15
Pin 11
Pin 6
15-pin CN2
Feedback Connector
Pin 10
Pin 5
Pin 1
CN1 44-pin
User I/O
Connector
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Motor Power
Connections
Motor Power
Cable Shield Clamp
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
1-4
Commissioning Your Ultra3000
Use the figure below to locate the front panel connections on the
Ultra3000 230V drives (3 kW).
Figure 1.2
Ultra3000 Front Panel Connections for 2098-DSD-030 and -030X
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Internal
External
Shunt
TB2
1
2
3
Motor
DC Bus
100-240 VAC
50/60 Hz
TB1
+
-
L1
L2/N
L1
AUX
L2/N
AUX
U
V
W
Seven Segment
Status LED
Logic Power LED
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Commissioning Your Ultra3000 1-5
Use the figure below to locate the front panel connections on the
Ultra3000 230V (7.5 and 15 kW).
Figure 1.3
Ultra3000 Front Panel Connections for 2098-DSD-075, -075X, -150, and -150X
9-pin CN3
Serial Connector
Internal
External
Shunt
TB2
1
2
3
Seven Segment
Status LED
Logic Power LED
Pin 9
Pin 6
Pin 5
Pin 1
Motor
DC Bus
100-240 VAC
50/60 Hz
TB1
-
+
L1
L2
L3
L1
AUX
L2/N
AUX
U
V
W
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
1-6
Commissioning Your Ultra3000
Use the figure below to locate the front panel connections on the
Ultra3000 460V drives (3W, 5 kW, 10 kW, 15 kW, and 22 kW).
Figure 1.4
Ultra3000 Front Panel Connections for 2098-DSD-HVxxx and HVxxxX
Seven Segment
Status LED
Logic Power LED
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
TB2
Hazardous voltage exists after power down.
1
2
3
W
V
U
+
-
L3
L2
L1
L1
AUX
L2
AUX
TB1
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
Pin 15
Pin 11
Pin 6
15-pin CN2
Feedback Connector
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
Commissioning Your Ultra3000 1-7
Applying Power To Your Ultra3000 Drive
This procedure assumes you have wired your Ultra3000 system, verified the wiring, and are ready to begin using your Ultraware software.
ATTENTION
!
High voltage exists in AC line filters. The filter must be grounded properly before applying power. Filter capacitors retain high voltages after power removal.
Before handling the equipment, voltages should be measured to determine safe levels. Failure to observe this precaution could result in personal injury.
To apply power to your Ultra3000 drive:
1. Disconnect any load to the motor. Ensure the motor is free of all linkages when initially applying power to the system.
ATTENTION
!
To avoid damage to the drive due to improper sequencing of input power and the Drive Enable
(Input 1) signal, do not apply Drive Enable signal without first applying input power.
2. Apply input power to the Ultra3000 and observe the front panel
Logic Power indicator LED as shown in the figure below.
Figure 1.5
Logic Power and Status LED Display
Status
Logic Power
If the Logic Power LED is:
ON
Then:
Not ON
1. Check your input power connections.
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If the Status LED display on your:
3. Observe the front panel seven segment Status LED display as
Is: Then:
2098-DSD-xxx, -xxxX,
-HVxxx, or -HVxxxX drive
Actively cycling segments in a full circle
Flashing an E followed by two numbers
The drive is ready. Go to Detecting
Your Ultra3000 Drive on page 1-8.
Go to Error Codes on page 2-2.
Detecting Your Ultra3000 Drive
This procedure assumes you have successfully applied power to your drive. By following these steps you will ensure that your Ultra3000 drive is communicating with your Ultraware software. To detect your
Ultra3000 drive:
1. Start your Ultraware software. Refer to the Ultraware User Manual
(publication 2098-UM001x-EN-P) for more information on starting the Ultraware software.
2. Create a new file. Ultraware will scan for on-line drives.
3. Click on the Stop Scanning button when your drive is detected or wait for the scanning to time out.
4. Look for the Ultra3000 icon (Ultra3k) under the On-Line Drives tree. The Ultra3000 icon indicates that your drive is detected.
Figure 1.6
Ultra3000 Icon
5. Click on the [+] next to the Ultra3k icon to expand the branch menu (as indicated in the window above).
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Click on the + next to the (3k) drive to expand the parameter group.
Double-click on the (3k) drive in the Ultraware workspace to display the various drive branches.
Configure the drive parameters for an off-line or on-line drive.
Open the Control Panel windows to issue motion commands.
Execute commands to clear faults, reset the drive, or reset the EEPROM.
Monitor the status of an on-line drive.
Commissioning Your Ultra3000 1-9
6.
If your Ultra3000 drive: Then:
Is detected and listed under the On-Line Drives tree
1. The software and hardware are communicating and the system is ready.
2. Go to the section Selecting a
Is not detected
1. Check your serial cable connections.
2. Use Recover Communications...
(in Ultraware) to establish a connection.
section.
Understanding the Workspace and Drive Branches
This section provides a description of the Ultraware workspace and various drive branches.
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Mode Configuration Branch
Click on the + next to Mode Configuration to select the drive's command source.
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Motor Branch
Use the Motor Branch to:
•
Select a motor for the associated on-line or off-line Ultra3000 drive. Once you select a motor, the status values associated with the selected motor appears in the Status pane of this window.
•
Monitor the status as related to the selected motor.
•
Perform diagnostics on the motor
Note: Diagnostic commands are not available for SERCOS drives.
Tuning Branch
Use the Tuning Branch to:
•
Configure Velocity and Position Regulator Gains that are used in tuning.
•
Monitor Velocity, Position, and Current loop status.
•
Open windows where you can execute commands for autotuning, manual position tuning, and manual velocity tuning.
Encoders Branch
Use the Encoders Branch to:
•
Define the motor and auxiliary encoders.
•
Configure the motor encoder and optional auxiliary encoder.
Commissioning Your Ultra3000 1-11
Digital Inputs Branch
Use the Digital Inputs Branch to:
•
Assign functionality to digital inputs.
•
Monitor the status of digital inputs.
Digital Outputs Branch
Use the Digital Outputs Branch to:
•
Assign functionality to digital outputs.
•
Set both active and inactive brake delays.
•
Monitor the status of digital outputs and the digital relay.
•
Open other windows where you can override the state of digital outputs and the relay.
Analog Outputs Branch
Use the Analog Outputs Branch to:
•
Assign drive signals to analog outputs
•
Monitor the status of Analog Outputs
•
Open a window where you can monitor and override the analog output value.
Monitor Branch
Use the Monitor Branch to:
•
View a collection of statuses.
•
Open the Monitor Setup window where you can select the collection of statuses to display in this window.
•
Load a monitor previously saved.
•
Save a monitor for later use.
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Oscilloscope Branch
Use the Oscilloscope Branch to trace one of four drive signals by:
•
Configuring the oscilloscope by selecting a the drive signal to trace.
•
Executing commands that run the oscilloscope's tracing function continuously or in response to the configured trigger.
•
Monitoring the oscilloscope as it traces the selected drive signal.
Faults Branch
Use the Faults Branch to:
•
Set fault limits
•
Monitor fault status
•
Execute the Clear Faults command
•
Open a window where you can review the drive's fault history
•
Enable or disable user faults.
Service Information Branch
Use the Service Information Branch to:
•
Modify the size of an off-line drive file before transferring the configuration to an on-line drive.
•
Display and monitor service information about the drive.
•
Display the firmware version of the drive.
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Selecting a Motor
This procedure assumes you have power applied to your drive and the drive is detected by the Ultraware software.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on selecting a motor.
To select a motor:
1. Double click on the Ultra3000 icon (Ultra3k) under the On-Line
Drives tree. The Ultra3000 Drive properties window opens.
Note: Actual values depend on your application.
2. Double click on the Motor branch. The motor branch property window opens.
3.
If you have this motor:
An Allen-Bradley motor with an intelligent encoder
All others
Then:
Leave Auto Motor Iden Enabled
Select Auto Motor Iden Disabled
4. In the box next to Motor Model, select the model number of your motor.
5. Close the Motor properties window.
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Assigning Digital Inputs
To assign Digital Inputs 1 and 2:
1. Double-click on the Digital Inputs branch. The Digital Inputs properties window opens.
2. Set Input 1 value to Drive Enable.
ATTENTION
!
To avoid fault action or damage to the drive due to improper sequencing of input power and the
Drive Enable signal, you must assign one of the eight inputs as Drive Enable (Input 1 is the default setting).
3. Set Input 2 value to Fault Reset.
4. Close the Digital Inputs window.
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Tuning Your Motor
This procedure assumes your drive is detected and you have selected a motor. In this procedure you will autotune your motor.
To autotune your motor:
1. Double-click on the Tuning branch. The Tuning branch properties window opens.
2. Select Autotuning. The Autotuning window opens.
3. Apply 12-24V to input 1. Input 1 was configured as Drive Enable in a previous step (Drive Enabled light turns yellow).
ATTENTION
!
To avoid damage to the drive due to improper sequencing of input power and the Drive Enable signal, do not apply Drive Enable signal without first applying input power.
4. Select appropriate autotune settings for your application.
5. Select Start Autotune. The motor responds and the tuning process is complete (Autotune Complete light turns yellow).
Note: Actual values depend on your application.
6. Close the Tuning properties window.
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Testing Your Motor (Non-Indexing Move)
This procedure assumes you have applied power to your drive, the
Ultraware software is running, the drive is detected, and you have selected a motor. In this procedure you will enable the drive and set the motor velocity to test the motor.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on using the velocity control panel.
To test your motor:
1. Double-click the U3k icon. The drive properties window opens.
Note: Actual values depend on your application.
2. Select Velocity Control Panel (as indicated in the window above). The velocity control panel window opens.
3. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
4. Select Enable Drive (as indicated in the window below).
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5. Enter an appropriate low speed in the velocity command value field.
6. Press Enter.
7. Observe the motor. The motor should be turning at the velocity
Commissioning Your Ultra3000
8. Observe the Status table (as indicated below).
1-17
•
Drive Enable status = lamp is on (yellow)
•
Velocity - Motor Feedback status = the value you entered in
9. Select Disable Drive. The motor stops.
10. Close the velocity control panel.
11. Select the Enable icon from the Ultraware toolbar.
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Testing Your Motor (Indexing Move)
This procedure assumes you have applied power to your drive, the
Ultraware software is running, the drive is detected, and you have selected a motor. In this procedure you will enable the drive and make an incremental move to test the motor.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on using the indexing control panel.
To test your motor:
1. Double-click the U3k icon. The drive properties window opens.
2. Select Indexing Control Panel (as indicated in the window above). The indexing control panel window opens.
3. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
4. Set the value of Index Number to 0.
5. Expand the Mode Configuration branch (as indicated in the window below) and double-click on Indexing. The Indexing
Setup window opens.
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6. Expand Index 0 Setup. Configure your incremental move with the following values for Index 0:
•
Mode = Incremental
•
Distance = 8000 counts
•
Batch count = 5
•
Dwell = 500 ms
•
Action When Complete = Stop
•
Leave other defaulted parameters as is
Note: These settings may not be appropriate for your application.
7. Select Indexing Control Panel. The indexing control panel opens.
8. Select Enable Drive.
9. Select Start Index. Your incremental move begins.
10. Observe the Batch Count value count down from 5 to 0 while your move is running.
11. Close the indexing control panel window.
12. Close the indexing mode window.
13. Select the Enable icon from the Ultraware toolbar.
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Indexing and Non-Indexing Move Examples
This section provides examples of indexing and non-indexing moves you can make with your Ultra3000 drive using Ultraware.
Analog Velocity Mode (Non-Indexing Move)
This procedure assumes you have applied power to your drive, the
Ultraware software is running, the drive is detected, and you have tested a motor. In this procedure you will run the drive in analog velocity mode.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on analog velocity mode.
To run your drive in analog velocity mode:
1. Double-click the U3k icon. The drive properties window opens.
2. Expand the Operation Modes parameter. Verify the Operation
Mode is Analog Velocity Input.
3. Close the Drive Branch user window.
4. Expand the Mode Configuration branch. Double-click Analog.
The Analog Setup window opens.
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5. Set the Velocity Scale to 300.0 RPM/Volt. Verify Velocity Offset is
0 millivolts.
Commissioning Your Ultra3000 1-21
6. Double-click on the Digital Inputs branch.
•
Verify that Input 1 is configured as Drive Enable input
(factory default).
•
Verify that Input 2 is configured as the Fault Reset input.
7. Double-click on the Monitor branch. The (default) Drive Status parameters display.
8. Select Setup. The Monitor Setup window opens. Check Velocity
Signals.
9. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
10. Observe the drive respond to a ±10V dc analog signal applied to
CN1-25 and -26.
•
Analog Command voltage
•
Velocity Command rpm (300 rpm/analog input voltage)
11. Remove the 12-24V dc (Drive Enable) from input 1.
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Preset Velocity Control (Non-Indexing Move)
This procedure assumes you have applied power to your drive, the
Ultraware software is running, the drive is detected, and you have tested a motor. In this procedure you will run the drive using preset velocity control.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on preset velocity control.
To use preset velocity control:
1. Double-click the U3k icon. The drive properties window opens.
2. Expand the Operation Modes parameter. Click on the current setting and use the drop down arrow to change the Operation
Mode to Preset Velocity.
3. Close the Drive Branch user window.
4. Expand the Mode Configuration branch and double-click on
Preset. The Preset setup window opens.
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5. Enter the Preset Velocity values as shown in the table above.
6. Set the Preset Velocity Input Limits value to Inactive, as shown in the table above.
7. Close the user windows.
Commissioning Your Ultra3000 1-23
8. Double-click the Digital Inputs branch. Use the drop-down arrows to change the input values as shown in the table below.
9. Select a preset location by placing 12-24V dc on the assigned preset input according to the table below.
Preset Selects
Select up to 64 locations via preselect inputs
5 through 0 using BCD format.
(codes for preset selects 1 and 0 are shown)
Binary Code
5 4 3 2 1 0
Selected Preset or Index
0 0 0 0 0 0 Preset 0 or Index 0 is selected.
0 0 0 0 0 1 Preset 1 or Index 1 is selected.
0 0 0 0 1 0 Preset 2 or Index 2 is selected.
0 0 0 0 1 1 Preset 3 or Index 3 is selected.
1 1 1 1 1 1 Preset 64 or Index 64 is selected.
10. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
11. Observe the motor running at the selected speed (rpm).
12. Double-click the Monitor branch. Select Setup and expand the
Velocity Signals branch.
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13. Check Velocity - Command and click OK.
14. Go to the Monitor Branch and verify the Velocity - Command signal coincides with the selected preset value.
15. Remove the 12-24V dc (Drive Enable) from input 1.
Master Follower and Preset Gear Ratios (Non-Indexing Move)
This procedure assumes you have applied power to your drive, the
Ultraware software is running, the drive is detected, and you have tested a motor. Also assumed is an external auxiliary incremental encoder wired to CN1-1 and -2 (power) and CN1-4, through -9
(encoder signals). In this procedure you will run the drive in position follower (Master Encoder) mode.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on position follower mode.
To run the drive in position follower mode:
1. Double-click the U3k icon. The drive properties window opens.
2. Expand the Operation Modes parameter. Click on the current setting and use the drop down arrow to change the Operation
Mode to Follower: Auxiliary Encoder.
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3. Close the Drive Branch user window.
4. Expand the Mode Configuration branch. Double-click on
Follower.
Commissioning Your Ultra3000 1-25
5. Enter the Gear Ratio preset values as shown in the table below.
6. Close the Mode Configuration window.
7. Double-click the Digital Inputs branch. Use the drop-down arrows to change the input values as shown in the table below.
8. Using BCD format (refer to the table on page 1-23) apply 12-24V
dc to assigned inputs 3, 4, and 5 to select your preset.
9. Close the Digital Inputs user window.
10. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
11. Verify the rotation of the auxiliary encoder results in a corresponding move of the axis.
12. Remove the 12-24V dc (Drive Enable) from input 1.
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Incremental Indexing (Indexing Move)
This procedure assumes you have applied power to your indexing drive, the Ultraware software is running, the drive is detected, and you have tested a motor. In this procedure you will run the drive in incremental indexing mode.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on incremental indexing moves.
To set parameters for an incremental indexing move:
1. Double-click the U3k icon. The drive properties window opens.
2. Expand the Operation Modes parameter. Click on the current setting and use the drop down arrow to change the Operation
Mode to Indexing.
3. Close the Drive Branch user window.
4. Expand the Mode Configuration branch. Double-click on
Indexing.
5. Enter the Index 0 parameter values as shown in the table below.
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6. Close the Indexing Parameters user window.
Commissioning Your Ultra3000 1-27
7. Double-click the Digital Inputs branch. Use the drop-down arrows to change the input values as shown in the table below.
8. Close the Digital Inputs user window.
9. Double-click the Digital Outputs branch. Use the drop-down arrows to change the output values as shown in the table below.
10. Close the Digital Outputs user window.
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To verify the number of indexing moves using drive signals:
1. Double-click the Monitor branch. Select Setup... Expand the
Mode Configuration branch/the Indexing branch/and check
Batch Count.
2. Select OK.
3. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
4. Apply 12-24V dc to input 3 to the indexing move.
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5. Double-click on the Monitor branch and watch Batch Count count down from 10 to 0.
6. Observe Outputs 2 and 3 for axis in dwell and in position.
7. Observe Output 4 when the Indexing move is complete.
8. Remove the 12-24V dc (Drive Enable) from input 1.
Commissioning Your Ultra3000 1-29
To use the stop indexing feature:
1. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
2. Apply 12-24V dc to input 3 to the indexing move.
3. Apply 12-24V dc to input 4 and verify that the indexing move has stopped.
4. Apply 12-24V dc to input 3 (again) and verify the original indexing move is re-initiated.
5. Apply 12-24V dc to input 5 and verify the index move is paused.
6. Double-click the Digital Outputs branch. Observe that Output 4 is not illuminated, indicating end of sequence has not been reached.
7. Close the Digital Outputs user window.
8. Observe the Monitor branch to see that the Batch Count value is held at the remaining value.
9. Remove the 12-24V dc from Input 5 and verify the indexing move continues.
10. Close the user windows.
11. Remove the 12-24V dc (Drive Enable) from input 1.
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Absolute Indexing (Indexing Move)
This procedure assumes you have applied power to your indexing drive, the Ultraware software is running, the drive is detected, and you have tested a motor. In this procedure you will run the drive in absolute indexing mode.
Note: Refer to the Ultraware User Manual (publication
2098-UM001x-EN-P) for more information on absolute indexing moves.
To set parameters for an absolute indexing move:
1. Double-click the U3k icon. The drive properties window opens.
2. Expand the Operation Modes parameter. Click on the current setting and use the drop down arrow to change the Operation
Mode to Indexing.
3. Close the Drive Branch user window.
4. Expand the Mode Configuration branch. Double-click on
Indexing.
5. Enter the Index 0 parameter values as shown in the table below.
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6. Enter the Index 1 parameter values as shown in the table below.
7. Close the Indexing Parameters user window.
8. Expand the Mode Configuration branch. Double-click on
Homing.
9. Enter the Homing parameter values as shown in the table below.
10. Close the Homing Parameters user window.
11. Close the Mode Configuration user window.
12. Double-click the Digital Inputs branch. Use the drop-down arrows to change the input values as shown in the table below.
13. Close the Digital Inputs user window.
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To use digital outputs to indicate an event has occurred:
1. Double-click the Digital Outputs branch. Use the drop-down arrows to change the output values as shown in the table below.
2. Close the Digital Outputs user window.
3. Apply 12-24V dc to input 1. Input 1 was configured as Drive
Enable in a previous step.
4. Apply 12-24V dc to input 3 (momentarily) to start the homing routine.
5. Apply 12-24V dc to input 4 (momentarily) to simulate a homing sensor. The drive goes into reverse to find the marker and completes the homing routine.
6. Double-click the Digital Outputs branch. Observe Digital
Outputs status.
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•
Output 1 is on because the drive is enabled.
•
Output 2 is on because the drive has been homed.
•
Output 3 is on because the motor is in position.
7. Apply 12-24V dc to input 5 and observe Digital Outputs 2 and 3 change states.
8. Apply 12-24V dc to input 6 (momentarily) to stop the indexing move. Turn off input 5.
9. Apply 12-24V dc to input 4 (momentarily again) to restart the indexing move. Turn off input 4.
Commissioning Your Ultra3000 1-33
10. Apply 12-24V dc to input 7 to pause the indexing move. Remove the 12-24V dc and observe the index move continue.
11. Close the user windows.
12. Remove the 12-24V dc (Drive Enable) from input 1.
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Configuring Your Ultra3000
Drive with Logix
In this section you will configure your Ultra3000 drive using Ultraware software, configure the Logix analog motion module using RSLogix
5000, and test/tune your axis.
Configuring Your Ultra3000 Drive
To configure your Ultra3000 drive:
1. Apply power to your Ultra3000 drive (refer to the section Applying
Power To Your Ultra3000 Drive).
2. Start your Ultraware software and ensure your Ultra3000 drive is
detected (refer to the section Detecting Your Ultra3000 Drive).
3. Select a motor (refer to the section Selecting a Motor).
4. Expand Operation Modes in the Drive properties window.
5. Select Analog Current Input as the operation mode (as indicated in the window below).
6. Double-click on Digital Outputs. The Digital Output properties window opens.
7. Select Ready as the value of Output 1.
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Configuring Your Logix Analog Motion Module
This procedure assumes that you have finished configuring your
Ultra3000 drive.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication.
For:
Detailed information on configuring and troubleshooting your ControlLogix motion module
Detailed information on configuring and troubleshooting your SoftLogix PCI card
Refer to this Document
ControlLogix Motion Module
Setup and Configuration Manual
SoftLogix Motion Card Setup and
Configuration Manual
Publication Number:
1756-UM006x-EN-P
1784-UM003x-EN-P
If you have already configured your Logix module using one of the
setup and configuration manuals listed above, go directly to Testing
and Tuning Your Axis (page 1-41). If not, go to Configuring Your
Logix Controller beginning below.
Configuring Your Logix Controller
To configure your Logix controller:
1. Apply power to your Logix chassis/PC containing the analog motion module and open your RSLogix 5000 software.
2. Select New in the File menu. The New Controller window opens.
•
Select controller type
•
Name the file
•
Select the ControlLogix chassis size
•
Select the ControlLogix processor slot
3. Select OK.
4. Select Controller Properties in the edit menu. The Controller
Properties window opens.
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5. Select the Date and Time tab. The following window opens.
6. Check the box Make this controller the Coordinated System
Time master.
7. Select OK.
Configuring Your Logix Module
To configure your Logix module:
1. Right-click on I/O Configuration in the explorer window and select New Module. The Select Module Type window opens.
2. Select 1756-M02AE or 1784-PM02AE as appropriate for your actual hardware configuration.
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3. Select OK. The Module Properties wizard opens.
1-37
•
Name the module
•
Select the slot where your module resides
•
Select an Electronic Keying option.
4. Select Next until the following window opens.
5. Select the New Axis button. The New Tag window opens.
•
Name the axis
•
Select AXIS_SERVO as the Data Type
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6. Select OK.
7. Assign your axis to a node address (as shown in the window below).
8. Select Finish.
Configuring the Motion Group
To configure the motion group:
1. Right-click Motion Groups in the explorer window and select New
Motion Group. The New Tag window opens.
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2. Name the new motion group.
3. Select OK. New group appears under Motion Group folder.
Commissioning Your Ultra3000 1-39
4. Right-click on the new motion group and select Properties. The
Motion Group Properties window opens.
5. Select the Axis Assignment tab and move your axis (created earlier) from Unassigned to Assigned.
6. Select the Attribute tab and edit the default values as appropriate for your application.
7. Select OK.
Configuring Axis Properties
To configure axis properties:
1. Right-click on an axis in the explorer window and select
Properties. The Axis Properties window opens.
2. Select the Servo tab.
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3. Select Torque as the External Drive Configuration.
4. Check the box Enable Drive Fault Input and select Normally
Closed.
5. Select the Units tab and edit default values as appropriate for your application.
6. Select the Conversion tab and edit default values as appropriate for your application.
7. Select OK.
8. Verify your Logix program and save the file.
Downloading Your Program
After completing the Logix configuration you must download your program to the Logix processor.
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Testing and Tuning Your Axis
This procedure assumes that you have configured your Ultra3000 and the analog motion module.
IMPORTANT
Before proceeding with testing and tuning your axis, verify that the seven-segment status LEDs are actively cycling in a full circle.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication.
For:
Detailed information on configuring and troubleshooting your ControlLogix motion module
Detailed information on configuring and troubleshooting your SoftLogix PCI card
Refer to this Document
ControlLogix Motion Module
Setup and Configuration Manual
SoftLogix Motion Card Setup and
Configuration Manual
Publication Number:
1756-UM006x-EN-P
1784-UM003x-EN-P
If you have already tested and tuned your axis using one of the setup and configuration manuals listed above, you are finished
commissioning your drive. If not, go to Testing Your Axis beginning
below.
Testing Your Axis
To test your axis:
1. Remove the load from your axis.
2. Right-click on the axis in your Motion Group folder in the explorer window and select Axis Properties. The Axis Properties window opens.
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3. Select the Hookup tab.
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4. Select 2.0 as the number of revolutions for the test (or another number more appropriate for your application).
This Test:
Test Marker
Test Feedback
Test Command &
Feedback
Performs this Test:
Verifies marker detection capability as you rotate the motor shaft.
Verifies feedback connections are wired correctly as you rotate the motor shaft.
Verifies motor power and feedback connections are wired correctly as you command the motor to rotate.
Also, allows you to define polarity.
5. Apply Drive Enable (Input 1) signal (CN1-31) for the axis you are testing.
ATTENTION
!
To avoid personal injury or damage to equipment, apply 24V Drive Enable signal
(CN1-31) only to the axis you are testing.
Commissioning Your Ultra3000 1-43
6. Select the Test (Marker/Feedback/Command & Feedback) button to verify connections. The Online Command window opens.
Follow the on-screen test instructions. When the test completes, the Command Status changes from Executing to Command
Complete
7. Select OK.
8. The Online Command - Apply Test window opens (Feedback and
Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.
9. Select OK.
If: Then:
Your test completes successfully, this window appears:
1. Select OK.
2. Remove Drive Enable signal
(CN1-31).
Your test failed, this widow appears:
1. Select OK.
2. Verify that the main three-phase bus power is up.
3. Verify that the Drive Enable signal
(CN1-31) is applied to the axis you are testing.
4. Verify conversion constant entered in the Conversion tab.
5. Return to step 6 and run the test
again.
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Commissioning Your Ultra3000
Tuning Your Axis
To tune your axis:
1. Verify the load is still removed from the axis being tuned.
ATTENTION
!
To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then re-attach the load and perform the tuning procedure again to provide an accurate operational response.
2. Select the Tune tab.
Publication 2098-IN005B-EN-P — August 2004
3. Enter values for Travel Limit and Speed. In this example, Travel
Limit = 5 and Speed = 2.
Note: Actual value of programmed units depend on your application. For more information, contact Allen-Bradley technical support.
4. Check Tune boxes as appropriate for your application.
5. Apply Drive Enable (Input 1) signal (CN1-31) for the axis you are tuning.
ATTENTION
!
To avoid personal injury or damage to equipment, apply 24V Drive Enable signal
(CN1-31) only to the axis you are tuning.
Commissioning Your Ultra3000 1-45
6. Select the Start Tuning button to auto-tune your axis. The Online
Command - Tune Servo window opens. When the test completes, the Command Status changes from Executing to Command
Complete.
7. Select OK. The Tune Bandwidth window opens.
Note: Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.
Record your bandwidth data for future reference.
8. Select OK.
9. The Online Command - Apply Tune window opens. When the test completes, the Command Status changes from Executing to
Command Complete.
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Commissioning Your Ultra3000
10. Select OK.
If:
Your test completes successfully, this window appears:
Then:
1. Select OK.
2. Remove Drive Enable (Input 1) signal (CN1-31) applied earlier.
3. You are finished tuning your
Ultra3000.
Your test failed, this widow appears:
1. Select OK.
2. Make an adjustment to motor velocity.
3. Refer to appropriate Logix motion module setup and configuration manual for more information.
4. Return to step 6 and run the test
again.
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Commissioning Your Ultra3000 1-47
Configuring Your Ultra3000 with SERCOS interface
Drive
The procedures in this section apply to Ultra3000-SE drives
(2098-DSD-xxx-SE and -HVxxx-SE) and describe how to:
•
Configure your Ultra3000-SE drive
•
Configure your SERCOS interface module using RSLogix 5000 software
•
Download your program to your Logix controller
•
Apply power to your Ultra3000-SE drive
•
Test and tune your motor using RSLogix 5000 software.
These procedures assume you have connected the fiber-optic cables between your Ultra3000-SE drive and the SERCOS interface module.
SERCOS interface
TM
CP OK
ControlLogix
1756-M xxSE SERCOS interface Module
Front Panel Connections
This section provides front panel connection information for your
Ultra3000-SE and the ControlLogix SERCOS interface module or
SoftLogix SERCOS PCI card.
Use the figure below to locate the SERCOS ring LEDs and fiber-optic cable connections on your SERCOS interface module.
Figure 1.7
ControlLogix and SoftLogix SERCOS Connector Locations
Front View
Tx (rear)
Rx (front)
Bottom View
SERCOS Receive Connector, Rx (front)
SERCOS Transmit Connector, Tx (rear)
RSLogix 5000
D
E
F
0
9A 8
1
2
3
67
OK
SoftLogix
1784-PM16SE SERCOS interface PCI Card
(as viewed from the back of your PC)
TX
CP
SERCOS Transmit Connector, Tx
RX
SERCOS Receive Connector, Rx
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Commissioning Your Ultra3000
Seven Segment
Status LED
Logic Power LED
DC Bus Connections for
Active Shunt Resistor Kit
AC Input Power
Connections
Motor Power
Connections
Motor Power
Cable Shield Clamp
Use the figure below to locate the front panel connections on the
Ultra3000-SE 230V drives (500W, 1 kW, and 2 kW).
Figure 1.8
Ultra3000-SE Front Panel Connections for 2098-DSD-005-SE, -010-SE, and -020-SE
9-pin CN3
Serial Connector
Module
Status LED
Network
Status LED
CN3 9-pin
Serial Port
Connector
Node Address
Switches
CN2 15-pin
Motor Feedback
Connector
Data Rate
Switch
Pin 9
Pin 6
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
8
SERCOS Interface
Receive (Rx) and
Transmit (Tx)
Connectors
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
CN1 44-pin
User I/O
Connector
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Commissioning Your Ultra3000 1-49
Use the figure below to locate the front panel connections on the
Ultra3000-SE 230V drive (3 kW).
Figure 1.9
Ultra3000-SE Front Panel Connections for 2098-DSD-030-SE
Internal
External
Shunt
TB2
1
2
3
Motor
DC Bus
100-240 VAC
50/60 Hz
TB1
+
-
L1
L2/N
L1
AUX
L2/N
AUX
U
V
W
8
Seven Segment
Status LED
Logic Power LED
Module Status LED
Network Status LED
Node Address Switches
Data Rate Switch
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
SERCOS interface
Receive (Rx) and
Transmit (Tx)
Connectors
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
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Commissioning Your Ultra3000
Use the figure below to locate the front panel connections on the
Ultra3000-SE 230V drives (7.5 and 15 kW).
Figure 1.10
Ultra3000-SE Front Panel Connections for 2098-DSD-075-SE and -150-SE
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Internal
External
Shunt
TB2
1
2
3
Motor
DC Bus
100-240 VAC
50/60 Hz
TB1
+
L2
L3
-
L1
L1
AUX
L2/N
AUX
U
V
W
8
Seven Segment
Status LED
Logic Power LED
Module Status LED
Network Status LED
Node Address Switches
Data Rate Switch
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
SERCOS interface
Receive (Rx) and
Transmit (Tx)
Connectors
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Commissioning Your Ultra3000 1-51
Use the figure below to locate the front panel connections on the
Ultra3000-SE 460V drives (3 kW, 5 kW, 10 kW, 15 kW, and 22 kW).
Figure 1.11
Ultra3000-SE Front Panel Connections for 2098-DSD-HVxxx-SE
TB2
Hazardous voltage exists after power down.
1
2
3
8
W
V
U
+
-
L3
L2
L1
L1
AUX
L2
AUX
TB1
Seven Segment
Status LED
Logic Power LED
Module Status LED
Network Status LED
Node Address Switches
Data Rate Switch
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
SERCOS interface
Receive (Rx) and
Transmit (Tx)
Connectors
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
Pin 15
Pin 11
Pin 6
15-pin CN2
Feedback Connector
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
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Commissioning Your Ultra3000
Configuring Your Ultra3000 Drive
Use the following procedures to configure your Ultra3000-SE drive
(2098-DSD-xxx-SE and -HVxxx-SE).
To configure your Ultra3000-SE drive:
1. Verify that there is no power applied to the drive, and the SERCOS fiber-optic cables are correctly plugged into the Tx and Rx connectors. To verify your fiber-optic cable connections, refer to the Ultra3000 Digital Servo Drives Installation Manual
(publication 2098-IN003x-EN-P).
2. Set the node address for each drive in your system. Valid node addresses are 01-99. The MSD rotary switch sets the most significant digit and the LSD rotary switch sets the least significant
digit. Refer to figures 1.8-1.11 for the location of the switches.
Refer to the table below for examples.
For this Node
Address:
10
11
12
1
1
Set the MSD switch to:
1
0
1
Set the LSD switch to:
2
Use the MSD and LSD rotary switches on the SERCOS panel of the drive to set node
examples.
3. Set the data rate. Valid data rates are 2M, 4M, and 8M baud. Refer
to figures 1.8-1.11 for the location of the switch.
Use the Data Rate rotary switch on the SERCOS panel of the drive to set the data rate.
8
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Commissioning Your Ultra3000 1-53
Refer to Figure 1.12 for an example of the fiber-optic connections
between the Ultra3000-SE drive(s) and the SoftLogix PCI card.
Although Figure 1.12 only illustrates the SERCOS fiber-optic ring
with the SoftLogix PCI card, node addressing for SoftLogix is done the same way as shown in the node addressing example with
Figure 1.12
Fiber-Optic Ring Connection
Transmit
Receive
E
F
OK
TX
CP
RX
SoftLogix
1784-PM16SE SERCOS interface PCI Card
SERCOS fiber-optic ring
Ultra3000-SE
Ultra3000-SE
Receive
Transmit
Receive
Transmit
Figure 1.13
Ultra3000-SE Node Addresses
1756-M08SE SERCOS interface Module
ControlLogix Chassis
Ultra3000-SE
Number 1
MSD = 1
LSD = 0
Node Address = 10
Ultra3000-SE
Number 2
MSD = 1
LSD = 1
Node Address = 11
SERCOS ring
SERCOS ring
SERCOS ring
4. Verify CN1-31 (Input 1) is configured as Drive Enable and tied to
12-24V dc.
5. If using Overtravel inputs, verify that 12-24V dc is tied to CN1-37 and -38.
IMPORTANT
Without CN1-37 and -38 inputs applied, the drive/system will fault.
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Commissioning Your Ultra3000
Configuring Your Logix SERCOS interface Module
This procedure assumes that you have configured the Ultra3000-SE baud rate and optical power switches.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication.
For:
Detailed information on configuring and troubleshooting your ControlLogix motion module
Detailed information on configuring and troubleshooting your SoftLogix PCI card
Refer to this Document
ControlLogix Motion Module
Setup and Configuration Manual
SoftLogix Motion Card Setup and
Configuration Manual
Publication Number:
1756-UM006x-EN-P
1784-UM003x-EN-P
If you have already configured your Logix controller using one of the
setup and configuration manuals listed above, go directly to Applying
Power To Your Ultra3000 with SERCOS (page 1-61). If not, go to
Configuring Your Logix Controller beginning below.
Configuring Your Logix Controller
To configure your Logix controller:
1. Apply power to your Logix chassis/PC containing the SERCOS interface module and open your RSLogix 5000 software.
2. Select New in the File menu. The New Controller window opens.
•
Select controller type
•
Name the file
•
Select the ControlLogix chassis size
•
Select the ControlLogix processor slot
3. Select OK.
4. Select Controller Properties in the edit menu. The Controller
Properties window opens.
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Commissioning Your Ultra3000 1-55
5. Select the Date and Time tab. The following window opens.
6. Check the box Make this controller the Coordinated System
Time master.
IMPORTANT
Only one ControlLogix processor can be assigned as the Coordinated System Time master.
7. Select OK.
Configuring Your Logix Module
To configure your Logix module:
1. Right-click on I/O Configuration in the explorer window and select New Module. The Select Module Type window opens.
2. Select 1756-MxxSE or 1784-PM16SE as appropriate for your actual hardware configuration.
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Commissioning Your Ultra3000
3. Select OK. The Module Properties wizard opens.
•
Name the module
•
Select the slot where your module resides
•
Select an Electronic Keying option.
4. Select Next until the following window opens.
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Commissioning Your Ultra3000 1-57
5. Select Data Rate, Cycle Time, and Optical Power settings.
•
Ensure the Data Rate setting matches Data Rate (baud rate) switch as set on the Ultra3000-SE drive, or use the Auto Detect setting.
•
Set the Cycle Time according to the table below.
Logix SERCOS
Module
1756-M08SE
(Series A)
1756-M08SE
(Series B)
1756-M16SE or
1784-PM16SE
Ultra3000-SE
Drive Series
A or B
B only
A or B
B only
Data
Rate
Mbit/s
4
0.5
1.0
2.0
0.5
8 1.0
2.0
0.5
1.0
4
2.0
No support for 9-16 axes
8
SERCOS Ring
Cycle Time ms
0.5
1.0
2.0
Number of Axes
N/A up to 4 up to 8
N/A up to 8
N/A up to 4 up to 8
N/A up to 8 up to 16
•
Set the Transmit Power setting to High.
6. Select Finish. Your new SERCOS module appears under the I/O
Configuration folder in the explorer window.
Configuring Your Ultra3000-SE
To configure your Ultra3000-SE drive:
1. Right-click on your new module and select New Module. The
Select Module Type window opens.
2. Select 2098-DSD-xxx-SE or -HVxxx-SE drive as appropriate for your actual hardware configuration.
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3. Select OK. The Module Properties window opens.
•
Name the module
•
Set the Base Node address
Note: Set the node address in the software to match the node
address setting on the drive. Refer to Configuring Your
Ultra3000 Drive, step 2, on page 1-52.
•
Electronic Keying option
4. Select Next until the following window appears.
5. Select the New Axis button. The New Tag window opens.
•
Name the axis
•
Select AXIS_SERVO_DRIVE as the Data Type
6. Assign your axis to a node address (as shown in the window below).
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7. Select Next. Bus Regulator Catalog Number (shunt option) does not apply. Select <none>.
ATTENTION
!
To avoid damage to your external shunt module, verify that the proper 230V or 460V fuse is installed prior to applying power. Refer to
Passive Shunt Modules Installation Instructions
(publication 2090-IN004x-EN-P) for more information.
8. Select Finish.
Configuring the Motion Group
To configure the motion group:
1. Right-click Motion Groups in the explorer window and select New
Motion Group. The New Tag window opens.
2. Name new motion group.
3. Select OK. New group appears under Motion Group folder.
4. Right-click on the new motion group and select Properties. The
Motion Group Properties window opens.
5. Select the Axis Assignment tab and move your axis (created earlier) from Unassigned to Assigned.
6. Select the Attribute tab and edit the default values as appropriate for your application.
7. Select Ok.
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Configuring Axis Properties
To configure axis properties:
8. Right-click on an axis in the explorer window and select Axis
Properties. The Axis Properties window opens.
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9. Select the Drive/Motor tab.
•
Set the Ultra3000 Amplifier (2098-DSD-xxx-SE or -HVxxx-SE)
•
Set the Motor Catalog Number
•
Set Loop Configuration to Position Servo
Note: For amplifier and motor catalog numbers refer to the amplifier and motor name plate.
10. Select the Motor Feedback tab and verify the Feedback Type shown is appropriate for your actual hardware configuration.
11. Select the Units tab and edit default values as appropriate for your application.
12. Select the Conversion tab and edit default values as appropriate for your application.
Commissioning Your Ultra3000 1-61
13. Select the Fault Actions tab and click on the Set Custom Stop
Action... tab. The Custom Stop Action Attributes window opens.
•
Set the Brake Engage Delay Time
•
Set the Brake Release Delay Time
•
Select Close
14. Select OK.
15. Verify your Logix program and save the file.
Downloading Your Program
After completing the Logix configuration you must download your program to the Logix processor.
Applying Power To Your Ultra3000 with SERCOS
This procedure assumes you have configured your Ultra3000-SE drive and your SERCOS interface module.
ATTENTION
!
High voltage exists in AC line filters. The filter must be grounded properly before applying power. Filter capacitors retain high voltages after power removal.
Before handling the equipment, voltages should be measured to determine safe levels. Failure to observe this precaution could result in personal injury.
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To apply power to your Ultra3000-SE drive:
1. Disconnect any load to the motor. Ensure the motor is free of all linkages when initially applying power to the system.
ATTENTION
!
To avoid damage to the drive due to improper sequencing of input power and the Drive Enable signal, do not issue the Drive Enable command from RSLogix 5000 without first applying input power.
2. Apply input power to the Ultra3000-SE and observe the front panel Logic Power indicator LED as shown in the figure below.
Figure 1.14
Logic Power and Status LED Display
Status
Logic Power
If the Logic Power LED is:
ON
Then:
Not ON
1. Check your input power connections.
If the Status LED display on your:
3. Observe the front panel seven segment Status LED display as
Is: Then:
2098-DSD-xxx-SE or
-HVxxx-SE drive
Displaying a fixed 4
Flashing an E followed by two numbers
The drive is ready. Go to main step 4.
Go to Error Codes on page 2-2.
4. Observe the module status LED.
If the module status LED: Then:
Is steady green
The drive is enabled. Go to step 5.
Flashes green
Is not steady green/ not flashing green
The drive is disabled. Go to step 5.
Go to SERCOS Module Status LED on page 2-8.
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Commissioning Your Ultra3000 1-63
5. Observe the network status LED.
If the network status
LED:
Then:
Flashes green
Illuminates steady green
Is not steady green/ not flashing green
Establishing communication with network (wait for steady green).
Communication is ready.
Go to DeviceNet Network Status
6. Observe the three SERCOS LEDs on the SERCOS module.
If the three SERCOS LEDs: Then:
Flash green and red
Illuminates steady green
Establishing communication
(wait for steady green on all three LEDs).
Communication ready. Go to
Is not flashing green and red/ not steady green
Go to the appropriate Logix motion module setup and configuration manual for specific instructions and troubleshooting.
Testing and Tuning Your Axis
This procedure assumes that you have configured your Ultra3000-SE, your SERCOS interface module, and applied power to the system.
IMPORTANT
Before proceeding with testing and tuning your axis, verify that the Ultra3000-SE status LEDs are as described in the table below.
Status LED:
Seven Segment
Module
Network
Must be:
Status:
The drive is ready.
Is steady green or Flashes green The drive is enabled.
SERCOS Communication is ready.
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For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication.
For:
Detailed information on configuring and troubleshooting your ControlLogix motion module
Detailed information on configuring and troubleshooting your SoftLogix PCI card
Refer to this Document
ControlLogix Motion Module
Setup and Configuration Manual
SoftLogix Motion Card Setup and
Configuration Manual
Publication Number:
1756-UM006x-EN-P
1784-UM003x-EN-P
If you have already tested and tuned your axis using one of the setup and configuration manuals listed above, you are finished
commissioning your drive. If not, go to Testing Your Axis beginning
below.
Testing Your Axis
To test your axis:
1. Verify the load was removed from your motor(s).
2. Right-click on the axis in your Motion Group folder in the explorer window and select Axis Properties. The Axis Properties window opens.
3. Select the Hookup tab.
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Commissioning Your Ultra3000 1-65
4. Select 2.0 as the number of revolutions for the test (or another number more appropriate for your application).
This Test:
Test Marker
Test Feedback
Test Command &
Feedback
Performs this Test:
Verifies marker detection capability as you rotate the motor shaft.
Verifies feedback connections are wired correctly as you rotate the motor shaft.
Verifies motor power and feedback connections are wired correctly as you command the motor to rotate.
Also, allows you to define polarity.
5. Apply Drive Enable (Input 1) signal (CN1-31) for the axis you are testing.
ATTENTION
!
To avoid personal injury or damage to equipment, apply 24V Drive Enable signal
(CN1-31) only to the axis you are testing.
6. Select the Test (Marker/Feedback/Command & Feedback) button to verify connections. The Online Command window opens.
Follow the on-screen test instructions. When the test completes, the Command Status changes from Executing to Command
Complete.
7. Select OK.
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8. The Online Command - Apply Test window opens (Feedback and
Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.
9. Select OK.
If: Then:
Your test completes successfully, this window appears:
1. Select OK.
2. Remove Drive Enable signal
(CN1-31).
Your test failed, this widow appears:
1. Select OK.
2. Verify that the main three-phase bus power is up.
3. Verify that the Drive Enable signal
(CN1-31) is applied to the axis you are testing.
4. Verify conversion constant entered in the Conversion tab.
5. Return to main step 6 and run the
test again.
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Tuning Your Axis
To tune your axis:
1. Verify the load is still removed from the axis being tuned.
ATTENTION
!
To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then re-attach the load and perform the tuning procedure again to provide an accurate operational response.
2. Select the Tune tab.
3. Enter values for Travel Limit and Speed. In this example, Travel
Limit = 5 and Speed = 2.
Note: Actual value of programmed units depend on your application. For more information, contact Allen-Bradley technical support.
4. Check Tune boxes as appropriate for your application.
5. Apply Drive Enable (Input 1) signal (CN1-31) for the axis you are tuning.
ATTENTION
!
To avoid personal injury or damage to equipment, apply 24V Drive Enable signal
(CN1-31) only to the axis you are tuning.
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6. Select the Start Tuning button to auto-tune your axis. The Online
Command - Tune Servo window opens. When the test completes, the Command Status changes from Executing to Command
Complete.
7. Select OK. The Tune Bandwidth window opens.
Note: Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.
Record your bandwidth data for future reference.
8. Select OK.
9. The Online Command - Apply Tune window opens. When the test completes, the Command Status changes from Executing to
Command Complete.
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10. Select OK.
If:
Your test completes successfully, this window appears:
Then:
1. Select OK.
2. Remove Drive Enable (Input 1) signal (CN1-31) applied earlier.
3. You are finished tuning your axis.
Your test failed, this widow appears:
1. Select OK.
2. Make an adjustment to motor velocity.
3. Refer to appropriate Logix motion module setup and configuration manual for more information.
4. Return to step 6 and run the test
again.
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Commissioning Your Ultra3000
Configuring Your Ultra3000 with DeviceNet Drive
The procedures in this section apply to Ultra3000-DN drives
(2098-DSD-xxx-DN, -xxxX-DN, -HVxxx-DN, and -HVxxxX-DN) and describe how to:
•
Configure your Ultra3000-DN drive
•
Apply power to your Ultra3000-DN drive
These procedures assume you have completed wiring the DeviceNet interface connector on your Ultra3000-DN drive.
Seven Segment
Status LED
DC Bus Connections for
Active Shunt Resistor Kit
AC Input Power
Connections
Motor Power
Connections
Motor Power
Cable Shield Clamp
Front Panel Connections
This section provides front panel connection information for your
Ultra3000-DN drive.
Use the figure below to locate the front panel connections on the
Ultra3000-DN 230V drives (500W, 1 kW, and 2 kW).
Figure 1.15
Ultra3000-DN Front Panel Connections for 2098-DSD-005-DN, -005X-DN, -010-DN, -010X-DN, -020-DN, and -020X-DN
9-pin CN3
Serial Connector
Logic Power LED
Module Status LED
Pin 9
Pin 6
Pin 5
Pin 1
Network Status LED
CN3 9-pin
Serial Port
Connector
Node Address
Switches
CN2 15-pin
Motor Feedback
Connector
Data Rate Switch
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
DeviceNet Interface
Connector Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
CN1 44-pin
User I/O
Connector
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Commissioning Your Ultra3000 1-71
Use the figure below to locate the front panel connections on the
Ultra3000-DN 230V drives (3 kW).
Figure 1.16
Ultra3000-DN Front Panel Connections for 2098-DSD-030-DN and -030X-DN
Internal
External
Shunt
TB2
1
2
3
Motor
U
V
W
DC Bus
+
-
L1
L2/N
100-240 VAC
50/60 Hz
TB1
L1
AUX
L2/N
AUX
,ALE?ANet
V-
Can_L
Shield
Can_H
V+
Seven Segment
Status LED
Logic Power LED
Module Status LED
Network Status LED
Node Address Switches
Data Rate Switch
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
DeviceNet Interface
Connector
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
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Commissioning Your Ultra3000
Use the figure below to locate the front panel connections on the
Ultra3000-DN 230V drives (7.5 and 15 kW).
Figure 1.17
Ultra3000-DN Front Panel Connections for 2098-DSD-075-DN, -075X-DN, -150-DN, and -150X-DN
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Internal
External
Shunt
TB2
1
2
3
Motor
DC Bus
100-240 VAC
50/60 Hz
TB1
L1
L2
L3
+
-
L1
AUX
L2/N
AUX
U
V
W
,ALE?ANet
V-
Can_L
Shield
Can_H
V+
Seven Segment
Status LED
Logic Power LED
Module Status LED
Network Status LED
Node Address Switches
Data Rate Switch
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
DeviceNet Interface
Connector
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
Publication 2098-IN005B-EN-P — August 2004
Passive Shunt
Resistor Connections
Motor Power
Connections
AC Input Power
Connections
Motor Power
Cable Shield Clamp
Commissioning Your Ultra3000 1-73
Use the figure below to locate the front panel connections on the
Ultra3000-DN 460V drives (3 kW, 5 kW, 10 kW, 15 kW, and 22 kW).
Figure 1.18
Ultra3000-DN Front Panel Connections for 2098-DSD-HVxxx-DN and HVxxxX-DN
(00-63, PGM)
TB2
Hazardous voltage exists after power down.
1
2
3
125kB
250kB
500kB
AUTO
PGM
+
-
W
V
U
TB1
L3
L2
L1
L1
AUX
L2
AUX
,ALE?ANet
V-
Can_L
Shield
Can_H
V+
Seven Segment
Status LED
Logic Power LED
Module Status LED
Network Status LED
Node Address Switches
Data Rate Switch
CN3 9-pin
Serial Port
Connector
CN2 15-pin
Motor Feedback
Connector
CN1 44-pin
User I/O
Connector
DeviceNet Interface
Connector
Pin 9
Pin 6
9-pin CN3
Serial Connector
Pin 5
Pin 1
15-pin CN2
Feedback Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Pin 44
44-pin CN1
I/O Connector
Pin 30
Pin 15
Pin 31
Pin 16
Pin 1
For CN1, CN2, and CN3 connector pin-out information, refer to the
Ultra3000 Digital Servo Drives Installation Manual (publication
2098-IN003x-EN-P).
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1-74
Commissioning Your Ultra3000
Configuring Your Ultra3000 with DeviceNet
Use the following procedures to configure your Ultra3000-DN drive
(2098-DSD-xxx-DN, -xxxX-DN, -HVxxx-DN, and -HVxxxX-DN) using
Ultraware software and apply power to the drive.
To configure your Ultra3000-DN drive:
1. Verify that there is no power applied to the drive, and the
DeviceNet cable is connected (refer to figures 1.15-1.18 for the
connector location).
2. Set the node address for each drive in your system. Valid node addresses are 00-63 and PGM. The MSD rotary switch sets the most significant digit and the LSD rotary switch sets the least
significant digit. Refer to figures 1.15-1.18 for the switch locations.
Refer to the table below for examples.
For this Node
Address:
10
11
12
Set the MSD switch to:
1
1
1
0
1
Set the LSD switch to:
2
Use the MSD and LSD rotary switches on the DeviceNet panel of the drive to set node addresses.
Note: Selecting an invalid node address (> 63) sets the node address according to a non-volatile parameter stored in the drive.
3. Set the data rate. Valid data rates are 125 kps, 250 kps, 500 kps,
AUTO, and PGM. Refer to figures 1.15-1.18 for the switch location.
Note: Selecting AUTO automatically matches the device data rate to the rate of the network. Selecting PGM sets the data rate according to a non-volatile parameter stored in the drive.
Use the Data Rate rotary switch on the DeviceNet panel of the drive to set the data rate.
Publication 2098-IN005B-EN-P — August 2004
Commissioning Your Ultra3000 1-75
Applying Power To Your Ultra3000 with DeviceNet
This procedure assumes you have wired your Ultra3000-DN system, verified the wiring, and are ready to begin using your Ultraware software.
ATTENTION
!
High voltage exists in AC line filters. The filter must be grounded properly before applying power. Filter capacitors retain high voltages after power removal.
Before handling the equipment, voltages should be measured to determine safe levels. Failure to observe this precaution could result in personal injury.
To apply power to your Ultra3000-DN drive:
1. Disconnect any load to the motor. Ensure the motor is free of all linkages when initially applying power to the system.
ATTENTION
!
To avoid damage to the drive due to improper sequencing of input power and the Drive Enable signal, you must assign one of the eight inputs as
Drive Enable (Input 1 is the default setting).
2. Apply input power to the Ultra3000-DN and observe the front panel Logic Power indicator LED as shown in the figure below.
Figure 1.19
Logic Power and Status LED Display
Status
Logic Power
If the Logic Power LED is: Then:
ON
Not ON
1. Check your input power connections.
Publication 2098-IN005B-EN-P — August 2004
1-76
Commissioning Your Ultra3000
3. Observe the front panel seven segment Status LED display as
Is: Then: If the Status LED display on your:
2098-DSD-xxx-DN,
-xxxX-DN, -HVxxx-DN, or
HV-xxxX-DN drive
Actively cycling segments in a full circle
Flashing an E followed by two numbers
The drive is ready. Go to step 4.
Go to Error Codes on page 2-2.
4. Observe the module status LED.
If the module status LED: Then:
Is steady green
The drive is ready. Go to step 5.
Is not steady green
Go to SERCOS Module Status LED on page 2-8.
5. Observe the network status LED.
If the network status LED:
Is off
Is flashing or steady green
Is not flashing or steady green
Then:
Establishing communication with network (wait for flashing or steady green).
Communication is ready.
6. For further commissioning procedures, refer to the following
sections beginning on page 1-8.
•
Detecting Your Ultra3000 Drive
•
Understanding the Workspace and Drive Branches
•
•
•
Testing Your Motor (Non-Indexing Move)
•
Testing Your Motor (Indexing Move)
•
Indexing and Non-Indexing Move Examples
Refer to the Ultra3000 with DeviceNet Reference Manual
(publication 2098-RM001x-EN-P) for information on communicating to the Ultra3000 using DeviceNet.
Publication 2098-IN005B-EN-P — August 2004
1
Chapter Objectives
Safety Precautions
Chapter
2
Troubleshooting Your Ultra3000
This chapter provides a description of maintenance and troubleshooting activities for the Ultra3000. This chapter includes these sections:
•
•
•
Troubleshooting for SERCOS Drives
•
Troubleshooting for DeviceNet Drives
Observe the following safety precautions when troubleshooting your
Ultra3000 drive.
ATTENTION
!
DC bus capacitors may retain hazardous voltages after input power has been removed. Before working on the drive, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval listed on the drive warning label. Failure to observe this precaution could result in severe bodily injury or loss of life.
Do not attempt to defeat or override the drive fault circuits. You must determine the cause of a fault and correct it before you attempt to operate the system. If you do not correct a drive or system malfunction, it could result in personal injury and/or damage to the equipment as a result of uncontrolled machine system operation.
Test equipment (such as an oscilloscope or chart recorder) must be properly grounded. Failure to include an earth ground connection could result in a potentially fatal voltage on the oscilloscope chassis.
Publication 2098-IN005B-EN-P — August 2004
2-2
Troubleshooting Your Ultra3000
General Troubleshooting
Refer to the Error Codes section below to identify problems, potential
causes, and appropriate actions to resolve the problems. If problems persist after attempting to troubleshoot the system, please contact your Allen-Bradley representative for further assistance. To determine if your Ultra3000 drive has an error, refer to the table below.
If the Logic Power LED is ON and the
Status LED display on your:
2098-DSD-xxx, -xxxX, -HVxxx, or -HVxxxX drive
2098-DSD-xxx-DN, -xxxX-DN, -HVxxx-DN,
-HVxxxX-DN drive
2098-DSD-xxx-SE or -HVxxx-SE drive
Is:
Actively cycling segments in a full circle
Displaying a fixed 4
Flashing E followed by two numbers
All drives
Flashing L
Then:
Your Ultra3000 drive is ready.
Your Ultra3000 drive is ready.
Your Ultra3000 drive is ready.
Your Ultra3000 drive has an error. Proceed to
the section Error Codes below.
Your Ultra3000 drive is in an Overtravel condition and motion restrictions are in effect.
Error
Code
E01
E02
Error Codes
The following list of problematic symptoms (no error code shown) and problems with assigned error codes is designed to help you resolve problems.
When a fault is detected, the seven-segment LED will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the problem is cleared.
Problem or Symptom Possible Cause(s) Action/Solution
Power (PWR) indicator not ON
No AC power or auxiliary logic power.
Verify AC power or auxiliary +5V logic power is applied to the Ultra3000.
Call your Allen-Bradley representative.
Power (PWR) indicator is ON, but seven segment Status LED display is OFF.
Note: This applies to 2098-DSD-005, -010, and -020 Ultra3000 models only.
Externally applied +5V auxiliary power supply voltage is too low.
Motor jumps when first enabled
Digital I/O not working correctly
Non-Volatile Memory Endurance Exceeded
Velocity Exceeds Position Rollover /2
Internal power supply malfunction.
Verify that the external +5V auxiliary power supply (as measured at the drive terminals) reads between 5.10V and 5.25V.
Motor wiring error.
Incorrect motor chosen.
I/O power supply disconnected.
Range of motion and number of home position definitions during the product life exceeds the maximum allowed (applies only to systems with absolute feedback).
The velocity command or feedback exceeds half the machine cycle length per millisecond (applies only when the machine cycle position rollover is enabled).
Check motor wiring.
Verify the proper motor is selected.
Verify connections and I/O power source.
This is an unrecoverable fault, the drive must be sent back to the factory.
Increase machine cycle size or reduce velocity profile. This error only applies to firmware versions prior to 1.10.
Publication 2098-IN005B-EN-P — August 2004
Troubleshooting Your Ultra3000 2-3
Error
Code
E03
Problem or Symptom
Absolute Feedback Range Exceeded
E04
E05
E06
E07
E08
E09
Motor Overtemperature
IPM Fault
Hardware Overtravel
(SERCOS only)
RESERVED
RESERVED
Bus Undervoltage
Possible Cause(s) Action/Solution
The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback).
Motor thermostat trips due to:
•
High motor ambient temperature
• and/or
Excessive current
Motor wiring error.
Incorrect motor selection.
Motor cables shorted.
Motor winding shorted internally.
Ultra3000 temperature too high.
Operation above continuous power rating.
Ultra3000 has a bad IPM output, short circuit, or overcurrent.
•
Decrease application range of motion.
•
Upgrade firmware.
•
Operate within (not above) the continuous torque rating for the ambient temperature (40°C maximum).
•
Lower ambient temperature, increase motor cooling.
Check motor wiring.
Verify the proper motor has been selected.
Verify continuity of motor power cable and connector.
Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced.
•
Check for clogged vents or defective fan.
•
Ensure cooling is not restricted by insufficient space around the unit.
•
Verify ambient temperature is not too high.
•
Operate within the continuous power rating.
•
Reduce acceleration rates.
Remove all power and motor connections, and preform a continuity check from the DC bus to the U, V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair.
An attempt was made to enable the drive without waiting at least 1.0 second after applying the main AC power. Note: This applies to 2098-DSD-005, -010, and -020
Ultra3000 models only (when using an external +5V auxiliary power supply).
Wait at least 1.0 second after the main AC is applied before enabling the drive.
Dedicated overtravel input is inactive.
•
Check wiring.
•
Verify motion profile.
Low AC line/AC power input.
Call your local Allen-Bradley representative.
•
Verify voltage level of the incoming AC power.
•
Check AC power source for glitches or line drop.
•
Install an uninterruptible power supply
(UPS) on your AC input.
Publication 2098-IN005B-EN-P — August 2004
2-4
Troubleshooting Your Ultra3000
Error
Code
E10
E11
E12
E13
E14
E15
E16
E17
E18
E19
Problem or Symptom
Bus Overvoltage
Illegal Hall State
Home Search Failed
Home Position In Limit
SERCOS Hardware Fault
(SERCOS drives only)
DeviceNet Communications Network problem (DeviceNet drives only)
Excessive Electrical Cycle Length
Software Overtravel
(SERCOS only)
User-Specified Current Fault
Overspeed Fault
Excess Position Error
Possible Cause(s) Action/Solution
Excessive regeneration of power.
When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the Ultra3000’s power supply. The system faults to save itself from an overload.
Excessive AC input voltage.
Incorrect phasing.
Bad connections.
Home sensor and/or marker is outside the overtravel limits.
Home sensor, marker, or final home position exceeds a hardware overtravel limit.
A fault was detected with the operation of the drive’s internal SERCOS hardware.
DeviceNet communications network is broken
Electrical cycle length exceeds maximum lines per electrical cycle
•
Change the deceleration or motion profile.
•
Use a larger system (motor and
Ultra3000).
•
Use a resistive shunt.
•
If a shunt is connected, verify the wiring is correct and shunt fuse is not blown.
Verify input is within specifications.
Check the Hall phasing.
•
Verify the Hall wiring.
•
Verify 5V power supply to the encoder.
•
Check wiring.
•
Reposition the overtravel limits or sensor.
•
Reposition the overtravel limits or home sensor.
•
Adjust the final home position.
Contact your local Allen-Bradley representative.
Troubleshoot DeviceNet communications.
Replace the linear motor/encoder.
Programmed overtravel limit has been exceeded.
•
Verify motion profile.
•
Verify overtravel settings are appropriate.
User-Specified average current level has been exceeded.
Increase to a less restrictive setting.
Motor speed has exceeded 125% of maximum rated speed.
Position error limit was exceeded.
•
Check cables for noise.
•
Check tuning.
•
Increase the feedforward gain.
•
Increase following error limit or time.
•
Check position loop tuning.
Publication 2098-IN005B-EN-P — August 2004
Error
Code
E20
E21
Problem or Symptom
Motor Encoder State Error
Auxiliary Encoder state error
E22 Motor Thermal Protection Fault
E23
E24
E25
E26
E27
IPM Thermal Protection Fault
Excess Velocity Error
Sensor Not Assigned
User-Specified Velocity Fault
Axis Not Homed
Troubleshooting Your Ultra3000 2-5
Possible Cause(s) Action/Solution
The motor encoder encountered an illegal transition.
•
Replace the motor/encoder.
•
Use shielded cables with twisted pair wires.
•
Route the feedback away from potential noise sources.
•
Check the system grounds.
•
Verify that the unbuffered encoder signals are not subjected to EMI in the
CN1 cable. Remove these signals from the CN1 cable if they are not being used.
•
Verify that the motor has a high-frequency bond to the drive’s enclosure panel.
•
Verify that any stage connected to the motor shaft (for example using a ball screw) has a high-frequency bond to the machine frame and the drive’s enclosure panel.
Bad encoder.
The auxiliary encoder encountered an illegal transition.
Setup time violation for Step/Direction or
CW/CCW input.
The internal filter protecting the motor from overheating has tripped.
The internal filter protecting the drive from over heating has tripped.
Velocity error limit was exceeded.
Replace motor/encoder.
•
Use shielded cables with twisted pair wires.
•
Route the encoder cable away from potential noise sources.
•
Bad encoder - replace encoder.
•
Check the ground connections.
Check timing of Step/Direction or CW/
CCW inputs to determine if setup time requirements are being met.
•
Reduce acceleration rates.
•
Reduce duty cycle (ON/OFF) of commanded motion.
•
Increase time permitted for motion.
•
Use larger Ultra3000 and motor.
•
Check tuning.
•
Reduce acceleration rates.
•
Reduce duty cycle (ON/OFF) of commanded motion.
•
Increase time permitted for motion.
•
Use larger Ultra3000 and motor.
•
Check tuning.
•
Increase time or size of allowable error.
•
Reduce acceleration.
•
Check tuning.
Homing or registration motion was attempted without a sensor assigned.
Assign a sensor to a digital input.
User specified velocity level was exceeded. Increase to a less restrictive setting.
Absolute positioning was attempted without homing.
Verify homing sequence.
Publication 2098-IN005B-EN-P — August 2004
2-6
Troubleshooting Your Ultra3000
Error
Code
E28
E29
E30
E31
E32
E33
E34
E35
E36
E37
E38
Problem or Symptom
Motor Parameter Error
Encoder Output Frequency Exceeded
Encoder Communication Fault
Encoder Data
Sine/Cosine Encoder Frequency Limit
Exceeded
Absolute Position Exceeds Position
Rollover
Ground Fault
Precharge Fault
Power Circuitry Overtemperature
AC Line Loss
RESERVED
Possible Cause(s) Action/Solution
Parameter loaded from smart encoder or received from SERCOS controller is incompatible with the drive.
Encoder output frequency exceeds the maximum user specified value. This only applies when the encoder output is synthesized by the drive.
Communication was not established with an intelligent encoder.
Encoder data is corrupted.
Maximum frequency of the sine/cosine circuitry has been exceeded.
•
Select a different motor through the
SERCOS controller.
•
Select a different motor.
•
Increase the encoder output maximum frequency parameter.
•
Decrease the encoder interpolation parameter.
•
Increase the encoder output divider parameter.
•
Verify motor selection.
•
Verify the motor supports automatic identification.
•
Verify motor encoder wiring.
Replace the motor/encoder.
•
Decrease velocity.
•
Use encoder with lower resolution
(before interpolation).
Motion is commanded to a position outside the position rollover range.
•
An absolute index is initiated that specifies a position outside the position rollover range.
•
A homing cycle is initiated with the home position outside the position rollover range.
•
A define home is initiated with the home position outside the position rollover range.
•
A preset position is initiated that specifies a position outside the position rollover range.
Wiring error.
Motor internal ground short.
Set motion command to a position within the position rollover range.
Check motor power wiring.
Replace motor.
Internal malfunction.
Disconnect motor power cable from drive and enable drive with current limit set to 0.
If fault remains, call your Allen-Bradley representative. If fault clears, then a wiring error or motor internal problem exists.
Check input AC voltage on all phases.
Low AC input voltage.
Internal malfunction.
Excessive heat exists in the power circuitry.
Call your Allen-Bradley representative.
•
Reduce acceleration rates.
•
Reduce duty cycle (ON/OFF) of commanded motion.
•
Increase time permitted for motion.
•
Use larger Ultra3000 and motor.
•
Check tuning.
One or more phases of the input AC power is missing.
Check input AC voltage on all phases.
Call your local Allen-Bradley representative.
Publication 2098-IN005B-EN-P — August 2004
Troubleshooting Your Ultra3000 2-7
Error
Code
E39
E40
E41
E42
E43
E50
All others
Problem or Symptom
Self-sensing Commutation Startup Error
230V Shunt Protection Fault
460V Shunt Protection Fault
Motor Keying Error (SERCOS drives only)
Drive Enable Input
(SERCOS drives only)
Duplicate Node Fault
(SERCOS drives only)
RESERVED
Possible Cause(s) Action/Solution
Motion required for self-sensing startup commutation was obstructed.
Ineffective shunt resistor
Excessive regeneration
Ineffective shunt resistor
Excessive regeneration
•
Verify that there are no impediments to motion at startup, such as hard limits.
•
Increase self-sensing current if high friction or load conditions exist.
•
Check motor or encoder wiring using wiring diagnostics.
•
Verify that the shunt resistor (internal or external) is connected.
•
If an external shunt resistor is connected, verify that the shunt fuse is not blown.
•
If a non Allen-Bradley external shunt resistor is used, verify that the resistance value is within specifications.
•
Verify that the motor is not being driven mechanically, causing the motor to behave as a generator.
The motor physically connected to the drive differs from the motor specified in the user program.
•
An attempt was made to enable the axis through software while the Drive
Enable hardware input was inactive.
•
The Drive Enable input transitioned from active to inactive while the axis was enabled.
Duplicate node address detected on
SERCOS ring.
Select the correct motor in the user program.
•
Disable the Drive Enable Input fault.
•
Verify that Drive Enable hardware input is active whenever the drive is enabled through software.
Verify that each SERCOS drive is assigned a unique node address.
Call your local Allen-Bradley representative.
Publication 2098-IN005B-EN-P — August 2004
2-8
Troubleshooting Your Ultra3000
Troubleshooting for
SERCOS Drives
SERCOS Module Status LED
Use the table below for troubleshooting the SERCOS Module Status
LED on your Ultra3000 (2098-DSD-xxx-SE or -HVxxx-SE).
If the SERCOS
Module Status
LED is:
Steady Green
Flashing Green
Status is:
Normal
Standby
Flashing Red-Green DC Bus Undervoltage
Flashing Red
Steady Red
Minor fault
Unrecoverable fault
Potential Cause is: Possible Resolution is:
Drive is enabled.
Drive is not enabled.
The DC bus voltage is low.
Drive is faulted, but the fault can be cleared.
Drive is faulted, and the fault cannot be cleared.
Normal operation when drive is enabled.
Normal operation when drive is disabled.
•
Normal operation when using auxiliary power (main AC power is not applied).
•
When using main AC power, refer to the
section Error Codes to continue
troubleshooting.
Refer to the section Error Codes to continue
troubleshooting.
Contact your local Allen-Bradley representative.
SERCOS Network Status LED
Use the table below for troubleshooting the SERCOS Network Status
LED on your Ultra3000 (2098-DSD-xxx-SE or -HVxxx-SE).
If the SERCOS
Network Status LED is:
Steady Green
Status is:
Communication ready
Flashing Green
Flashing Red
Establishing communication
No communication
1
Potential Cause is: Possible Resolution is:
No faults or failures.
System is still in the process of establishing
SERCOS communication.
Node address setting on the drive module does not match SERCOS controller configuration.
Loose fiber optic connection.
Broken fiber optic cable.
Receive fiber optic cable connected to
SERCOS transmit connector and vice versa.
N/A
Wait for steady green LED status.
Verify proper node switch setting.
Verify proper fiber optic cable connections.
Replace fiber optic cable.
Check proper SERCOS fiber optic cable connections.
1
Refer to Fiber Optic Cable Installation and Handling Instructions (publication 2090-IN010x-EN-P) for more information.
Publication 2098-IN005B-EN-P — August 2004
Troubleshooting Your Ultra3000 2-9
Understanding Logix/Drive Fault Behavior
This section provides the Ultra3000-SE drive fault actions and indicates whether the fault action is programmable.
The following drive fault action definitions apply:
Drive Fault Action
Disable Drive
Definition
The drive is disabled. Uncontrolled Stop, motor coasts to a stop.
When a fault is detected, the seven-segment LED will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the problem is cleared.
RSLogix
Programmable
Fault Action?
NO
Fault Message RSLogix
(Ultraware)
DriveHardFault
(Non-Volatile Memory
Endurance Exceeded)
DriveHardFault
(Velocity Exceeds Position
Rollover /2)
DriveHardFault
(Absolute Feedback Range
Exceeded)
MotorOvertempFault
(Motor Overtemperature)
DriveHardFault
(IPM Fault)
HardOvertravelFault
(+/- Hard Overtravel)
MotFeedbackFault
(Channel BM Line Loss)
MotFeedbackFault
(Channel AM Line Loss)
DriveUndervoltageFault
(Bus Undervoltage)
DriveOvervoltageFault
(Bus Overvoltage)
CommutationFault
(Illegal Hall State)
DriveHardFault
(Home Search Failed)
DriveHardFault
(Home Position In Limit)
Error
Code
E01
E02
E03
E04
E05
E06
E07
E08
E09
E10
E11
E12
E13
Description
Drive Fault
Action
Range of motion and number of home position definitions during the product life exceeds the maximum allowed (applies only to systems with absolute feedback).
DISABLE
The velocity command or feedback exceeds half the machine cycle length per millisecond (applies only when the machine cycle position rollover is enabled).
DISABLE
The motor position exceeds +/- 2047 revolutions from the home position (applies only to systems with absolute feedback).
DISABLE
The motor thermal switch was tripped.
A problem in the drive power structure was detected. Motor cables shorted, motor winding shorted internally, temperature too high, operation above continuous power rating, or has a bad IPM output, short circuit, or overcurrent.
Axis moved beyond the physical travel limits in the positive/negative direction. This fault can be configured for status only.
DISABLE
The feedback wiring is open, shorted or missing.
The feedback wiring is open, shorted or missing.
With 3 phase present, the DC bus voltage is below limits. The trip point if 275V and 137V DC for 460V/230V drives respectively.
State of Hall inputs is incorrect.
Home sensor and/or marker is outside the overtravel limits.
Home sensor, marker, or final home position exceeds a hardware overtravel limit.
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
The DC bus voltage is above limits. The trip point is 820V and 410V dc for 460V/230V drives respectively.
DISABLE
DISABLE
DISABLE
DISABLE
NO
NO
YES
NO
NO
NO
NO
NO
NO
NO
YES
NO
Publication 2098-IN005B-EN-P — August 2004
2-10
Troubleshooting Your Ultra3000
Fault Message RSLogix
(Ultraware)
Error
Code
SERCOSFault
(SERCOS or DeviceNet
Communications Network problem)
DriveHardFault
(Excessive Electrical Cycle
Length)
SoftOvertravelFault
(+/- Software Overtravel)
DriveHardFault
(User-Specified Current Fault)
OverspeedFault
(Overspeed Fault)
PositionErrorFault
(Excess Position Error)
MotFeedbackFault
(Motor Encoder State Error)
AuxFeedbackNoiseFault
(Auxiliary Encoder State
Error)
OverloadFault
(Motor Thermal Protection
Fault)
DriveOvertempFault
(IPM Thermal Protection
Fault)
DriveHardFault
(Excess Velocity Error)
DriveHardFault
(Sensor Not Assigned)
DriveHardFault
(User-Specified Velocity
Fault)
DriveHardFault
(Axis Not Homed)
DriveHardFault
(Motor Parameter Error)
DriveHardFault
(Encoder Output Frequency
Exceeded)
DriveHardFault
(Encoder Communication
Fault)
DriveHardFault
(Encoder Data)
E14
E15
E16
E17
E18
E19
E20
E21
E22
E23
E24
E25
E26
E27
E28
E29
E30
E31
Description
SERCOS or DeviceNet communications network is broken
Configuration information is not valid.
Programmed positive/negative overtravel limit has been exceeded.
DISABLE
User-Specified average current level has been exceeded.
Motor speed has exceeded 125% of maximum rated speed.
Axis position error limit has been exceeded. This fault can be configured for status only.
The motor encoder encountered an illegal transition.
The auxiliary encoder encountered an illegal transition.
The internal filter protecting the motor from overheating has tripped. DISABLE
The internal filter protecting the drive from over heating has tripped.
DISABLE
Velocity error limit was exceeded.
Homing or registration motion was attempted without a sensor assigned.
User specified velocity level was exceeded.
Absolute positioning was attempted without homing.
Parameter loaded from smart encoder or received from SERCOS controller is incompatible with the drive.
Encoder output frequency exceeds the maximum user specified value. This only applies when the encoder output is synthesized by the drive.
Communication was not established with an intelligent (i.e.
Stegmann) encoder on the motor feedback port.
Encoder data is corrupted.
Drive Fault
Action
DISABLE
N/A
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
YES
RSLogix
Programmable
Fault Action?
NO
NO
NO
NO
YES
NO
NO
YES
NO
NO
NO
NO
NO
YES
NO
NO
NO
Publication 2098-IN005B-EN-P — August 2004
Troubleshooting Your Ultra3000 2-11
Fault Message RSLogix
(Ultraware)
Error
Code
DriveHardFault
(Sine/Cosine Encoder
Frequency Limit Exceeded)
DriveHardFault
(Absolute Position Exceeds
Position Rollover)
DriveHardFault
(Ground Fault)
DriveHardFault
(Precharge Fault)
DriveHardFault
(Power Circuitry
Overtemperature)
DriveHardFault
(AC Line Loss)
SERCOSFault
(SERCOS Ring Fault)
DriveHardFault
(Self-sensing Commutation
Startup Error)
DriveHardFault
(230V Shunt Protection Fault)
DriveHardFault
(460V Shunt Protection Fault)
ConfigFault
(Motor Keying Error)
DriveEnableInputFault
(Drive Enable Input)
SERCOSFault
(Duplicate Node Fault)
E32
E33
E34
E35
E36
E37
E38
E39
E40
E41
E42
E43
E50
RESERVED
All
Others
Description
Maximum frequency of the sine/cosine circuitry has been exceeded.
DISABLE
Absolute position exceeds position rollover.
Excessive ground current in the converter was detected.
The converter pre-charge cycle has failed.
Excessive heat exists in the power circuitry.
One or more phases of the input AC power is missing.
The SERCOS ring is not active after being active and operational.
Self-sense commutation fault detected
Ineffective shunt resistor
Ineffective shunt resistor
The motor physically connected to the drive differs from the motor specified in the user program.
Generated when Enable input switches off when drive is enabled.
Duplicate node address detected on SERCOS ring.
Drive Fault
Action
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
N/A
DISABLE
DISABLE
RSLogix
Programmable
Fault Action?
NO
NO
NO
NO
NO
NO
NO
YES
NO
NO
NO
NO
NO
Publication 2098-IN005B-EN-P — August 2004
2-12
Troubleshooting Your Ultra3000
Troubleshooting for
DeviceNet Drives
DeviceNet Module Status LED
Use the table below for troubleshooting the DeviceNet Module Status
LED on your Ultra3000 (2098-DSD-xxx-DN, -xxxX-DN, -HVxxx-DN, or
-HVxxxX-DN).
If the Module
Status LED is:
Off
Steady-Green
Flashing-Green
Flashing-Red
Steady-Red
Flashing-Red/
Green
Status is: Potential Cause is:
Not powered
Operational
No power
Normal operation
Device is in stand-by
Processing or waiting for input
Recoverable fault Not operational
Unrecoverable fault
Drive problem
Self testing Self-test in progress
Possible Resolution is:
There is no power going to the device.
Normal operation - no action needed.
Normal operation - no action needed.
Power cycle or reset the drive.
1. Check drive for power-up error.
2. Replace drive.
The device is in self test, wait.
DeviceNet Network Status LED
Use the table below for troubleshooting the DeviceNet Network Status
LED on your Ultra3000 (2098-DSD-xxx-DN, -xxxX-DN, -HVxxx-DN, or
-HVxxxX-DN).
If the Network
Status LED is:
Off
Flashing-green
Steady-green
Flashing-red
Steady-red
Status is:
•
Not powered
•
Not on-line
•
On-line
•
Not connected
•
•
On-line
Connected
•
On-line
•
Time-out
Potential Cause is:
•
No power going to the device
•
Failed Duplicate
MAC ID check
•
Passed Duplicate
MAC ID check
•
No connection established
One or more connections established
I/O connection timed out
Network Failure
•
Failed Duplicate
MAC ID check
•
Bus-off
Possible Resolution is:
1. Check the Module Status LED to verify that the drive is powered.
2. Check that one or more nodes are communicating on the network.
3. Check that at least one other node on the network is operational and the data rate is the same as the drive.
No action is needed. The LED is flashing to signify that there are no open communication connections between the drive and any other device. Any connection
(I/O or explicit message) made to the drive over DeviceNet will cause the LED to stop flashing and remain Steady-ON for the duration of any open connection.
No action needed. This condition is normal.
1. Re-initiate I/O messaging by the master controller.
2. Reduce traffic or errors on the network so that messages can get through within the necessary time frame.
1. Ensure that all nodes have unique addresses.
2. If all node addresses are unique, examine network for correct media installation.
3. Ensure that all nodes have the same Data Rate.
Publication 2098-IN005B-EN-P — August 2004
Troubleshooting Your Ultra3000 2-13
Node Problems
Give particular attention to the task of setting initial addresses and data rates. Survey the network to ensure all assignments are known.
Some nodes can be logically assigned to a group of devices, but physically located away from those devices. One incorrect node can cause other nodes to appear to be Bus-off (Steady-Red LED). If a node goes Bus-off and the device is reset only to go Bus-off again, the problem is likely not with the device, but rather the setting of the address, data rate, or a network-wide problem related to topology, grounding, intermittent power/data connections, or electrical noise. If a scanner goes Bus-off, nodes will not reallocate (Flashing-green or red) even if they are functioning correctly.
Device Failure - LED Status Check
A Steady-Red Module Status LED can mean an error. If the Network
Status LED goes Steady-Red at power-up, it could mean there is a
Duplicate MAC ID. The user response is to test all devices for unique addresses. If a Steady-Red LED remains on after the Duplicate MAC ID test shows all devices to have a unique node address, it means a
Bus-off error. Do the following:
1. Check data rate settings.
2. If symptom persists, replace node address (with another address and correct data rate).
3. If symptom persists, replace tee tap.
4. If symptom persists, check topology.
5. If symptom persists, check power for noise with oscilloscope or power disturbance analyzer.
Publication 2098-IN005B-EN-P — August 2004
2-14
Troubleshooting Your Ultra3000
Scanner Problems
If using a scanner, check the scan list, data rate, and addresses of devices. Verify series and revision of the scanner is the latest. If the scanner is Bus-off, recycle the 24V supply and then reset the scanner.
If the scanner goes Bus-off again, the problem is some combination of:
•
Defective node device
•
Incorrect node data rate
•
Bad network topology
•
Faulty wiring
•
Faulty scanner
•
Faulty power supply
•
Bad grounding
•
Electrical noise
Power Supply Problems
If a single power supply is used, add up the current requirements of all devices drawing power from the network. This total should be considered the minimum current rating in selecting the power supply used. In addition check the:
•
Length and current level in trunk and drop cables
•
Size and length of the cable supplying power to the trunk
•
Voltage measured at the middle and ends of the network
•
Noise in network power measured with an oscilloscope
Publication 2098-IN005B-EN-P — August 2004
Troubleshooting Your Ultra3000 2-15
Cable Installation and Design Problems
Cable installation and design refers to the physical layout and connections on the network. Walk the network if possible to determine the actual layout and connections. Network management software displays only a logical record of the network. Ensure that you have a diagram of the physical layout and a record of the information from the tables below.
Cable Checks
Number of nodes.
Individual drop lengths.
Branched drop length.
Cumulative drop length.
Total trunk length.
Power supply cable length and gauge.
Terminator locations and size.
Power Checks
Break the earth ground of the V- and Shield and verify >1.0
Mohm to frame ground with power supply off.
Use a multi-meter to check for short circuit between CAN_H and
CAN_L, or CAN (H or L) to Shield, V- or V+.
Total power load and at its distribution points.
Spot check power for noise.
Adjusting the Physical Network Configuration
Ways to improve the efficiency of your physical network configuration include:
•
Shortening the overall length of the cable system
•
Moving the power supply in the direction of an overloaded cable section
•
Moving devices from an overloaded cable section to a less loaded section
•
Moving higher current loads closer to the power supply
•
Adding another power supply to an overloaded network
Moving the power supply from the end to the middle of the network
Publication 2098-IN005B-EN-P — August 2004
2-16
Troubleshooting Your Ultra3000
Publication 2098-IN005B-EN-P — August 2004
Chapter Objectives
Appendix
A
Interconnect Diagrams
This appendix contains the following interconnect diagrams:
•
•
Shunt Module Interconnect Diagrams
•
Ultra3000/Motor Interconnect Diagrams
•
Control String Examples (120V ac)
•
•
Ultra3000 to Logix Cable and Interconnect Diagrams
•
Ultra3000 to IMC-S Compact Cable and Interconnect Diagram
1
Publication 2098-IN005B-EN-P — August 2004
A-2
Interconnect Diagrams
Ultra3000 Interconnect
Diagram Notes
The notes in the table below apply to the power, drive/motor, shunt, and 120V ac control string interconnect diagrams.
ATTENTION
!
The National Electrical Code and local electrical codes take precedence over the values and methods provided. Implementation of these codes are the responsibility of the machine builder.
20
21
16
17
18
19
14
15
11
12
13
7
8
5
6
3
4
Note: Information:
1 A disconnecting device is required for maintenance and safety. If a grounded neutral is used instead of L2, only L1 may be switched or fused.
2 An isolation transformer is optional. If the transformer secondary has a neutral connection, neutral must be bonded to ground. Multiple drive modules may be powered from one transformer or other AC supply source.
9
10
Do not daisy chain drive module power connections. Make separate connections directly to the AC supply.
For power wiring specifications, refer to the Ultra3000 Installation Manual (publication 2098-IN003x-EN-P).
For input fuse sizes, refer to the Ultra3000 Installation Manual (publication 2098-IN003x-EN-P).
May be used to maintain power to logic section of drive and status LEDs 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).
For AC line filter specifications, refer to the Ultra3000 Installation Manual (publication 2098-IN003x-EN-P).
Drive Enable input must be opened when main power is removed and auxiliary power is present, or a drive fault will occur. A delay of at least 1.0 second must be observed before attempting to enable the drive after main power is restored.
Cable shield clamp must be used in order to meet CE requirements. No external connection to chassis ground required.
ATTENTION
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories. For more information refer to
Understanding the Machinery Directive (publication SHB-900).
!
The recommended minimum wire size for wiring the safety circuit to the contactor enable connector is 1.5 mm
2
(16 AWG).
For motor cable specifications and drive/motor cable combinations, refer to the Motion Control Selection Guide (publication GMC-SG001x-EN-P).
The Ultra3000 referenced is either a 2098-DSD-xxx or -xxxX (Ultra3000 with indexing), -xxx-SE (SERCOS interface), -xxx-DN (DeviceNet interface),
-xxxX-DN (DeviceNet with indexing) 230V drive.
The Ultra3000 referenced is either a 2098-DSD-HVxxx or -HVxxxX (Ultra3000 with indexing), -HVxxx-SE (SERCOS interface), -HVxxx-DN
(DeviceNet interface), -HVxxxX-DN (DeviceNet with indexing) 460V drive.
Wire colors are for flying lead cable (2090-XXNFxx-Sxx) and may vary from the premolded connector cable (2090-UXNFBxx-Sxx). Wires without terminations at the drive are not shown for clarity.
If flying lead feedback cable has a drain wire, it must be folded back and clamped with the cable shield (CN2 breakout board 2090-UXBB-DM15).
Only the MPG-Bxxx encoder uses the +5V dc supply. MPL-Bxxx and 1326AB (M2L/S2L) encoders use the +9V dc supply.
Only the MPL-A5xx and MPF-A5xx encoders use the +9V dc supply. MPG-Axxx encoders use the +5V dc supply.
Use a flyback diode for noise suppression of the motor brake coil. For more information, refer to System Design for Control of Electrical Noise
Reference Manual (publication GMC-RM001x-EN-P).
Relay Output (CN1, pins 43 and 44) must be configured as Ready in Ultraware software.
The preferred method for supplying the auxiliary power is by using the 12- or 44-pin drive-mounted breakout board with 24V to 5V auxiliary power converter (catalog number 2090-U3CBB-DM12 or -DM44). Auxiliary +5V power is required to maintain encoder position when the main AC power is disconnected.
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-3
Power Interconnect
Diagrams
Single-Phase AC Line
50/60 Hz
Fused Disconnect or Circuit Breaker*
Isolation
Transformer*
Single-Phase Input
100-240V ac RMS
L2/N
L1
Chassis
The Ultra3000 (2098-DSD-005x-xx, -010x-xx, and -020x-xx) power wiring with 24V dc control string (non-SERCOS drives only) is shown in the figure below. To avoid a separate 5V dc auxiliary logic power supply, the 24V to 5V converter breakout board (2090-U3CBB-DMxx) is used to wire the control interface (CN1) connector. For the control
string diagram with 120V ac input refer to Figure A.16.
For SERCOS drives, input line contactor is part of the PLC program and output control.
Input Fusing*
Bonded Cabinet
Ground Bus*
Figure A.1
Typical Power Wiring of Ultra3000 System
(2098-DSD-005x-xx, -010x-xx, and -020x-xx)
M1*
Single-Phase
AC Line Filter
Ultra3000
Digital Servo Drives
2098-DSD-005x-xx,
-010x-xx, and -020x-xx
TB1
DC+
DC-
DC Bus Connections for Active Shunt Module
L1
L2/N
AC Input Power
Connections
Three-Phase
Motor Power
Connections
U
V
W
Motor Power
Connections
CN1
43
44
3
2
N.O. Relay Output+
N.O. Relay Output-
Aux Logic Power In +5V
Aux +5V Common
From CN1 Breakout
Board with 24V to 5V
Aux Power Converter
(2090-U3CBB-DMxx)
Cable Shield
Clamp
Terminal
Blocks*
To additional
Ultra3000 drive
CN1
43
* INDICATES USER-SUPPLIED COMPONENT
44
START*
STOP*
CR1*
CR1*
M1*
CR1*
Refer to Attention statement (Notes 10, 11)
24V dc
Publication 2098-IN005B-EN-P — August 2004
A-4
Interconnect Diagrams
The Ultra3000 (2098-DSD-030x-xx) power wiring with 24V dc control string (non-SERCOS drives only) is shown in the figure below. For the
control string diagram with 120V ac input refer to Figure A.17.
For SERCOS drives, input line contactor is part of the PLC program and output control.
Figure A.2
Typical Power Wiring of Ultra3000 System
(2098-DSD-030x-xx)
Three-Phase
Motor Power
Connections
TB1
U
V
W
Ultra3000
Digital Servo Drives
2098-DSD-030x-xx
Motor Power
Connections
TB2
1
2
3
External Passive
Shunt Connections
(refer to figures
Single-Phase AC Line
50/60 Hz
Single-Phase
AC Line Filter
Fused Disconnect or Circuit Breaker*
Isolation
Transformer*
L1
Single-Phase Input
100-240V ac RMS
L2/N
Chassis
Bonded Cabinet
Ground Bus*
Terminal
Blocks*
* INDICATES USER-SUPPLIED COMPONENT
To additional
Ultra3000 drive
M1*
Input Fusing*
DC+
DC-
L1
L2/N
L1 AUX
L2/N AUX
AC Input Power
Connections
Cable Shield
Clamp
CN1
43
44
N.O. Relay Output+
N.O. Relay Output-
CN1
START*
STOP*
CR1*
CR1*
M1*
CR1*
Refer to Attention statement (Notes 10, 11)
24V dc
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-5
Fused Disconnect or Circuit Breaker*
Three-Phase AC Line
50/60 Hz
Isolation
Transformer*
L1
Neutral
Chassis
Three-Phase Input
100-240V ac RMS
L2
L3
Terminal
Blocks*
* INDICATES USER-SUPPLIED COMPONENT
The Ultra3000 (2098-DSD-075x-xx and -150x-xx) power wiring with
24V dc control string (non-SERCOS drives only) is shown in the figure below. For the control string diagram with 120V ac input refer to
For SERCOS drives, input line contactor is part of the PLC program and output control.
Figure A.3
Typical Power Wiring of Ultra3000 System
(2098-DSD-075x-xx and -150x-xx)
Three-Phase
Motor Power
Connections
Ultra3000
Digital Servo Drives
2098-DSD-075x-xx and
-150x-xx
TB1
TB2
U
1
V
Motor Power
Connections
2
W
3
External Passive
Shunt Connections
(refer to figures
Three-Phase
AC Line Filter
Input Fusing*
Bonded Cabinet
Ground Bus*
M1*
DC+
DC-
L1
L2
L3
L1 AUX
L2/N AUX
AC Input Power
Connections
CN1
43
44
N.O. Relay Output+
N.O. Relay Output-
Cable Shield
Clamp
CN1
START*
STOP*
CR1*
CR1*
M1*
CR1*
Refer to Attention statement (Notes 10, 11)
24V dc
To additional
Ultra3000 drive
Publication 2098-IN005B-EN-P — August 2004
A-6
Interconnect Diagrams
The Ultra3000 (2098-DSD-HVxxx-xx and -HVxxxX-xx) power wiring with 24V dc control string is shown in the figure below. For the
control string diagram with 120V ac input refer to Figure A.18.
Figure A.4
Typical Power Wiring of Ultra3000 System
(2098-DSD-HVxxx-xx and -HVxxxX-xx)
Three-Phase
Motor Power
Connections
DC+
DC-
W
V
U
Ultra3000
Digital Servo Drives
2098-DSD-HVxxx-xx and
-HVxxxX-xx
TB1
TB2
Motor Power
Connections
1
2
3
External Passive
Shunt Connections
(refer to figures
Fused Disconnect or Circuit Breaker*
Three-Phase AC Line
50/60 Hz
Isolation
Transformer*
Neutral
Chassis
Three-Phase
AC Line Filter
M1*
Input Fusing*
L3
L2
L1
L1 AUX
L2/N AUX
AC Input Power
Connections
Cable Shield
Clamp
CN1
43
44
N.O. Relay Output+
N.O. Relay Output-
Bonded Cabinet
Ground Bus*
CN1
L3
Three-Phase Input
230-480V ac RMS
L2
L1
Terminal Blocks*
* INDICATES USER-SUPPLIED COMPONENT
To additional
Ultra3000 drive
START* STOP*
CR1*
CR1*
M1*
CR1*
Refer to Attention statement (Notes 10, 11)
24V dc
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams
Shunt Module Interconnect
Diagrams
This section contains the interconnect diagrams connecting the
Ultra3000 drives with active and passive shunt modules.
A-7
Active Shunt Module Diagrams
In the figure below, the Ultra3000 (2098-DSD-005x-xx, -010x-xx, or
-020x-xx) is shown wired with the 2090-UCSR-A300 active shunt module.
Figure A.5
External Active Shunt Module Interconnect Diagram
External Active
Shunt Module
2090-UCSR-A300
DC+
DC-
L1
L2/N
Ultra3000
Digital Servo Drives
2098-DSD-005x-xx,
-010x-xx, and -020x-xx
TB1
DC+
DC-
L1
L2/N
DC Bus Connections for Active Shunt Module
AC Input Power
Connections
Passive Shunt Module Diagrams
In the Figure A.6, the Ultra3000 is shown wired for internal shunt
operation. This is the factory default jumper setting.
IMPORTANT
Internal shunt operation is only present on the drives listed in the figure below.
Figure A.6
Internal Shunt Interconnect Diagram
TB2
1
2
3
Ultra3000
Digital Servo Drives
2098-DSD-030x-xx,
-075x-xx, -150x-xx,
-HVxxx-xx, and
-HVxxxX-xx
Internal Passive Shunt
Resistor Connections
Publication 2098-IN005B-EN-P — August 2004
A-8
Interconnect Diagrams
In the figure below, the Ultra3000 is shown wired with an external passive shunt resistor.
Figure A.7
External Passive Shunt Module Interconnect Diagram
External Passive
Shunt Module
DC+
COL
TB2
1
2
3
Ultra3000
Digital Servo Drives
2098-DSD-030x-xx,
-075x-xx, -150x-xx,
-HVxxx-xx, and
-HVxxxX-xx
External Passive Shunt
Resistor Connections
In the figure below, the Ultra3000 (2098-DSD-150x-xx) is shown wired with two external passive shunt resistors. When two 900W shunt modules are connected in parallel, the shunt capacity is doubled for a total of 1800W of continuous power dissipation.
Figure A.8
External Passive Shunt Module Interconnect Diagram
External Passive
Shunt Module
2090-UCSR-P900
Ultra3000
Digital Servo Drives
2098-DSD-150x-xx
DC+
COL
External Passive
Shunt Module
2090-UCSR-P900
TB2
1
2
3
External Passive Shunt
Resistor Connections
DC+
COL
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-9
Bonitron
Shunt Module *
M3575R-Hxxxx
RES
TEMP
Alarm
115VAC
Fan
GRN
5
6
7
3
4
1
2
In the figure below, the Ultra3000 (2098-DSD-HV150x-xx or
-HV220x-xx) is shown wired to a Bonitron shunt module.
Figure A.9
External Passive Shunt Module Interconnect Diagram
Ultra3000
Digital Servo Drives
2098-DSD-HV150x-xx or
2098-DSD-HV220x-xx
TB2
1
2
3
External Passive Shunt
Resistor Connections
Shunt Wiring Methods:
Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
Twisted pair, 2 twists per foot min. (3rd choice).
Maximum Length: 3.05 m (10 ft).
START*
STOP*
CR1*
CR1*
M1*
CR1*
Refer to Attention statement (Notes 10, 11)
120V ac
50/60 Hz
Bonded Cabinet
Ground Bus*
115V ac
Fan Power*
* INDICATES USER-SUPPLIED COMPONENT
Publication 2098-IN005B-EN-P — August 2004
A-10
Interconnect Diagrams
Ultra3000/Motor
Interconnect Diagrams
This section contains the motor power, brake, and feedback signal interconnect diagrams between the Ultra3000 and MP-Series, 1326AB-
(M2L/S2L), F-, H-, N-, and Y-Series motors.
In the figure below, the Ultra3000 (460V) is shown connected to
MP-Series or 1326AB (M2L/S2L) servo motors.
Figure A.10
Ultra3000 to MP-Series or 1326AB (M2L/S2L) Motor Configuration
2090-XXNPMP-xxSxx
Motor Power Cable
MPL-B and MPG-B (460V) or 1326AB (M2L/S2L)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
BLU
BLK
BRN
GN/YL
W
V
U
Motor
Power
TB1
Ultra3000 460V Drive
Green/Yellow
Blue
Black
Brown
D
C
B
A
BR-
BR+ N
R
K
L
E
F
C
D
A
B
S
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
Motor Feedback
(CN2) Connector
Motor Feedback
(15-pin) Connector
CN2
2090-UXNBMP-18Sxx Brake Cable
43
Black
C
Control Interface
(44-pin) Connector
CN1
44
White
COM
+24V
User Supplied
+24V dc Power Supply
(1A max.)
A
Cable Shield
Clamp
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
Motor Brake
Thermostat
P
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS+
C
A
D
C
B
A
MPL-B (460V) SERVO MOTORS
WITH INCREMENTAL FEEDBACK
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
A
B
N
R
K
L
E
F
C
D
Thermostat
BR-
BR+
Motor Brake
U
V
S
T
P
2090-XXNFMP-Sxx (flying lead) or 2090-UXNFBMP-Sxx (with drive-end connector) Feedback Cable
Motor Feedback
(CN2) Connector
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
S3
3
4
1
2
5
10
14
6
11
12
13
8
1
2
3
4
5
10
14
6
7
11
2090-XXNFMP-Sxx (flying lead) or 2090-UXNFBMP-Sxx (with drive-end connector) Feedback Cable
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-11
In the figure below, the Ultra3000 (230V) is shown connected to
MP-Series (low inertia and integrated gear) 230V servo motors.
Figure A.11
Ultra3000 to MP-Series (230V) Motor Configuration
2090-XXNPMP-xxSxx
Motor Power Cable
MPL-A and MPG-A (230V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
BRN
BLK
BLU
GN/YL
U
V
W
Motor
Power
TB1
Ultra3000 230V Drive
Motor Feedback
(15-pin) Connector
CN2
Green/Yellow
D
Blue
C
Black
B
Brown
A
2090-UXNBMP-18Sxx Brake Cable
43
Black
C
Control Interface
(44-pin) Connector
CN1
44
White
COM +24V
User Supplied
+24V dc Power Supply
(1A max.)
A
Cable Shield
Clamp
W
V
U
GND
Three-Phase
Motor Power
BR-
BR+
Motor Feedback
Motor Brake
Thermostat
N
R
K
L
E
F
C
D
A
B
S
P
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS+
Motor Feedback
(CN2) Connector
C
A
D
C
B
A
MPL-A (230V) SERVO MOTORS
WITH INCREMENTAL FEEDBACK
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
A
B
N
R
K
L
E
F
C
D
Thermostat
BR-
BR+
Motor Brake
P
U
V
S
T
2090-XXNFMP-Sxx (flying lead) or 2090-UXNFBMP-Sxx (with drive-end connector) Feedback Cable
Motor Feedback
(CN2) Connector
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
S3
3
4
1
2
5
10
14
6
11
12
13
8
3
4
1
2
5
10
14
6
7
11
2090-XXNFMP-Sxx (flying lead) or 2090-UXNFBMP-Sxx (with drive-end connector) Feedback Cable
IMPORTANT
MPL-A5xxx motors are not compatible with
Ultra3000 (2098-DSD-005, -010, -020) drives.
Publication 2098-IN005B-EN-P — August 2004
A-12
Interconnect Diagrams
In the figure below, the Ultra3000 (230V) is shown connected to
MP-Series food grade servo motors.
BRN
BLK
BLU
GN/YL
U
V
W
Motor
Power
TB1
Ultra3000 Drive
Motor Feedback
(15-pin) Connector
CN2
Figure A.12
Ultra3000 to MP-Series Food Grade Motor Configuration
Green/Yellow
Blue
Black
Brown
2090-XXNPMF-xxSxx
Motor Power Cable
43
Control Interface
(44-pin) Connector
CN1
44
Black
White
COM +24V
Cable Shield
Clamp
User Supplied
+24V dc Power Supply
(1A max.)
D/
C/W
B/V
A/U
G/-
F/+
MPF-A (230V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
W
V
U
BR-
BR+
GND
Three-Phase
Motor Power
Motor Feedback
Motor
Brake
Thermostat
3
4
9
10
5
6
11
13
1
2
14
12
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
2090-XXNFMF-Sxx Feedback Cable
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS+
Motor Feedback
(CN2) Connector
3
4
1
2
5
10
14
6
7
11
MPF-B (460V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
D/
C/W
B/V
A/U
G/-
F/+
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
Thermostat
5
6
9
10
11
13
1
2
3
4
14
BR-
BR+
Motor
Brake
12
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
−
ECOM
+9VDC
TS+
Motor Feedback
(CN2) Connector
3
4
1
2
5
10
6
7
11
2090-XXNFMF-Sxx Feedback Cable
IMPORTANT
MPF-A5xxx motors are not compatible with
Ultra3000 (2098-DSD-005, -010, -020) drives.
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-13
BRN
BLK
BLU
GN/YL
U
V
W
Motor
Power
TB1
2090-XXNPH/HF-xxSxx or -UXNPBH/HF-xxSxx
Motor Power Cable
Ultra3000 230V Drive
Motor Feedback
(15-pin) Connector
CN2
In the figure below, the Ultra3000 (230V) is shown connected to H- and F-Series (230V) servo motors.
Figure A.13
Ultra3000 to H- and F-Series (230V) Motor Configuration
H- or F-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
Green/Yellow
Blue
Black
Brown
D
C
B
A
Motor Feedback
(CN2) Connector
9101-0330 Brake Cable Connector Kit
43
Black
C
Control Interface
(44-pin) Connector
CN1
44
White
COM +24V
User Supplied
+24V dc Power Supply
(1A max.)
Cable Shield
Clamp
A
W
V
U
GND
Three-Phase
Motor Power
BR-
BR+
Motor Feedback
Motor Brake
N
T
H
L
M
K
J
R
P
E
F
A
B
C
D
Thermostat
S
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BROWN
BROWN
GRAY
WHT/GRAY
BLUE
WHT/BLUE
VIOLET
WHT/VIOLET
ECOM
S2
S1
–
TS-
AM+
AM-
BM+
BM-
IM+
IM-
TS+
S3
+5VDC
3
4
1
2
5
10
11
8
14
6
13
12
6
2090-XXNFHF-Sxx (flying lead) or 2090-UXNFBHF-Sxx (with drive-end connector)
Feedback Cable
Publication 2098-IN005B-EN-P — August 2004
A-14
Interconnect Diagrams
In the figure below, the Ultra3000 (230V) is shown connected to
N-Series (230V) servo motors.
Figure A.14
Ultra3000 to N-Series (230V) Motor Configuration
BRN
BLK
BLU
GN/YL
U
V
W
Motor
Power
TB1
2090-XXNPN-16Sxx
Motor Power Cable
Ultra3000 230V Drive
Motor Feedback
(15-pin) Connector
CN2
Green/Yellow
Blue
Black
Brown
E
D
C
B
A
9101-1698 Brake Cable Connector Kit
43
Black
C
Control Interface
(44-pin) Connector
CN1
44
White
COM +24V
User Supplied
+24V dc Power Supply
(1A max.)
Cable Shield
Clamp
A
N-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
N/C
W
V
U
BR-
BR+
GND
Three-Phase
Motor Power
Motor Feedback
Motor Brake
A
B
L
M
K
J
U
T
R
V
E
F
C
D
H
Thermostat
S
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BROWN
BROWN
GRAY
WHT/GRAY
BLUE
WHT/BLUE
VIOLET
WHT/VIOLET
ECOM
S2
S1
–
TS-
AM+
AM-
BM+
BM-
IM+
IM-
TS+
S3
+5VDC
Motor Feedback
(CN2) Connector
3
4
1
2
5
10
11
8
14
6
13
12
6
2090-XXNFN-Sxx (flying lead) or 2090-UXNFBN-Sxx (with drive-end connector)
Feedback Cable
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-15
In the figure below, the Ultra3000 (230V) is shown connected to
Y-Series (230V) servo motors.
Figure A.15
Ultra3000 to Y-Series (230V) Motor Configuration
Y-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
1-BLK
2-BLK
3-BLK
GN/YL
U
V
W
Motor
Power
TB1
Ultra3000 230V Drive
Motor Feedback
(15-pin) Connector
CN2
Green/Yellow
3/Black
2/Black
1/Black
2090-XXNPY-16Sxx
Motor Power Cable
4
3
2
1
43
Control Interface
(44-pin) Connector
CN1
44
BLK
BLK
9
7
COM +24V
Cable Shield
Clamp
User Supplied
+24V dc Power Supply
(1A max.)
Pigtail
W
V
U
GND
Three-Phase
Motor Power
BR-
BR+
Motor
Feedback
Motor
Brake
Pigtail
13
14
15
17
19
–
22
23
24
9
10
11
12
Motor Feedback
(CN2) Connector
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BLUE
BLUE
BROWN
WHT/BROWN
GRAY
WHT/GRAY
AM+
AM-
BM+
BM-
IM+
IM-
S1
S2
S3
–
+5VDC
ECOM
DRAIN
2090-XXNFY-Sxx (flying lead) or 2090-UXNFBY-Sxx (with drive-end connector)
Feedback Cable
5
10
12
13
8
3
4
1
2
14
6
Publication 2098-IN005B-EN-P — August 2004
A-16
Interconnect Diagrams
Control String Examples
(120V ac)
This section provides information to assist you in using the configurable Drive Ready output in a control string with 120V ac input voltage.
The 120V ac control string wired to the Ultra3000 (2098-DSD-005x-xx,
-010x-xx, or -020x-xx) drives is shown in the figure below.
ATTENTION
!
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories. For more information refer to Understanding the
Machinery Directive (publication SHB-900).
Figure A.16
120V ac Single-Phase Control String Example
Ultra3000
Single-Phase
AC Line
50/60 Hz
Fuse
Block
M1
L1
L2/N
CN1
CR2
START
STOP
CR1
CR1
CR1
Refer to Attention statement above
M1
120V AC
50/60 Hz
43
N.O. Relay Output+
44
N.O. Relay Output-
3
Aux Logic Power In +5V
2
Aux +5V Common
CR2
24V DC
From CN1 Breakout Board with 24V to 5V Aux Power
Converter (2090-U3CBB-DM xx)
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-17
The 120V ac control string wired to the Ultra3000 (2098-DSD-030x-xx) drives is shown in the figure below.
ATTENTION
!
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories. For more information refer to Understanding the
Machinery Directive (publication SHB-900).
Figure A.17
120V ac Single-Phase Control String Example
Ultra3000
Internal
External
Shunt
TB2
1
2
3
Single-Phase
AC Line 50/60 Hz
Motor
Fuse
Block
DC Bus
M1
L1
L2/N
L1 Aux
L2/N Aux
100-240 VAC
50/60 Hz
TB1
+
-
L1
L2/N
L1
AUX
L2/N
AUX
U
V
W
CR2
START
STOP
CR1
CR1
CR1
Refer to Attention statement above
M1
120V AC
50/60 Hz
CN1
43
N.O. Relay Output+
44
N.O. Relay Output-
CR2
24V DC
Publication 2098-IN005B-EN-P — August 2004
A-18
Interconnect Diagrams
Three-Phase
AC Line
50/60 Hz
Ultra3000
Internal
External
Shunt
TB2
1
2
3
Ultra3000
Motor
Fuse
Block
DC Bus
M1
L1
L2
L3
L1 Aux
L2/N Aux
100-240 VAC
50/60 Hz
TB1
-
+
L1
L2
L3
L1
AUX
L2/N
AUX
U
V
W
The 120V ac control string wired to the Ultra3000 (2098-DSD-075x-xx,
-150x-xx, -HVxxx-xx, and -HVxxxX-xx) drives is shown in the figure below.
ATTENTION
!
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories. For more information refer to Understanding the
Machinery Directive (publication SHB-900).
Figure A.18
120V ac Three-Phase Control String Example
CR2
START
STOP
CR1
CR1
CR1
Refer to Attention statement above
M1
120V AC
50/60 Hz
CN1
43
N.O. Relay Output+
44
N.O. Relay Output-
CR2
24V DC
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-19
Controlling a Brake
Example
Compatible Brake Motors
F-4030, -4050, and -4075
H-3007 and -3016
H-4030, -4050, and -4075
N-2302, and -2304
N-3406, -3412, -4214, and -4220
N-5630, -5637, and -5647
Y-1002 and -1003
Y-2006 and -2012
Y-3023
Ultra3000
The relay output of the Ultra3000 is suitable for directly controlling a motor brake, subject to the relay voltage limit of 30V dc, and the relay current limit of 1A dc. For brake requirements outside of these limits, an external relay must be used. If a transistor output is used, a control relay is also required.
The following table lists Allen-Bradley motors that are compatible with the internal relay output (CN1, pins 43 and 44), when used for controlling a brake. All other motors require an external control relay.
Brake Current
0.88A
0.60A
0.69A
0.28A
0.36A
0.71A
0.26A
0.31A
0.37A
1
Applies to 230V and 460V motors.
Compatible Brake Motors
MPL/MPF-x310, -x320, -x330
1
MPL-x420, -x430, -x4520, -x4530, -x4540
1
MPF-x430, -x4530, -x4540
1
MPG-x004
1
MPG-x010
1
MPG-x025
1
MPG-x050
1
MPG-x110
1
1326AB-B4xxx
Brake Current
0.50A
0.64A
0.33A
0.45A
0.50A
1.0A
0.88A
Figure A.19 shows an example configuration using Digital Output 1
and an external control relay to control a motor brake which exceeds internal relay ratings.
Figure A.19
Example Configuration Controlling a Motor Brake
Power Supply
3A @ 24V dc
+
_
29
I/O Power
27
I/O Common
CR1
1
CN1
39
Digital Output 1
2, 3
28
I/O Common
CR1
Brake
Feedback
Power
Servo
Motor
1
Flyback diode (1N4004 rated 1.0A @ 400V dc) suppresses collapsing field of brake coil.
2
Digital Output 1 (pin 39) configured as Brake in Ultraware software.
3
For Digital Output 1 specifications, refer to the Ultra3000 Installation Manual (publication 2098-IN003x-EN-P).
IMPORTANT
Flyback diodes must be used when controlling a brake coil with the relay or digital output.
Publication 2098-IN005B-EN-P — August 2004
A-20
Interconnect Diagrams
Ultra3000 to Logix Cable and Interconnect Diagrams
This section provides information to assist you in wiring the Ultra3000
CN1 (44-pin) cable connector with either the ControlLogix
1756-M02AE servo module or SoftLogix 1784-PM02AE motion card.
Use the 2090-U3AE-D44xx control interface cable (shown below) when connecting two Ultra3000 drives to the 1756-M02AE servo module. This cable includes the 1756-TBCH pre-wired terminal block.
Refer to Figure A.22 for the interconnect diagram.
Figure A.20
2090-U3AE-D44xx Two Axis Cable
Pin 44
Pin 31
Pin 1
Connector,
D-sub, high density 44-pin with 45° black
PVC overmold
Pin 15
AXIS 0 - CN1
AXIS 0 - CN1
AXIS 1 - CN1
AXIS 1 - CN1
IO - AX0
RELAY - AX0
IO PWR - AX0
AUX PWR - AX0
M02AE view shown without cover
AUX PWR - AX1
IO PWR - AX1
RELAY - AX1
IO - AX1
Use the 2090-U3CC-D44xx control interface cable (shown below) when connecting a single Ultra3000 drive to either the 1756-M02AE
(ControlLogix) servo module or 1784-PM02AE (SoftLogix) PCI card.
The 1756-TBCH removable terminal block is required when wiring to the ControlLogix module. The 1784-PM02AE-TPxx termination panel
is required when wiring to the SoftLogix PCI Card. Refer to Figure
A.23 for the interconnect diagram.
Figure A.21
Control Interface Cable and Terminations
AXIS 0 - CN1
45
Pin 15
Pin 44
Connector,
D-sub, high density 44-pin with 45° black
PVC overmold
Pin 31
Pin 1
1756-TBCH
Removable Terminal Block
(use with 1756-M02AE ControlLogix Servo Module)
26
28
30
32
18
20
22
24
34
36
10
12
14
16
6
8
2
4
25
27
29
31
17
19
21
23
33
35
9
11
13
15
5
7
1
3
2090-U3CC-D44xx
Control Interface Cable
AUX PWR - AX0
IO PWR - AX0
RELAY - AX0
IO - AX0
1784-PM02AE-TPxx
Termination Panel
(use with 1784-PM02AE SoftLogix PCI Card)
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-21
43
44
RELAY +
RELAY -
30
28
IO PWR
IO COM
3
2
AUX PWR +5
AUXCOM ECOM
25
26
ANALOG COMMAND +
ANALOG COMMAND -
29
31
39
27
IO POWER
INPUT 1 ENABLE
2
OUTPUT 1 READY
3
IO COM
19
20
21
16
17
18
AOUT +
AOUT -
BOUT +
BOUT -
IOUT +
IOUT -
WHT/ORG 22GA
WHT/YEL 22GA
DRAIN
WHT/RED 22GA
WHT/BLACK 22GA
DRAIN
RED 22GA
BLACK 22GA
DRAIN
AXIS 0
WHT/GRN 22GA
WHT/BLU 22GA
DRAIN
BROWN 28GA
RED 28GA
ORANGE 28GA
YELLOW 28GA
DRAIN
GREEN 28GA
BLUE 28GA
VIOLET 28GA
GRAY 28GA
WHITE 28GA
BLACK 28GA
DRAIN
Figure A.22
Ultra3000 to ControlLogix Servo Module Interconnect Diagram
RELAY
(user configured)
IO PWR
1
AUX PWR
(optional)
2 AXIS SERVO
CH0 CH1
FDBK FDBK
DRIVE DRIVE
OK
RELAY
(user configured)
1
IO PWR
AUX PWR
(optional)
WHT/ORG 22GA
WHT/YEL 22GA
DRAIN
WHT/RED 22GA
WHT/BLACK 22GA
DRAIN
RED 14GA
BLACK 14GA
DRAIN
AXIS 1
+OUT-0
-OUT-0
CHASSIS
2
4
12
+ENABLE-0
-ENABLE-0
DRVFLT-0
IN_COM
6
8
10
14
+CHA-0
-CHA-0
+CHB-0
-CHB-0
+CHZ-0
-CHZ-0
CHASSIS
26
28
30
32
34
36
24
23
25
27
15
17
19
21
29
31
33
35
11
13
7
9
1
3
5
24
26
28
16
18
20
22
30
32
34
36
8
10
12
14
2
4
6
1
3
11
+OUT-1
-OUT-1
CHASSIS
5
7
9
13
+ENABLE-1
-ENABLE-1
DRVFLT-1
IN_COM
25
27
29
31
33
35
23
+CHA-1
-CHA-1
+CHB-1
-CHB-1
+CHZ-1
-CHZ-1
CHASSIS
WHT/GRN 22GA
WHT/BLU 22GA
DRAIN
BROWN 28GA
RED 28GA
ORANGE 28GA
YELLOW 28GA
DRAIN
GREEN 28GA
BLUE 28GA
VIOLET 28GA
GRAY 28GA
WHITE 28GA
BLACK 28GA
DRAIN
RELAY +
RELAY -
43
44
IO PWR
IO COM
30
28
AUX PWR +5
AUXCOM ECOM
3
2
ANALOG COMMAND +
ANALOG COMMAND -
25
26
IO POWER
2
INPUT 1 ENABLE
3
OUTPUT 1 READY
IO COM
29
31
39
27
AOUT +
AOUT -
BOUT +
BOUT -
IOUT +
IOUT -
16
17
18
19
20
21
2090-U3AE-D44 xx
Controller Interface
Cable
4
Ultra3000
CN1 Connector
(Axis 0)
33
34
35
36
37
38
40
41
42
6
7
8
4
5
9
32
22
23
24
1
BLACK 28GA
WHT/BLK 28GA
BROWN 28GA
WHT/BRN 28GA
RED 28GA
WHT/RED 28GA
ORANGE 28GA
WHT/ORG 28GA
YELLOW 28GA
WHT/YEL 28GA
GRAY 28GA
WHT/GRY 28GA
PINK 28GA
WHT/PNK 28GA
WHT/BLK/RED 28GA
RED/BLK 28GA
WHT/BLK/ORG 28GA
ORG/BLK 28GA
WHT/BLK/YEL 28GA
YEL/BLK 28GA
DRAIN
1756-M02AE SERVO MODULE
ACOM ANALOG GRD
ANALOG OUT PROG
ILIMIT
EPWR +5 OUT
AX+
AX-
BX+
BX-
IX+
IX-
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
OUTPUT 2
OUTPUT 3
OUTPUT 4
ACOM ANALOG GRD
ANALOG OUT PROG
ILIMIT
EPWR +5 OUT
AX+
AX-
BX+
BX-
IX+
IX-
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
OUTPUT 2
OUTPUT 3
OUTPUT 4
BLACK 28GA
WHT/BLK 28GA
BROWN 28GA
WHT/BRN 28GA
RED 28GA
WHT/RED 28GA
ORANGE 28GA
WHT/ORG 28GA
YELLOW 28GA
WHT/YEL 28GA
GRAY 28GA
WHT/GRY 28GA
PINK 28GA
WHT/PNK 28GA
WHT/BLK/RED 28GA
RED/BLK 28GA
WHT/BLK/ORG 28GA
ORG/BLK 28GA
WHT/BLK/YEL 28GA
YEL/BLK 28GA
DRAIN
8
9
32
6
7
24
1
4
5
22
23
40
41
42
33
34
35
36
37
38
2090-U3AE-D44 xx
Controller Interface
Cable
4
Ultra3000
CN1 Connector
(Axis 1)
1
I/O power (pins 28 and 30) must be connected to user-supplied 12-24V dc.
2
Input 1 (pin 31) must configured as Drive Enable using Ultraware software.
3
Output 1 (pin 39) must be configured as Ready using Ultraware software.
4
This cable does not carry the unbuffered motor encoder signals (CN1 pins 10-15). Contact your Allen-Bradley sales representative if these signals are required for your application.
Publication 2098-IN005B-EN-P — August 2004
A-22
Interconnect Diagrams
43
44
RELAY +
RELAY -
30
28
IO PWR
IO COM
3
2
AUX PWR +5
AUXCOM ECOM
25
26
ANALOG COMMAND +
ANALOG COMMAND -
29
31
39
27
IO POWER
INPUT 1 ENABLE
2
OUTPUT 1 READY
3
IO COM
19
20
21
16
17
18
AOUT +
AOUT -
BOUT +
BOUT -
IOUT +
IOUT -
2090-U3CC-D44 xx
Controller Interface
Cable
4
Ultra3000
CN1 Connector
(Axis 0)
6
7
8
4
5
9
32
22
23
24
1
36
37
38
40
41
42
33
34
35
WHT/ORG 22GA
WHT/YEL 22GA
DRAIN
WHT/RED 22GA
WHT/BLACK 22GA
DRAIN
RED 22GA
BLACK 22GA
DRAIN
Figure A.23
Ultra3000 to SoftLogix PCI Card Interconnect Diagram
RELAY
(user configured)
IO PWR
1
AUX PWR
(optional)
RELAY
(user configured)
1
IO PWR
AUX PWR
(optional)
WHT/ORG 22GA
WHT/YEL 22GA
DRAIN
WHT/RED 22GA
WHT/BLACK 22GA
DRAIN
RED 14GA
BLACK 14GA
DRAIN
RELAY +
RELAY -
43
44
IO PWR
IO COM
30
28
AUX PWR +5
AUXCOM ECOM
3
2
AXIS 0
WHT/GRN 22GA
WHT/BLU 22GA
DRAIN
BROWN 28GA
RED 28GA
ORANGE 28GA
YELLOW 28GA
DRAIN
GREEN 28GA
BLUE 28GA
VIOLET 28GA
GRAY 28GA
WHITE 28GA
BLACK 28GA
DRAIN
+OUT-0
-OUT-0
CHASSIS
P3-B-7
P3-B-8
P3-B-6
+ENABLE-0
-ENABLE-0
DRVFLT-0
IN_COM
P3-A-6
P3-A-7
P3-A-0
P3-A-5
P2
+CHA-0
-CHA-0
+CHB-0
-CHB-0
+CHZ-0
-CHZ-0
CHASSIS
P3-B-0
P3-B-1
P3-B-2
P3-B-3
P3-B-4
P3-B-5
P3-B-6
P3
P4-B-7
P4-B-8
P4-B-6
P4-A-6
P4-A-7
P4-A-0
P4-A-5
+OUT-1
-OUT-1
CHASSIS
+ENABLE-1
-ENABLE-1
DRVFLT-1
IN_COM
P4-B-0
P4-B-1
P4-B-2
P4-B-3
P4-B-4
P4-B-5
P4-B-6
P4
+CHA-1
-CHA-1
+CHB-1
-CHB-1
+CHZ-1
-CHZ-1
CHASSIS
AXIS 1
WHT/GRN 22GA
WHT/BLU 22GA
DRAIN
BROWN 28GA
RED 28GA
ORANGE 28GA
YELLOW 28GA
DRAIN
GREEN 28GA
BLUE 28GA
VIOLET 28GA
GRAY 28GA
WHITE 28GA
BLACK 28GA
DRAIN
ANALOG COMMAND +
ANALOG COMMAND -
25
26
IO POWER
2
INPUT 1 ENABLE
3
OUTPUT 1 READY
IO COM
29
31
39
27
AOUT +
AOUT -
BOUT +
BOUT -
IOUT +
IOUT -
16
17
18
19
20
21
B B
A A
0 1
0 9 0 9
1784-PM02AE-TP xx Termination Panel Connector Pin-out
BLACK 28GA
WHT/BLK 28GA
BROWN 28GA
WHT/BRN 28GA
RED 28GA
WHT/RED 28GA
ORANGE 28GA
WHT/ORG 28GA
YELLOW 28GA
WHT/YEL 28GA
GRAY 28GA
WHT/GRY 28GA
PINK 28GA
WHT/PNK 28GA
WHT/BLK/RED 28GA
RED/BLK 28GA
WHT/BLK/ORG 28GA
ORG/BLK 28GA
WHT/BLK/YEL 28GA
YEL/BLK 28GA
DRAIN
ACOM ANALOG GRD
ANALOG OUT PROG
ILIMIT
EPWR +5 OUT
AX+
AX-
BX+
BX-
IX+
IX-
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
OUTPUT 2
OUTPUT 3
OUTPUT 4
ACOM ANALOG GRD
ANALOG OUT PROG
ILIMIT
EPWR +5 OUT
AX+
AX-
BX+
BX-
IX+
IX-
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
OUTPUT 2
OUTPUT 3
OUTPUT 4
BLACK 28GA
WHT/BLK 28GA
BROWN 28GA
WHT/BRN 28GA
RED 28GA
WHT/RED 28GA
ORANGE 28GA
WHT/ORG 28GA
YELLOW 28GA
WHT/YEL 28GA
GRAY 28GA
WHT/GRY 28GA
PINK 28GA
WHT/PNK 28GA
WHT/BLK/RED 28GA
RED/BLK 28GA
WHT/BLK/ORG 28GA
ORG/BLK 28GA
WHT/BLK/YEL 28GA
YEL/BLK 28GA
DRAIN
8
9
32
6
7
24
1
4
5
22
23
40
41
42
33
34
35
36
37
38
2090-U3CC-D44 xx
Controller Interface
Cable
4
Ultra3000
CN1 Connector
(Axis 1)
1
I/O power (pins 28 and 30) must be connected to user-supplied 12-24V dc.
2
Input 1 (pin 31) must configured as Drive Enable using Ultraware software.
3
Output 1 (pin 39) must be configured as Ready using Ultraware software.
4
This cable does not carry the unbuffered motor encoder signals (CN1 pins 10-15). Contact your Allen-Bradley sales representative if these signals are required for your application.
Publication 2098-IN005B-EN-P — August 2004
Interconnect Diagrams A-23
Ultra3000 to IMC-S
Compact Cable and
Interconnect Diagram
This section provides information to assist you in wiring the
IMC-S/23x-xx Compact Controller when connecting the 4100-CCS15F feedback cable and 4100-CCA15F I/O cable to your Ultra3000.
Figure A.24
Ultra3000 to IMC-S/23x-xx Compact Controller Configuration
IMC S Class Compact Controller
IMC-S/23 x-xx
Axis Servo and Feedback Connector
(located on bottom of controller)
4
10
A+
A-
8
2
1
7
3
9
5
11
B+
B-
6
12
Z+
Z-
ENC PWR
ENC COM
SHIELD
STROBE
REF+
REF-
4100-CCS15F Feedback Cable
WHITE
BLACK
GREEN
BLACK
BLUE
BLACK
BLACK
N/C
Ultra3000
44-pin Breakout Board
(without SERCOS interface)
CN1 Connector
18
19
20
21
3
2
16
17
A+
A-
B+
B-
Z+
Z-
+ENC (5V)
1
ENC COM
25
26
CMD+
CMD-
Axis I/O Connector
(located on top of controller)
4
1
+ 24V
HOME
2
3
POS OT
NEG OT
9
5
24V COM
DRIVE EN
6
8
DRIVE EN
DRIVE FLT-
7
DRIVE FLT+
RED
WHITE
GREEN
BROWN
4100-CCA15F I/O Cable
BLACK
BLUE
ORANGE
PURPLE
YELLOW
30
29
+24V I/O PWR
+24V I/O PWR
28
27
31
24V I/O COM
24V I/O COM
DIGITAL INPUT 1
39 DIGITAL OUT 1
2
32 DIGITAL INPUT 2
Fault Reset P.B.
2
43
44
RELAY OUT+
3
RELAY OUT-
3
STOP*
START*
24V AC/DC or
120V AC,
50/60 HZ
CR1*
M1*
CR1*
CR1*
Refer to Attention statement below
1
The preferred method for supplying the auxiliary +5V is by using the 12- or 44-pin drive mounted breakout board with 24V to 5V auxiliary power converter (catalog number 2090-U3CBB-DM12 or -DM44). Auxiliary +5V power is required to maintain encoder position with an external position controller during a controlled stop condition.
2
Drive Enable and Fault Reset are configured in Ultraware software.
3
Relay Output (CN1, pins 43 and 44) must be configured as Ready in Ultraware software.
ATTENTION
!
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories. For more information refer to Understanding the
Machinery Directive (publication SHB-900).
Publication 2098-IN005B-EN-P — August 2004
A-24
Interconnect Diagrams
Publication 2098-IN005B-EN-P — August 2004
Chapter Objectives
Appendix
B
Understanding Motor Feedback Signals and
Outputs
This appendix contains motor encoder input signal information and drive encoder output information specific to the Ultra3000 drives. The following motor encoder types are included:
•
High resolution SIN/COS encoders
•
Incremental A quad B encoders
1
Publication 2098-IN005B-EN-P — August 2004
B-2
Understanding Motor Feedback Signals and Outputs
Introduction
The Ultra3000 is compatible with motors equipped with both incremental A quad B or high resolution (Stegmann Hiperface
®
)
SIN/COS encoders.
The buffered motor encoder outputs use RS-485 differential drivers and have a maximum signal frequency of 2.5 MHz. The drivers can drive a 2V differential voltage into a 100 ohm load. Use the block diagram below to follow the motor encoder input through CN2 to the buffered and unbuffered outputs on CN1.
Figure B.1
Motor Encoder Outputs
Ultra3000 Drive
Position
Feedback
Division
1
Interpolation
1
TTL: x4
Sin/Cos: x4 to x1024
Filtering
Differential
Receivers
TTL or A quad B (incremental)
If (A leads B) in
(A leads B) out
SIN/COS (high resolution)
If (A leads B) in
(B leads A) out
Buffered
Selected
Output
Type
CN2
Motor
Encoder
Unbuffered
Encoder
Output
CN1
Frequency
Limit
(0.5 to 8 MHz)
Interpolated
Divided
2
2
Differential
Drivers
Buffered
Encoder
Output
1
Interpolation and division operations are performed in firmware and the resulting output frequency is updated at
250
µ s intervals.
2
Interpolated and divided output not available on SERCOS drives.
Unbuffered Encoder Outputs
The unbuffered outputs available from the drive (CN1-10 through -15) are tied directly to the incoming (incremental or high resolution) encoder signals (CN2-1 through -6). The unbuffered outputs are not filtered or conditioned.
Publication 2098-IN005B-EN-P — August 2004
Understanding Motor Feedback Signals and Outputs B-3
Incremental Encoder Output
Incremental encoder counts are generated in the drive by counting the
(high to low and low to high) transitions of the incoming A and B
encoder signals. In Figure B.2 the channel A signal has two
transitions, as does the channel B signal, which results in x4 interpolation (4 transitions/line equals 4 counts/line). For example, typical 2000 line/rev encoder output becomes 8000 counts/rev in the drive. Counts are not directly available at the encoder outputs, only the A quad B representation.
Figure B.2
Incremental Encoder Counts
One Cycle
Channel A
Channel B
Counts
CW
CN2-1
The incremental buffered outputs (listed below) are available from the drive (CN1-16 through -21) and software selectable.
•
Buffered Outputs are a filtered representation of the original incoming encoder (CN2) signals. Buffered outputs have the same number of cycles/rev as found on CN2.
•
Interpolated Outputs are the same as buffered outputs when using an incremental encoder. The only interpolation performed on an A quad B signal is the drive’s internal counting of transitions
(4 counts/line). Because counts are not available outside the drive, selecting this in software is the same as selecting buffered (as described above).
•
Divided Outputs are the same as buffered outputs, except when divided is selected in the software, the lines/rev are then reduced by the value of the divisor chosen in the software (as shown in the figure below).
Figure B.3
Incremental Encoder Divided
Signal A+ from Incremental Encoder
CN1-10
CN1-16
Unbuffered Signal A+ Output from Drive
Divided (by two) Signal A+ Buffered Output from Drive
Publication 2098-IN005B-EN-P — August 2004
B-4
Understanding Motor Feedback Signals and Outputs
High Resolution Encoder Output
When the incoming encoder feedback on CN2 is a high resolution
(SIN/COS) signal, the drive is capable of generating more than just 4 counts/cycle (as with incremental encoders). The Ultra3000 drive is capable of breaking the SIN/COS encoder signals into as many as
1024 counts/cycle. For example, a 1024 cycle/rev SIN/COS encoder can result in 1024 x 1024 (high resolution) counts/rev.
Figure B.4
Absolute High Resolution Encoder Signals
1
One
Cycle
3
CN1-10 (SIN/AM+) Unbuffered encoder feedback signal to drive, 1024 cycles/rev.
Voltage
2
4
CN1-12 (COS/BM+) Unbuffered encoder feedback signal to drive, 1024 cycles/rev.
Voltage
1
3
CN1-16 (SIN/AMOUT+) Buffered output from drive
2
4
Time
CN1-18 (COS/BMOUT+) Buffered output from drive
The high resolution buffered outputs (listed below) are available from the drive (CN1-16 through -21) and software selectable.
•
Buffered Outputs are conditioned SIN/COS signals resulting in a
square wave (A quad B) signal (refer to Figure B.4). This signal
will have the same number of cycles/rev as the incoming SIN/COS encoder signals found on CN2.
•
Interpolated Outputs are square wave (A quad B) signals reflecting the interpolation value chosen in software. The minimum interpolation value allowed is x4, which gives the same output as selecting buffered (as described above).
•
Divided Outputs are the result of a divisor (selected in software) and an interpolation value (also selected in software). For example, with an interpolation value of x8 and a divisor of 2, the
CN1 buffered output will be the (x4) square wave representation of the original incoming SIN/COS signal from CN2.
IMPORTANT
The interpolation value selected in software is what the drive uses internally to close the feedback loops regardless of any divisor value chosen to condition the signals present on CN1.
Publication 2098-IN005B-EN-P — August 2004
Understanding Motor Feedback Signals and Outputs B-5
Voltage
Figure B.5
Interpolated and Divided Absolute High Resolution Encoder Counts
One
Cycle
8
2
4
6
1
3
5
7
CN1-10 (SIN/AM+) Unbuffered encoder feedback signal to drive, 1024 cycles/rev.
CN1-12 (COS/BM+) Unbuffered encoder feedback signal to drive, 1024 cycles/rev.
2 4 6 8
Voltage
1 3 5 7
CN1-16 (SIN/AMOUT+) x8 Interpolated output from drive
CN1-18 (COS/BMOUT+) x8 Interpolated output from drive
2 4
Voltage
1 3
Time
Divided output from drive (divisor = 2)
Publication 2098-IN005B-EN-P — August 2004
B-6
Understanding Motor Feedback Signals and Outputs
Publication 2098-IN005B-EN-P — August 2004
1
Index
Numerics
16 axis SERCOS interface PCI card installation instructions
2090-U3AE-D44 cable
A-20 interconnect diagram
A-21
2090-U3CC-D44 cable
A-20 interconnect diagram
A-22
3, 8 or 16 axis SERCOS interface module installation instructions
A
abbreviations
absolute feedback range exceeded
absolute indexing
absolute position exceeds position rollover
AC line loss
analog encoder PCI card installation instructions
analog encoder servo module installation instructions
analog outputs branch
analog velocity move
see troubleshooting axis not homed
axis properties
B
base node address
brake
A-19 bus overvoltage
undervoltage
Ultra3000 to Logix
A-20
Ultra3000 to MP-series motor
A-10
,
A-11
,
A-12
Ultra3000 to N-series motor
A-14
Ultra3000 to Y-series motor
A-15 certifications
Rockwell Automation Product
Certification
commissioning your Ultra3000
applying power
,
configuring
,
analog drive with logix
drive detection
drive with DeviceNet
drive with SERCOS
Ultraware software
contents of manual
control string
120V single-phase, 0.5, 1, and
2 kW
A-16
120V single-phase, 3 kW
A-17
120V three-phase, 7.5 and 15 kW
A-18 control string examples
A-16 controlling a brake
A-19
Controllogix motion module programming manual
ControlLogix Motion Module
Setup and Configuration
Manual
ControlLogix motion module setup and configuration manual
conventions used in this manual
conversion tab
cycle time
C
cables
2090-U3AE-D44
A-20
2090-U3CC-D44
A-20
Ultra3000 to 1326AB motors
A-10
Ultra3000 to H- and F-series motor
A-13
Ultra3000 to IMC-S
A-23
D
data rate
rotary switch
dc bus undervoltage
DeviceNet cable installation problems
communication network problem
Publication 2098-IN005B-EN-P — August 2004
I-2
Index
Publication 2098-IN005B-EN-P — August 2004 configuration
LED status check
MAC ID
module status LED
network config problems
network status LED
node address problems
power supply problems
scanner problems
DeviceNet cable system planning and installation manual
digital I/O not working correctly
digital inputs branch
digital outputs branch
digital relay output
A-2 disable drive
download program
drive enable input
drive ready
A-16 drive tab
duplicate node fault
front panel connections
,
,
,
,
2098-DSD-005, -005X, -010,
-010X, -020, and -020X
2098-DSD-005-DN, -005X-DN,
-010-DN, -010X-DN,
-020-DN, and -020X-DN
2098-DSD-005-SE, -010-SE, and
-020-SE
2098-DSD-030 and -030X
2098-DSD-030-DN, and
-030X-DN
2098-DSD-030-SE
2098-DSD-075, -075X, -150, and -150X
2098-DSD-075-DN, -075X-DN,
-150-DN, and -150X-DN
2098-DSD-075-SE and -150-SE
2098-DSD-HVxxx and HVxxxX
2098-DSD-HVxxx-DN and
-HVxxxX-DN
2098-DSD-HVxxx-SE
with SERCOS
,
E
encoder communication fault
encoder data
encoder output frequency exceeded
encoders absolute
buffered
high resolution
,
incremental
unbuffered
encoders branch
error codes and messages
excess position error
excess velocity error
excessive electrical cycle length
F
fault action
fault action, programmable
fault actions tab
faults branch
feedback tab
Fiber Optic Cable Installation and
Handling Instructions
flyback diodes
A-19
G
ground fault
H
hardware overtravel (SERCOS only
high resolution encoders
home position in limit
home search failed
I
illegal hall state
incremental encoders
incremental indexing
indexing move absolute indexing
incremental indexing
interconnect diagrams controlling a brake example
A-19 power
A-3
,
A-4
,
A-5
,
A-6 shunt module
A-7
,
A-8
,
A-9
Index I-3
Ultra3000 to 1326AB motors
A-10
Ultra3000 to H- and F-series motor
A-13
Ultra3000 to IMC-S
A-23
Ultra3000 to Logix
A-20
Ultra3000 to MP-series motor
A-10
,
A-11
,
A-12
Ultra3000 to N-series motor
A-14
Ultra3000 to servo module
A-21
Ultra3000 to SoftLogix
A-22
Ultra3000 to Y-series motor
A-15 introduction
IPM fault, see troubleshooting
see troubleshooting
K
Kinetix Motion Control Selection
Guide
manuals on-line
master follower
minor fault
mode configuration
module status LED
,
module status LED (DeviceNet)
module status LED (SERCOS)
monitor branch
Motion Analyzer CD
motion control problem report form
motion group properties
motor and feedback tab
motor branch
motor encoder error
motor jumps when first enabled
motor keying error
motor overtemperature
motor parameter error
motor thermal protection fault
motors testing
tuning
MSD and LSD rotary switch
L
LED logic power
,
module status
module status (DeviceNet)
module status (SERCOS)
network status
,
network status (DeviceNet)
network status (SERCOS)
SERCOS module
status
LED indicator
logic power LED
,
Logix controller motion instruction set reference manual
loop configuration
M
MAC ID
maintenance troubleshooting
N
network status LED
network status LED (Device Net)
network status LED (DeviceNet)
network status LED (SERCOS)
no communication
noise
non-indexing move analog velocity move
master follower
preset gear ratios
preset velocity move
non-volatile memory endurance exceeded
notes
A-2
Publication 2098-IN005B-EN-P — August 2004
I-4
Index
Publication 2098-IN005B-EN-P — August 2004
O
oscilloscope branch
overspeed fault
P
power applying power
power (PWR) indicator not on
power circuity overtemperature
power diagrams
2098-DSD-005, -010, -020
A-3
2098-DSD-030
A-4
2098-DSD-075, -150
A-5
2098-DSD-HVxxx
A-6 precautions general startup
precharge fault
preset gear ratios
preset velocity move
problem report form
purpose of this manual
shunt module interconnect diagram
A-7
,
A-8
,
A-9 shunt protection fault, 230V
shunt protection fault, 460V
sine/cosine encoder frequency limit exceeded
SoftLogix Motion Card Setup and
Configuration Manual
,
,
software overtravel (SERCOS only)
start-up procedure
status LED
status LEDs
storage responsibility
support comments regarding this manual
local product
technical product assistance
System Design for Control of
Electrical Noise Reference
Manual
R
ready
A-2 related documentation
Ultra3000 with DeviceNet reference manual
relay output
A-2
,
A-19 rotary switch data rate
MSD and LSD
,
S
selecting a motor
self-sensing commutation startup error
sensor not assigned
SERCOS configuration
hardware fault
module status LED
network status LED
service information branch
servo tab
setting data rate
node address
,
T
testing axes hookup tab
,
testing your motor
troubleshooting
DeviceNet cable installation problems
LED status check
MAC ID
module status LED
network config problems
network status LED
node address problems
power supply problems
scanner problems
disable drive
error codes
fault action
general
Index I-5
230V shunt protection fault
460V shunt protection fault
absolute feedback range exceeded
absolute position exceeds position rollover
AC line loss
auxiliary encoder error
axis not homed
bus undervoltage
DeviceNet communication network problem
digital I/O not working correctly
drive enable input
duplicate node fault
encoder communication fault
encoder data
encoder output frequency exceeded
excess position error
excess velocity error
excessive electrical cycle length
ground fault
hardware overtravel
(SERCOS only)
home position in limit
home search failed
illegal hall state
IPM fault
IPM thermal protection fault
motor encoder error
motor jumps when first enabled
motor keying error
motor overtemperature
motor parameter error
motor thermal protection fault
non-volatile memory endurance exceeded
overspeed fault
power (PWR) indicator not on
power circuity overtemperature
precharge fault
self-sensing commutation startup error
sensor not assigned
SERCOS hardware fault
sine/cosine encoder frequency limit exceeded
software overtravel
(SERCOS only)
user-specified current fault
user-specified velocity fault
velocity exceeds position rollover
Logix/drive fault behavior
module status LED
programmable fault action
SERCOS module status LED
network status LED
tuning axes tune tab
,
tuning branch
tuning your motor
U
Ultra3000 DeviceNet reference manual
Ultra3000 with DeviceNet
Reference Manual
Ultraware CD installation instructions
Ultraware software
analog outputs branch
digital inputs branch
digital outputs branch
encoders branch
faults branch
mode configuration
monitor branch
motor branch
oscilloscope branch
service information branch
Publication 2098-IN005B-EN-P — August 2004
I-6
Index
tuning branch
workspace
Ultraware user manual
units tab
unrecoverable fault
user-specified current fault
user-specified velocity fault
V
velocity exceeds position rollover
W
who should use this manual
Publication 2098-IN005B-EN-P — August 2004
For more information refer to our web site: www.ab.com/motion
For Allen-Bradley Technical Support information refer to: www.ab.com/support or Tel: (1) 440.646.5800
Publication 2098-IN005B-EN-P — August 2004
Supersedes Publication 2098-IN005A-EN-P — July 2001 Copyright © 2004 Rockwell Automation. All rights reserved. Printed in USA.
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Key features
- Ultraware or RSLogix 5000 software
- Power up procedures
- System integration
- Troubleshooting tables
- Stand alone control
- Logix controller
- SERCOS interface and DeviceNet communication
