1398-UM000A-EN-P ULTRA 200 Series Digital Servo Drives ...

1 User ManualULTRA 200 SeriesDigital Servo Drives Allen-BradleyImportant User InformationBecause 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 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 , 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 of the contents of this copyrighted publication, in whole or in part, without written permission of Allen-Bradley Company, Inc.

2 , is this manual we use notes to make you aware of safety considerations. For example: Attention statements help you to:lidentify a hazardlavoid the hazardlrecognize the consequencesMathcad is a registered trademark of MathSoft, , MS-DOS and Windows are trademarks of Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.!IntroATTENTION:This symbol identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss. Note:This symbol identifies information that is critical for successful application and understanding of the October 1998 Table of ContentsIntroTable of ContentsTable of ContentsIntro-1 List of FiguresIntro-7 List of TablesIntro-11 PrefaceIntro-15 About This Instructions and Commands and ULTRA and and Wording Symbols and Warning 1 SafetyInstalling and Using the ULTRA 200 2 Selecting Other System ComponentsULTRA 200 Series Power 200 Series Performance Microcontroller and Digital Input Protection Master October 1998 Intro-2 Table of Union 3 ULTRA Master InstallationHardware and Software ULTRA and Quitting ULTRA ULTRA Master Start-Up readme 4 Unpacking.

3 Inspecting and StoringUnpacking the the Checkout the 5 InstallationMechanical Installation AC Line AC Line 6 InterfacesJ1 I/O Outputs ..6-16 Motor Encoder Output Signals ..6-17 Auxiliary Encoder Inputs ..6-19 Interface Cable Terminal Strip/Breakout Encoder ..6-27 Publication October 1998 Table of ContentsIntro-3J2 Terminal Strip/Breakout 6-30J3 Auxiliary Port .. 6-31J4 and J5 Serial Port .. 6-34 Serial Communications 6-36RS-232 6-38 Four Wire RS-485 6-40A1, A2, and COM Analog 6-44 Interface 6-45 Chapter 7 Power ConnectionsTB1 DC Bus and AC Power Overload Stop Power 7-10TB2 Shunt 7-11 External Shunt 7-14 Chapter 8 Application and Configuration ExamplesAnalog Diagram .. Diagram .. 8-11 Position Follower (Master Encoder).. 8-12 Hardware 8-12 Connection Diagram .. 8-13 Tuning .. 8-16 Position Follower (Step/Direction).

4 8-17 Hardware 8-17 Connection Diagram .. 8-18 Tuning .. 8-20 Publication October 1998 Intro-4 Table of Follower (Step Up/Step Down)..8-22 Hardware Diagram .. Indexing ..8-27 Hardware Diagram .. Indexing ..8-33 Hardware Diagram .. Diagram .. User the Display Units 9 TuningTuning Tuning Inertia Tune Tune .. Loop Tuning Examples ..9-10 Chapter 10 Status DisplayOperating October 1998 Table of ContentsIntro-5 Error 10-2 Run-Time Error 10-2 Power-Up Error 10-3 Chapter 11 Maintenance and 11-1 Periodic 11-1 Fuse 11-1 EEPROM Personality 11-2 Firmware 11-5 Firmware Upgrade Procedure using ULTRA 11-6 Error 11-6RS-232 Communication Digital Digital Analog Positive and Negative Current Encoder AOptions and AccessoriesULTRA 200 Series and Interface Feedback Power BCable Diagrams, Schematics and ExamplesInterface Interface Cables.

5 B-11 Encoder Feedback B-14 Motor Power Cables .. B-21 Cabling B-26 Allen-Bradley 9/ Series CNC Family CTouchPad InstructionsInstallation and October 1998 Intro-6 Table of ContentsMotor DCreating Custom Motor FilesDrive and Motor File Configuration with ULTRA D-2 Motor Parameter D-2 General D-5 Feedback D-8 Electrical of Custom Motor File s Conversions ..D-15 Custom Motor Custom Motor Files ..D-16 Appendix EElectromagnetic Compatibility Guidelines for Machine Line Filter and FDynamic Braking Resistor SelectionDynamic Braking GSpecifications G-5 Power G-7 IndexIndex-1 Publication October 1998 List of FiguresIntroList of FiguresProduct Parts Explained ..Intro-21 Chapter 1 SafetyChapter 2 Selecting Other System ComponentsChapter 3 ULTRA Master InstallationChapter 4 Unpacking, Inspecting and StoringConnection Diagram ..4-4 Chapter 5 Installation1398-DDM Mounting Dimensions (sheet 1 of 2).

6 5-3 MDF AC Line Filter Mounting Diagrams ..5-8 MIF Single Phase AC Line Filter Mounting Diagram ..5-10 Power Wiring Diagrams (sheet 1 of 3) ..5-11 Chapter 6 InterfacesDigital Input Circuit ..6-4 drive Input Connected to a Switch/Relay Contact ..6-7 drive Input Connected to an Opto-Isolator ..6-7 drive Input Connected to an Active High Sourcing Transistor ..6-7 drive Input Connected to Active Low Output using a Switch/Relay ..6-7 drive Input Connected to Active Low Output using an Opto-Isolator ..6-8 drive Input Connected to Sourcing Output ..6-8 READY and BRAKE Circuits ..6-9 Digital Output Circuit ..6-10 drive Output Connected to an Opto-Isolator ..6-11 drive Output Connected to an LED Indicator ..6-12 drive Output Connected to a Resistive Load ..6-12 drive Output Connected to a Switch/Relay ..6-12 drive Output Connected to Active Low Input using a Switch/Relay ..6-13 drive Output Connected to Active Low Input using an Opto-Isolator.

7 6-13 drive Output Connected to Active High (Sinking) Input ..6-13 Positive and Negative Current Limit Circuits ..6-14 Analog COMMAND Input Circuit ..6-15 ANALOG 1 and ANALOG 2 Output Circuits ..6-16 Output Encoder Interface Circuit ..6-17 Auxiliary Encoder Input Types ..6-19 Auxiliary Encoder Input Circuit ..6-19 Publication October 1998 Intro-8 List of FiguresExternal Encoder Interface via TTL Differential Line Drivers ..6-21 Complementary Encoder Interface via 7406 Line Drivers with Pull-up Resistors ..6-21 Complementary Encoder Interface via Standard TTL Logic ..6-22 Single-Ended Encoder Interface via Open Collector Transistor without Pull-up (not recommended) ..6-22 Single-Ended Encoder Interface via Standard TTL Signals (not recommended) ..6-23 Single-Ended Encoder Interface via Open Collector Transistor with 5 VDC to 12 VDC Pull-up (not recommended) ..6-23 Single-Ended Encoder Interface via Open Collector Transistor with 24 VDC Pull-up (not recommended).

8 6-24 External Step/Direction Interface via TTL Differential Line Drivers ..6-25 External Step/Direction Interface via Single-Ended TTL Line Drivers (not recommended) ..6-25 External CW/CCW (Step Up/Step Down) Interface via TTL Differential Line Drivers ..6-25 External CW/CCW (Step Up/Step Down) Interface via Single-Ended Line Drivers (not recommended) ..6-26 Motor Encoder Interface Circuit ..6-28 Hall Effect Sensor Circuit ..6-28 ULTRA 200 Series Motor Encoder Connections ..6-30RS-232/485 Interface Circuit ..6-34 Sixteen Position Rotary Addressing Switch ..6-36RS-232 Connection Diagrams ..6-38RS-485/RS-422 Communication Comparison ..6-40 Four Wire RS-485 Daisy Chain Connection Diagram ..6-42RS-232 to RS-485 Multi-Drop Connection Diagram ..6-43 ANALOG 1 and ANALOG 2 Output Circuits ..6-441398-DDM Interface Connection Diagram ..6-45 Chapter 7 Power ConnectionsMotor Power EMC Shield Connection.

9 7-3 Pigtail Ground .. 7-4 Emergency Stop Contactor Wiring .. 7-7 External Shunt Wiring Examples ..7-13 External Shunt Mounting Diagram ..7-14 Chapter 8 Application and Configuration ExamplesAnalog Controller Connection Diagram .. 8-2 Preset Controller Connection Diagram .. 8-8 Master Encoder Connection Diagram ..8-13 Step/Direction Controller Connection Diagram ..8-18 Step Up/Step Down Controller Connection Diagram ..8-23 Incremental Indexing Examples ..8-27 Incremental Indexing Connection Diagram ..8-29 Registration Indexing Examples ..8-33 Publication October 1998 List of FiguresIntro-9 Registration Indexing Connection Diagram ..8-35 Absolute Indexing Examples ..8-39 Absolute Indexing Connection Diagram ..8-40PC Display Units Default Dialog ..8-45 Chapter 9 TuningVelocity Loop Structure ..9-3 Torque Current Conditioning Structure ..9-3 Signal Nomenclature ..9-10 Underdamped Signal.

10 9-11 Overdamped Signal ..9-11 Critically Damped Signal (Ideal Tuning) ..9-12 Chapter 10 Status DisplayChapter 11 Maintenance and TroubleshootingFuse and Jumper Locations ..11-4 Appendix AOptions and AccessoriesAppendix BCable Diagrams, Schematics and ExamplesJ1 to J3 Interface Cable (P/N 9101-1367) ..B-3J1 to No Connector Interface Cable (P/N 9101-1370) .. B-4J3 to J3 Interface Cable (P/N 9101-1463) ..B-5J3 to No Connector Interface Cable (P/N 9101-1368) .. B-6J1 to 50-pin Terminal Block Kit Diagram (P/N 9101-1391 and 9101-1560) ..B-7J1 to 50-pin D-Connector Cable (P/N 9101-1369) .. B-8J2 to 25-pin Terminal Block Kit Diagram (P/N 9101-1392) .. B-9J2 to 25-pin D-Connector Cable (P/N 9101-1371) .. B-10J5 to 9-pin D-Shell Interface Diagram (P/N 9101-1372) .. B-11J5 to J5 Serial Interface Cable (P/N 9101-1374) .. B-12J5 to No Connector Serial Interface Cable (P/N 9101-1379).