Page 1 Ultra5000 Intelligent Positioning Drives (Catalog Numbers 2098-IPD-005, -005-DN 2098-IPD-010, -010-DN 2098-IPD-020, -020-DN 2098-IPD-030, -030-DN, -HV030, -HV030-DN 2098-IPD-HV050, -HV050-DN 2098-IPD-075, -075-DN, 2098-IPD-HV100, -HV100-DN 2098-IPD-150, -150-DN, -HV150, -HV150-DN 2098-IPD-HV220, -HV220-DN Installation Manual...
Page 2 Allen-Bradley is a registered trademark of Rockwell Automation. ControlLogix, RSLogix 5000, Ultra5000, and Ultraware are trademarks of Rockwell Automation. CSA is a registered trademark of Canadian Standards Association. DeviceNet is a trademark of the Open DeviceNet Vendor Association.
Page 3: Table Of Contents
Table of Contents Preface Introduction ........P-1 Who Should Use this Manual .
Page 4 Table of Contents 7.5 kW, and 15 kW Ultra5000 (2098-IPD-075, and -150) ....2-10 I/O Connectors ......2-11 Motor Encoder Connector .
Page 5 Table of Contents Chapter 3 Connecting Your Ultra5000 Chapter Objectives....... 3-1 Powering the Digital I/O .
Page 6 Table of Contents Appendix A Specifications and Objectives ........A-1 Dimensions Ultra5000 Specifications .
Page 7 Table of Contents Appendix C Catalog Numbers and Chapter Objectives....... C-1 Accessories Ultra5000 Drives .
Page 8 Table of Contents Publication 2098-IN001E-EN-P — April 2002...
Page 9: Preface
Purpose of this Manual This manual describes the function and installation of the Ultra5000 products and standard Rockwell Automation/Allen-Bradley motors recommended for use with the Ultra5000. The manual is intended for engineers or technicians directly involved in the installation, operation, and field maintenance of the Ultra5000.
Page 10 Preface Contents of this Manual Refer to the following listing for the descriptive contents of this installation manual. Chapter Title Contents Preface Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended. Installing Your Ultra5000 Provides mounting information for the Ultra5000.
Page 11: Related Documentation
Preface Related Documentation The following documents contain additional information concerning related Allen-Bradley products. To obtain a copy, contact your local Rockwell Automation office or distributor, or access the documents on-line at www.theautomationbookstore.com or www.ab.com/manuals/gmc. For: Read This Document: Catalog Number:...
Page 12: Conventions Used In This Manual
Preface Conventions Used in this The following conventions are used throughout this manual. 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. •...
Page 13: Allen-Bradley Support
Preface Allen-Bradley Support Allen-Bradley offers support services worldwide, with over 75 Sales/ Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world. Local Product Support Contact your local Allen-Bradley representative for: •...
Page 14 Preface Publication 2098-IN001E-EN-P — April 2002...
Page 15: Installing Your Ultra5000
Motion Control products. The web site is the authoritative source for verifying compliance and suitability for use of this and other Rockwell Automation/Allen-Bradley products. The web site also provides links to other certification agencies (UL, CSA, etc.).
Page 16: Emc Directive
Installing Your Ultra5000 EMC Directive This unit is tested to meet Council Directive 89/336/EEC Electromagnetic Compatibility (EMC) using a technical construction file and the following standards, in whole or in part: • EN 50081-2 EMC - Emission Standard, Part 2 - Industrial Environment •...
Page 17: Before Mounting Your System
Installing Your Ultra5000 Before Mounting Your Before you mount your Ultra5000 system make sure you understand the following: System • How to Store Your Ultra5000 Before Installation • How to Unpack the System • Minimum Mounting Requirements How to Store Your Ultra5000 Before Installation The Ultra5000 should remain in the shipping container prior to installation.
Page 18: How To Unpack The System
Installing Your Ultra5000 How to Unpack the System Each Ultra5000 ships with the following: • One Ultra5000 drive • One installation manual, publication 2098-IN001 • Two I/O connector plugs (28 pin CN1A and 14 pin CN1B) • One screwdriver • One clear plastic terminal strip cover Do not discard the clear plastic terminal strip cover.
Page 19: Minimum Mounting Requirements
Installing Your Ultra5000 Minimum Mounting Requirements There are several things that you need to take into account when preparing to mount the Ultra5000: • The Ultra5000 is classified as IEC controlgear, and must be housed in an enclosure that meets IEC60529 requirements for electrical enclosure of controlgear.
Page 20: Ventilation Requirements
Installing Your Ultra5000 Ventilation Requirements This section provides information to assist you in sizing your cabinet and locating your Ultra5000 drive(s) inside the cabinet. Figure 1.1 Minimum Clearance Requirements 50.8 mm (2.0 in.) clearance for airflow and installation Allow 12.7 mm (0.5 in.) Allow 12.7 mm (0.5 in.) side clearance side clearance...
Page 21: Sizing An Enclosure
Installing Your Ultra5000 Sizing an Enclosure As an additional aid in sizing an enclosure, with no active method of heat dissipation, either of the following approximate equations can be used: Metric Standard English 0.38Q 4.08Q ----------------------- - ---------------- 1.8T 1.1 –...
Page 22 This factor minimizes the effects of the secondary line voltage sagging in the transformer during peak current periods. If you are using the Rockwell Automation/ IMPORTANT Allen-Bradley system sizing program, the average speed and average torque data has already been calculated and can be used in the equation.
Page 23: Fuse Sizing
Installing Your Ultra5000 Fuse Sizing The Ultra5000 is listed by Underwriters Laboratories, Inc. with fuses sized as four times the continuous output current of the drives (FLA), according to UL 508C. In most cases, fuses selected to match the drive input current rating will meet the NEC requirements and provide the full drive capabilities.
Page 24: Bonding Your System
1-10 Installing Your Ultra5000 Bonding Your System Bonding is the practice of connecting metal chassis, assemblies, frames, shields and enclosures to reduce the effects of electromagnetic interference (EMI). Bonding Modules Unless specified, most paints are not conductive and they act as insulators.
Page 25: Bonding Multiple Subpanels
1-11 Installing Your Ultra5000 Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels.
Page 26: Mounting Your Ultra5000 Drive
1-12 Installing Your Ultra5000 Mounting Your Ultra5000 The procedures in this section assume you have prepared your panel and understand how to bond your system. For installation instructions Drive regarding other equipment and accessories, refer to the instructions that came with each of the accessories for their specific requirements. This product contains ESD (Electrostatic Discharge) ATTENTION sensitive parts and assemblies.
Page 27: Ultra5000 Connector
Chapter Ultra5000 Connector Information Chapter Objectives This chapter provides connector information and procedures for wiring your Ultra5000 and making cable connections. This chapter includes: • Understanding Ultra5000 Controller Functions • Understanding Ultra5000 Connectors • Understanding Ultra5000 I/O Specifications • Understanding Motor Encoder Feedback Specifications •...
Page 28: Understanding Ultra5000 Controller Functions
Ultra5000 Connector Information Understanding Ultra5000 This section provides a short overview of the Ultra5000. Controller Functions Ultra5000 Block Diagram The Ultra5000 uses a two-stage circuit card solution with the capability of adding two additional option cards. The first stage is the processor circuit board and the second stage handles I/O connections including a power module interface.
Page 29: Understanding Ultra5000 Connectors
Ultra5000 Connector Information Understanding Ultra5000 The following table provides a brief description of the Ultra5000 front panel connectors and describes the connector type. Connectors Designator Description Connector CN1A User Input/Output 28-pin, 3.5mm, double-row, plugable spring clamp CN1B User Input/Output 14-pin, 3.5mm, double-row, plugable spring clamp Motor Feedback 15-pin high-density D-shell...
Page 30: 230V Ultra5000 Front Panel Connections
Ultra5000 Connector Information 230V Ultra5000 Front Panel Connections This section describes and provides a visual reference to the drive’s connectors. 500W, 1 kW, and 2 kW Ultra5000 (2098-IPD-005, -010, and -020) Use the figure below to locate the front panel connections on the Ultra5000 230V drives (500W, 1 kW, and 2 kW).
Page 31: I/O Connectors
Ultra5000 Connector Information I/O Connectors CN1A (28-pin) and CN1B (14-pin) are plugable, double-row, spring clamp connectors with 3.5mm spacing. Maximum wire gauge for these connectors is 0.75 mm (18 AWG). The following tables provide the signal description and pin-outs for the CN1A and CN1B I/O connectors.
Page 32: Motor Encoder Connector
Ultra5000 Connector Information Motor Encoder Connector The following table provides the signal descriptions and pin-outs for the CN2 motor encoder (15-pin) connector. CN2 Pin Description Signal Channel A+ Channel A- Channel B+ Channel B- Pin 10 Channel I+ Pin 15 Pin 5 Common ECOM...
Page 33: Serial Port Connectors
Ultra5000 Connector Information Serial Port Connectors The following table provides the signal descriptions and pin-outs for the CN3A (Main) and CN3B (Auxiliary) serial port (9-pin) connectors. Refer to Default Serial Interface Settings on page 2-34 for additional information. CN3 Pin Description Signal RS-422/RS-485 Input+ RCV+...
Page 34: Kw Ultra5000 (2098-Ipd-030)
Ultra5000 Connector Information 3 kW Ultra5000 (2098-IPD-030) Use the figure below to locate the front panel connections on the Ultra5000 230V drive (3 kW). Detailed descriptions of the digital connections are provided on pages through 2-7. Power connections are described below. Figure 2.3 Ultra5000 Front Panel Connections for 2098-IPD-030...
Page 35: Terminal Blocks
Ultra5000 Connector Information Terminal Blocks The following tables list the connections on the Ultra5000 230V drive (3 kW) power (TB1) and the shunt (TB2) terminal blocks. Refer to Wiring Power Connections on page 3-14 for additional information. Terminal Block 1 (TB1) Locations (2098-IPD-030-xx) U (Motor) V (Motor)
Page 36: Kw, And 15 Kw Ultra5000 (2098-Ipd-075, And -150)
2-10 Ultra5000 Connector Information 7.5 kW, and 15 kW Ultra5000 (2098-IPD-075, and -150) Use the figure below to locate the front panel connections on the Ultra5000 230V drives (7.5 kW, and 15 kW). Detailed descriptions of the digital connections are provided on pages through 2-7.
Page 37: I/O Connectors
2-11 Ultra5000 Connector Information I/O Connectors CN1A (28-pin) and CN1B (14-pin) are plugable, double-row, spring clamp connectors with 3.5mm spacing. Refer to the tables on page for pin-outs. Motor Encoder Connector CN2 (15-pin) motor encoder connector is a standard D-shell connector.
Page 38 2-12 Ultra5000 Connector Information Terminal Block 1 (TB1) Locations (2098-IPD-075-xx and -150-xx) U (Motor) V (Motor) W (Motor) Motor Case Ground DC Bus+ DC Bus- L1 (Main AC) L2 (Main AC) L3 (Main AC) Safety (Earth) Ground L1 (Aux AC) L2/N (Aux AC) Do not connect an external I/O power supply to the DC bus.
Page 39: 230V Ultra5000 With Devicenet Front Panel Connections
2-13 Ultra5000 Connector Information 230V Ultra5000 with DeviceNet Front Panel Connections This section describes and provides a visual reference to drive’s having the DeviceNet interface. 500W, 1 kW, and 2 kW Ultra5000 with DeviceNet (2098-IPD-005-DN, -010-DN, and -020-DN) Use the figure below to locate the front panel connections on the 230V Ultra5000 with DeviceNet drives (500W, 1 kW, and 2 kW).
Page 40: I/O Connectors
2-14 Ultra5000 Connector Information I/O Connectors CN1A (28-pin) and CN1B (14-pin) are plugable, double-row, spring clamp connectors with 3.5mm spacing. Refer to the tables on page for pin-outs. Motor Encoder Connector CN2 (15-pin) motor encoder connector is a standard D-shell connector.
Page 41: Kw, 7.5 Kw, And 15 Kw Ultra5000 (2098-Ipd-005-Dn, -010-Dn, And -020-Dn)
2-15 Ultra5000 Connector Information 3 kW, 7.5 kW, and 15 kW Ultra5000 (2098-IPD-005-DN, -010-DN, and -020-DN) Use the figure below to locate the front panel connections on the 230V Ultra5000 with DeviceNet drives (3 kW, 7.5 kW, and 15 kW). Detailed descriptions of the connections are provided.
Page 42: 460V Ultra5000 Front Panel Connections
2-16 Ultra5000 Connector Information 460V Ultra5000 Front Panel Connections Use the figure below to locate the front panel connections on the 460V Ultra5000 drives (3 kW, 5 kW, 10 kW, 15 kW and 22 kW). Detailed descriptions of the digital connections are provided on pages through 2-7.
Page 43: I/O Connectors
2-17 Ultra5000 Connector Information I/O Connectors CN1A (28-pin) and CN1B (14-pin) are plugable, double-row, spring clamp connectors with 3.5mm spacing. Refer to the tables on page for pin-outs. Motor Encoder Connector CN2 (15-pin) motor encoder connector is a standard D-shell connector.
Page 44 2-18 Ultra5000 Connector Information Terminal Block 1 (TB1) Locations (2098-IPD-HVxxx-xx) DC Bus+ DC Bus- W (Motor) V (Motor) U (Motor) Ground (Motor and Earth) L3 (Main AC) L2 (Main AC) L1 (Main AC) L1 (Aux AC) L2 (Aux AC) Do not connect an external I/O power supply to the DC bus. The DC+ and DC- terminals connect directly to the power bus of the drive.
Page 45: Understanding Ultra5000 I/O Specifications
2-19 Ultra5000 Connector Information Understanding Ultra5000 A description of the Ultra5000 input/output is provided on the following pages. I/O Specifications Digital I/O Power Supply Power for the digital I/O on 0.5 kW, 1.0 kW, and 2.0 kW Ultra5000 230V drives (2098-IPD-005 through -020) and all 460V drives (2098-IPD-HVxxx-xx) must be provided by an external 12-24V dc power supply.
Page 46: Digital Inputs
2-20 Ultra5000 Connector Information Digital Inputs There are sixteen general purpose digital inputs. They are not connected in hardware to perform a particular function. All digital inputs have the same hardware configuration, shown in Figure 2.8. Configure your digital inputs, in a group, as active IMPORTANT high (current sinking) or active low (current sourcing).
Page 47 2-21 Ultra5000 Connector Information Parameter Description (Continued) Minimum Maximum -3.0V 1.0V OFF State Voltage, Voltage applied to the input, with Active Low respect to IOPWR, to guarantee an OFF Configuration state. Propagation Signal propagation delay from the high — 0.5 mS Delay, speed digital input to the firmware High Speed Inputs...
Page 48: Digital Outputs
2-22 Ultra5000 Connector Information Digital Outputs There are eight general purpose digital outputs. They are not connected in hardware to perform a particular function. Seven digital outputs are transistor outputs, and the drive has a single relay output (Output 8) with normally open contacts. The configuration of the transistor outputs is shown in Figure 2.9, and...
Page 49: Analog Inputs
2-23 Ultra5000 Connector Information Figure 2.10 Relay Output Hardware Configuration CN1A-26 Relay + Normally Open Relay CN1A-27 Relay - The following table provides a description of the relay output specifications. Parameter Description Minimum Maximum ON State Current flow when the relay is closed —...
Page 50: Analog Outputs
2-24 Ultra5000 Connector Information Parameter Description Minimum Maximum Offset Error Deviation from the correct value expected from — 50 mV analog-to-digital conversion when 0V is applied to the input. Gain Error Deviation of the transfer function from unity — gain, expressed in a percent of full scale. Propagation Delay from the input to the firmware-accessible —...
Page 51: Understanding Motor Encoder Feedback Specifications
2-25 Ultra5000 Connector Information Understanding Motor The Ultra5000 can accept motor encoder signals from the following types of encoders: Encoder Feedback • Incremental encoders with TTL outputs, with or without Hall Specifications signals • Sine/Cosine encoders, with or without Hall signals •...
Page 52 2-26 Ultra5000 Connector Information The Ultra5000 supports both TTL and Sine/Cosine encoders. The following table provides a description of the AM, BM, and IM inputs for TTL encoders. Parameter Description Minimum Maximum AM, BM, and IM Input voltage difference between the + +1.0V +12.0V ON State...
Page 53: Hall Inputs
2-27 Ultra5000 Connector Information Hall Inputs The Ultra5000 uses Hall Signals to initialize the commutation angle for sinusoidal commutation. Hall Signals must be single-ended and can be either open collector type or TTL type. Figure 2.14 shows the configuration of the Hall inputs. If the motor does not have Hall signals, the drive can configured through software to omit the Hall signal requirement.
Page 54: Limit And - Limit Inputs
2-28 Ultra5000 Connector Information Figure 2.16 Typical Thermostat Connection Drive Motor/Encoder Thermostat normally closed ECOM + Limit and - Limit Inputs The Ultra5000 drive includes overtravel limit inputs on the motor encoder connector that can be programmed to halt motion. The logic is designed so that an open condition will halt motion in the corresponding direction.
Page 55: Encoder Phasing
2-29 Ultra5000 Connector Information Encoder Phasing For proper motor commutation and control, it is important that the motor feedback signals are phased properly. The drive has been designed so that a positive current applied to a motor will produce a positive velocity and increasing position readings, as interpreted by the drive.
Page 56 2-30 Ultra5000 Connector Information Figure 2.21 shows the proper phasing of TTL A/B encoder signals when positive current is applied. Figure 2.21 Phasing of TTL A/B Encoder Signals Figure 2.22 shows the proper phasing of Sine/Cosine encoder signals when positive current is applied. Notice that the Sine/Cosine encoder signals phasing IMPORTANT is different than the phasing of the TTL encoders.
Page 57: Motor Encoder Connection Diagram
2-31 Ultra5000 Connector Information Motor Encoder Connection Diagram Figure 2.23 shows a typical wiring diagram of a motor feedback cable. If the thermostat or limit signals are not available, no connections are required, but the drive must be configured through software to ignore these signals.
Page 58: Understanding Auxiliary Encoder Feedback Specifications
2-32 Ultra5000 Connector Information Understanding Auxiliary The Ultra5000 can accept an auxiliary encoder signal of the following type. Encoder Feedback Figure 2.24 Specifications Auxiliary Encoder Input Signal Types Auxiliary Encoder Interface All encoder input signals (CN1B) are filtered using analog and digital filtering, including illegal state change detection.
Page 59 2-33 Ultra5000 Connector Information The following table provides a description of the auxiliary encoder interface. Parameter Description Minimum Maximum ON State Input voltage difference between the + +1.0V +7.0V Input Voltage input and the - input that is detected as an ON state.
Page 60: Understanding The Serial Interface
2-34 Ultra5000 Connector Information Understanding the Serial The Ultra5000 provides two physically identical serial ports (Main Serial Port CN3A and Auxiliary Serial Port CN3B) that implement the Interface standard NRZ asynchronous serial format, and supports RS-232, RS-422, and RS-485 communication standards. However, functionality differs between the ports: •...
Page 61: Connecting Your Ultra5000
Chapter Connecting Your Ultra5000 Chapter Objectives This chapter provides you with information for wiring your Ultra5000. This chapter includes these sections: • Powering the Digital I/O • Understanding Basic Wiring Requirements • Grounding Your Ultra5000 • Wiring Your Ultra5000 Before you begin these procedures, be sure to read and understand the information in the previous chapters of this manual.
Page 62: Accessing The Internal Digital I/O Power Supply
Connecting Your Ultra5000 Specifications on the internal digital I/O power supply are: Parameter Description Minimum Maximum Output Voltage Voltage difference between I/O PWR and 21.6V 28.0V I/O COM Output Current Current flow — 300 mA Accessing the Internal Digital I/O Power Supply The 230V (2098-IPD-030 through -150) Ultra5000 drives can power the digital I/O from a 24V dc power source internal to the drive.
Page 63 Connecting Your Ultra5000 2. Relocate the digital I/O power jumpers on the regulator board. Figure 3.2 shows the location of the J12 and J13 jumpers. Move both jumpers from the EXT position to the INT position. Note: The fuse (F1) protects the circuit only when the internal power is selected.
Page 64: Understanding Basic Wiring Requirements
Connecting Your Ultra5000 Understanding Basic This section contains basic wiring information for the Ultra5000. Wiring Requirements Plan the installation of your system so that you can ATTENTION perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. The system is of an open type construction and care must be taken to prevent metal debris from falling into it.
Page 65: Routing High And Low Voltage Cables
Connecting Your Ultra5000 Routing High and Low Voltage Cables Be aware that when you connect and route power and signal wiring on a machine or system, radiated noise from nearby relays (relay coils should have surge suppressors), transformers, and other electronic drives, can be induced into motor or encoder feedback, communications, or other sensitive low voltage signals.
Page 66: Grounding Your Ultra5000
Connecting Your Ultra5000 Grounding Your Ultra5000 We recommend that all equipment and components of a machine or process system have a common earth ground point connected to their chassis. A grounded system provides a safety ground path for short circuit protection. Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.
Page 67: Grounding Multiple Subpanels
Connecting Your Ultra5000 Grounding Multiple Subpanels To ground multiple subpanels, refer to the figure below. Figure 3.5 Subpanels Connected to a Single Ground Point Always follow NEC and applicable local codes Ground grid or power distribution ground Motor Power Cable Shield Termination Factory supplied motor power cables for F-Series, H-Series, MP-Series, N-Series, and W-Series motors are shielded, and the power cable is designed to be terminated at the drive during installation.
Page 68 Connecting Your Ultra5000 Figure 3.6 Motor Power Cable Shield Connection (bottom of drive) Ultra5000 Motor cable jacket Clamp Shield Motor cable jacket Clamp screws Figure 3.7 Motor Power Cable Shield Connection (front of drive) Clamp screws Motor cable jacket Clamp Ultra5000 Shield Motor cable jacket...
Page 69: Wiring Your Ultra5000
Connecting Your Ultra5000 Wiring Your Ultra5000 These procedures assume you have bonded and mounted your Ultra5000 to the subpanel and that there is no power applied to the system. This product contains ESD (Electrostatic Discharge) ATTENTION sensitive parts and assemblies. Follow static control precautions when you install, test, service, or repair this assembly.
Page 70: Connecting To A Devicenet Network
3-10 Connecting Your Ultra5000 Figure 3.9 Inserting Wires into the Connector Housing 3. Remove the screw driver and gently pull on the wire to make sure it does not come out of its terminal. Re-insert and test any loose wires. Connecting to a DeviceNet Network A DeviceNet network is an arrangement of electrical power and device distribution.
Page 71: Connecting Your Devicenet Cable
3-11 Connecting Your Ultra5000 Connecting Your DeviceNet Cable To attach a plugable, open style, screw-connector to the DeviceNet cable: 1. Strip 65 mm (2.6 in.) to 75 mm (2.96 in.) of the outer jacket from the end of the cable, leaving no more than 6.4 mm (0.25 in.) of the braided shield exposed.
Page 72: Assigning Your Ultra5000 Devicenet Address
3-12 Connecting Your Ultra5000 4. Insert each wire into the appropriate clamping cavity of the plugable screw connector, according to the color of the cable insulation. Tighten the clamping screws to secure each wire. 5. Use an 1/8 inch flat blade screwdriver to firmly attach wires in the connector.
Page 73 3-13 Connecting Your Ultra5000 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 for the switch locations.
Page 74: Wiring Power Connections
3-14 Connecting Your Ultra5000 Wiring Power Connections The 2098-IPD-HVxxx-xx drives can be powered with IMPORTANT 230-240 Vrms in order to be used in conjunction with motors designed for 230V operation. In such cases, the voltage levels used for shunting and DC bus overvoltage limits are adjusted to be compatible with the voltage limit of the motor.
Page 75 3-15 Connecting Your Ultra5000 High voltage can be present on the shield of a power ATTENTION cable if the shield is not grounded. Motor power connectors are to be used for connection purposes only - do not use them to turn the unit on and off. To avoid hazard of electrical shock, ensure shielded power cables are grounded at a minimum of one point for safety.
Page 76 3-16 Connecting Your Ultra5000 Figure 3.14 CE Clamp Cable Preparation L (refer to table below) 12 mm (0.50 in.) Exposed braid Motor cable For these Ultra5000 drives: The dimension L has this value: 2098-IPD-005 or -005-DN 185 mm (7.25 in.) 2098-IPD-010 or -010-DN 2098-IPD-020 or -020-DN 2098-IPD-030, -030-DN, -HV030, or -HV030-DN...
Page 77 3-17 Connecting Your Ultra5000 4. Using a screw driver, loosen the screw for each of the terminal locations and attach wires as shown in the table below. Refer to Appendix B for the power wiring diagram for your Ultra5000 drive. Terminal Block (TB) Locations Terminal Block 1 (TB1) Locations (2098-IPD-005xx, -010-xx, -020-xx)
Page 78 3-18 Connecting Your Ultra5000 5. Tighten each terminal screw to the appropriate torque value. Ultra5000 Drives: Terminal Block Torque Values: 2098-IPD-005xx, -010-xx, and -02-xx 1.25 Nm (11 lb-in.) 2098-IPD-030-xx 2098-IPD-075-xx 2098-IPD-150-xx 2.26 Nm (20 lb-in.) 2098-IPD-HVxxx-xx 1.25 Nm (11 lb-in.) 6.
Page 79 3-19 Connecting Your Ultra5000 8. Determine whether or not a shunt resistor is necessary And your If your Ultra5000 catalog application Then: number begins with: requires: 2098-IPD-005 or -005-DN no shunt You are finished 2098-IPD-010 or -010-DN wiring your 2098-IPD-020 or -020-DN Ultra5000 power connections.
Page 80 3-20 Connecting Your Ultra5000 9. You are finished wiring your Ultra5000 power connections. Go to the chapter Commissioning Your Ultra5000 beginning on Page 4-1. Publication 2098-IN001E-EN-P — April 2002...
Page 81: Commissioning Your Ultra5000
Chapter Commissioning Your Ultra5000 Chapter Objectives This chapter provides you with information to apply power and configure your Ultra5000. This chapter includes these sections: • General Startup Precautions • Understanding Communication Switch Settings • Applying Power To Your System • Configuring Your Ultra5000 Before you begin these procedures, be sure to read and understand the information in the previous chapters of this manual.
Page 82: Understanding Communication Switch Settings
Commissioning Your Ultra5000 This product contains ESD (Electrostatic Discharge) ATTENTION sensitive parts and assemblies. Follow static control precautions when you install, test, service, or repair this assembly. Refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook. Failure to observe this precaution may result in damage to the equipment.
Page 83: Applying Power To Your System
Commissioning Your Ultra5000 Applying Power To Your This procedure assumes you have wired your Ultra5000 system, verified the wiring, and are ready to begin using your Ultraware System software. To apply power to your Ultra5000 system: 1. Disconnect any load to the motor. Ensure the motor is free of all linkages when initially applying power to the system.
Page 84: Configuring Your Ultra5000
Commissioning Your Ultra5000 Figure 4.1 Logic Power and Status LED Display Status If the Logic Power LED is: Then: Go to step Not ON Check your input power connections. Repeat step 4. Observe the front panel seven segment Status LED display as shown in Figure 4.1.
Page 85 Commissioning Your Ultra5000 Configuring Your Ultra5000 This procedure assumes you have successfully applied power to your system. To configure your Ultra5000 system: 1. Start your Ultraware software. Refer to the Ultraware User Manual, publication 2098-UM001, for information on starting the Ultraware software.
Page 86 Commissioning Your Ultra5000 Publication 2098-IN001E-EN-P — April 2002...
Page 87: Maintaining Your Ultra5000
Chapter Maintaining Your Ultra5000 Chapter Objectives This chapter provides a description of maintenance and troubleshooting activities for the Ultra5000. This chapter includes these sections: • Maintaining the Drive • General Troubleshooting • Troubleshooting for DeviceNet Drives Maintaining the Drive The Ultra5000 Drive is designed to function with a minimum of maintenance.
Page 88: Inspecting The Cables
Maintaining Your Ultra5000 Inspecting the Cables Ensure input power is disconnected before touching cables or connections and perform the following: • Visually inspect all cables for abrasion. • D-shell and Digital I/O connectors should be inspected for proper seating and signal continuity end-to-end. General Troubleshooting Refer to the Error Codes...
Page 89 Maintaining Your Ultra5000 Error Problem or Symptom Possible Cause(s) Action/Solution Code Motor jumps when first enabled Motor wiring error. Check motor wiring. Incorrect motor chosen. Verify the proper motor is selected. Digital I/O not working correctly I/O power supply disconnected or Verify: •...
Page 90 Maintaining Your Ultra5000 Error Problem or Symptom Possible Cause(s) Action/Solution Code • Change the deceleration or motion Bus Overvoltage Excessive regeneration of power. profile. • Use a larger system (motor and When the motor is driven by an external mechanical power source, it Ultra5000).
Page 91 Maintaining Your Ultra5000 Error Problem or Symptom Possible Cause(s) Action/Solution Code • Use shielded cables with twisted Auxiliary Encoder state error The auxiliary encoder encountered an illegal transition. pair wires. • Route the encoder cable away from potential noise sources. •...
Page 92: Troubleshooting For Devicenet Drives
Maintaining Your Ultra5000 Error Problem or Symptom Possible Cause(s) Action/Solution Code AC Line Loss One or more phases of the input AC Check input AC voltage on all phases. power is missing. Reserved Call your local Allen-Bradley representative. • Verify that there are no Self-sensing Commutation Startup Motion required for self-sensing Error...
Page 93: Devicenet Network Status Led
Maintaining Your Ultra5000 DeviceNet Network Status LED Use the table below for troubleshooting the DeviceNet Network Status LED on your Ultra5000 (2098-IPD-xxx-DN, or -HVxxx-DN). If the Network Status is: Potential Cause is: Possible Resolution is: Status LED is: • Not powered •...
Page 94: Node Problems
Maintaining Your Ultra5000 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).
Page 95: Scanner Problems
Maintaining Your Ultra5000 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 •...
Page 96: Cable Installation And Design Problems
5-10 Maintaining Your Ultra5000 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.
Page 97: 2098-Ipd-005-Xx, -010-Xx, And -020-Xx
Appendix Specifications and Dimensions Objectives This appendix covers the following topics: • Ultra5000 Specifications • Dimensions Ultra5000 Specifications The following sections provide specifications for the Ultra5000. General Power Specifications 2098-IPD-005-xx, -010-xx, and -020-xx The table below lists general power specifications and requirements for the Ultra5000 230V drives.
Page 98: 2098-Ipd-030-Xx, -075-Xx, And -150-Xx
Specifications and Dimensions 2098-IPD-030-xx, -075-xx, and -150-xx The table below lists general power specifications and requirements for the Ultra5000 230V drives. Specification Description 2098-IPD-030, 2098-IPD-075, 2098-IPD-150, 2098-IPD-030-DN 2098-IPD-075-DN 2098-IPD-150-DN 100-240V 100-240V AC Input Voltage Single Phase Three Phase AC Input Frequency 47 - 63 Hz Main AC Input Curren Nominal,...
Page 99: 2098-Ipd-Hv030-Xx, -Hv050-Xx, -Hv100-Xx, -Hv150-Xx
Specifications and Dimensions 2098-IPD-HV030-xx, -HV050-xx, -HV100-xx, -HV150-xx, and -HV220-xx The table below lists general power specifications and requirements for the Ultra5000 460V drives. Description 2098-IPD-HV030 2098-IPD-HV050 2098-IPD-HV100 2098-IPD-HV150 2098-IPD-HV220 Specification 2098-IPD-HV030-DN 2098-IPD-HV050-DN 2098-IPD-HV100-DN 2098-IPD-HV150-DN 2098-IPD-HV220-DN 230-480V 1, 2 AC Input Voltage Three Phase AC Input Frequency 47 - 63 Hz...
Page 100: Physical And Environmental
Specifications and Dimensions Physical and Environmental The table below lists physical and environmental specifications and requirements. Specification Description Weight 2098-IPD-005 1.77 (3.9) 2098-IPD-010 2.07 (4.55) 2098-IPD-020 2.05 (4.51) 2098-IPD-030 6.16 (13.58) 2098-IPD-075 9.23 (20.35) 2098-IPD-150 13.96 (30.78) 2098-IPD-005-DN 2.11 (4.7) 2098-IPD-010-DN 2.41 (5.3)
Page 101: Power Dissipation
Specifications and Dimensions Power Dissipation The maximum power losses Ultra5000 are shown below to help in sizing an enclosure and any required ventilation. Typical heat losses can run approximately one-half maximum power losses. Catalog Number Maximum Loss (Watts) 2098-IPD-005, 005-DN 48 + dissipative shunt 2098-IPD-010, -010-DN 48 + dissipative shunt...
Page 102: User Programming
Specifications and Dimensions User Programming The table below lists physical and programming specifications. Specification Description Language Compiled ANSI C subset with Library of Motion Functions Programming Environment Full-featured Color Syntax Editor and C Compiler Integrated with Ultraware Operating System Real-time, multi-tasking, field upgradable flash User Program Memory 512 Kbytes Flash Memory, 100,000 Write Cycles...
Page 103: Inputs And Outputs
Specifications and Dimensions Inputs and Outputs The table below lists I/O specifications. Specification Description General Purpose 16 Optically Isolated 12-24 Volt Inputs Digital Inputs Inputs/Outputs - Software Selectable as a Group to be Active High, Current Sinking Sinking/Sourcing or Active Low, Current Sourcing Selection General Purpose 7 Optically Isolated 12-24 Volt Outputs - 50 Milliamperes Maximum...
Page 104: Motor Feedback
Specifications and Dimensions Motor Feedback The table below lists motor feedback specifications. Specification Description Encoder Types Incremental, Sine/Cosine, Intelligent, and Absolute Maximum Input Frequency 100 kHz (Sine/Cosine Input) 2.5 MHz (TTL Input) per channel Commutation Startup Hall Sensor Auxiliary Feedback The table below lists auxiliary feedback specifications.
Page 105: Dimensions
Specifications and Dimensions Dimensions The following diagrams show the dimensions and mounting hole locations for the Ultra5000 drives. Note: The DeviceNet Interface is an add-on feature available with all Ultra5000 drives. Overall dimensions are provided for each Ultra5000 drive that include and exclude the DeviceNet interface.
Page 106 A-10 Specifications and Dimensions Figure A.2 Dimensions and Mounting Diagram (2098-IPD-010-xx and 2098-IPD-020-xx) 139.70 [5.50] 83.82 [3.30] 20.32 43.18 [0.80] [1.70] 131.83 [5.19] 193.55 205.23 [7.62] [8.08] 184.91 [7.28] 144.53 [5.69] 114.30 [4.50] Fan only on 2 kW units Note: Inch dimensions are shown in brackets Publication 2098-IN001E-EN-P —...
Page 107 A-11 Specifications and Dimensions Figure A.3 Dimensions and Mounting Diagram 2098-IPD-030-xx 120,5 4.74 25,4 [ 1.00 ] 20,3 50,8 8.94 [ 2.00 ] [ 227 ] 360,7 335,1 349,3 [ 14.20 ] [ 13.19 ] [ 13.75 ] 172,3 6.78 149,3 5.88 243,9...
Page 108 A-12 Specifications and Dimensions Figure A.4 Dimensions and Mounting Diagram 2098-IPD-075-xx 166.4 [ 5.55 ] 25,4 [ 1.00 ] [ 8.94 ] 24,3 88,9 [ 3.50 ] [ .96 ] 360,7 335,2 [ 14.20 ] 349,3 [ 13.20 ] [ 13.75 ] 172,3 [ 6.78 ] 152,7...
Page 109 A-13 Specifications and Dimensions Figure A.5 Dimensions and Mounting Diagram 2098-IPD-150-xx 218.3 [ 7.59 ] 25,4 [ 1.00 ] 189,3 227,0 [ 7.45 ] [ 8.94 ] 69,9 69,9 24,9 [ 2.75 ] [ 2.75 ] [ 0.98 ] 335,1 [ 13.19 ] 349.3 [ 13.75]...
Page 110 A-14 Specifications and Dimensions Figure A.6 Dimensions and Mounting Diagram 2098-IPD-HV030-xx and 2098-IPD-HV050-xx 164.1 [ 6.46 ] 18.5 50.8 50.8 [ 0.73 ] [ 2.00 ] [ 2.00 ] DANGER 349.3 360.7 331.5 DeviceNet [ 13.75 ] [ 14.20 ] [ 13.05 ] 172.3 [ 6.78 ]...
Page 111 A-15 Specifications and Dimensions Figure A.7 Dimensions and Mounting Diagram 2098-IPD-HV100-xx and 2098-IPD-HV150-xx 177.0 [ 6.97 ] 25.0 50.8 50.8 [ 0.99 ] [ 2.00 ] [ 2.00 ] 360.7 [ 14.20 ] 349.3 [ 13.75 ] DANGER 331.5 DeviceNet [ 13.05 ] 172.3 [ 6.78 ]...
Page 112 A-16 Specifications and Dimensions Figure A.8 Dimensions and Mounting Diagram 2098-IPD-HV220-xx 228.6 [ 9.00 ] 203.2 [ 8.00 ] 25.4 76.2 76.2 [ 1.00 ] [ 3.00 ] [ 3.00 ] 391.8 [ 15.43 ] 380.4 362.6 DANGER [ 14.98 ] [ 14.28 ] DeviceNet 172.3...
Page 113: Interconnect Diagrams
Appendix Interconnect Diagrams Objectives This appendix contains the following interconnect diagrams: • Ultra5000 and Motor Cable Diagrams • Ultra5000 Power Wiring Diagrams • Using an Emergency Stop Contactor • Grounding for Ultra5000 CE Requirements • Ultra5000 Shunt Module Information Ultra5000 and Motor Cable This section provides information to assist you in wiring your MP, N, H/F, W, and Y-Series motors when connecting to your Ultra5000.
Page 114 Interconnect Diagrams Figure B.1 Ultra5000 Motor/Drive Cable Connections Catalog Number Motor Power Cables 500W, 1 kW, 2 kW Ultra5000 to H-Series Motors 2090-UXNPAH-16Sxx Ultra5000 500W, 1 kW, 2 kW Ultra5000 to H-Series Motors 2090-UXNPAH-16Rxx 15 kW Ultra5000 to H-Series Motors 2090-UXNPAH-6Sxx 15 kW Ultra5000 to H-Series Motors 2090-UXNPAH-6Rxx...
Page 115: Ultra5000 To Motor Interconnect Diagrams
Interconnect Diagrams Ultra5000 to Motor Interconnect Diagrams Figure B.2 Ultra5000 to 1326AB-Bxxxx-M2L or -S2L Motor Configuration (mating connector) 2090-UXNFBMP-Sxx 2090-UXNFBMP-Sxx 1326AB-Bxxxx-M2L or -S2L Motor 1326AB-Bxxxx-M2L or -S2L Motor Ultra5000 Ultra5000 Motor Feedback Cable with 15-pin Connector Motor Feedback Cable with 15-pin Connector BLACK BLACK SIN+...
Page 116 Interconnect Diagrams Figure B.3 Ultra5000 to 1326AB-Bxxxx-M2L or -S2L Motor Configuration (flying leads) 1326AB-B 1326AB-B xxxx xxxx -M2L or -S2L Motor -M2L or -S2L Motor 2090-UXNFDMP-S 2090-UXNFDMP-S xx xx Ultra5000 Ultra5000 Motor Feedback Cable with Flying Leads Motor Feedback Cable with Flying Leads BLACK BLACK SIN+...
Page 117 Interconnect Diagrams Figure B.4 Ultra5000 to MP-Series Motor Configuration (mating connector) 2090-UXNFBMP-S xx xx 2090-UXNFBMP-S MP-Series Motor MP-Series Motor Ultra5000 Ultra5000 Motor Feedback Cable with 15-pin Connector Motor Feedback Cable with 15-pin Connector BLACK BLACK A+ A+ or or SIN+ SIN+ WHT/BLACK WHT/BLACK...
Page 118 Interconnect Diagrams Figure B.5 Ultra5000 to MP-Series Motor Configuration (flying leads) MP-Series Motor MP-Series Motor 2090-UXNFDMP-S 2090-UXNFDMP-S xx xx Ultra5000 Ultra5000 Motor Feedback Cable with Flying Leads Motor Feedback Cable with Flying Leads BLACK BLACK A+ A+ or or SIN+ SIN+ WHT/BLACK WHT/BLACK...
Page 119 Interconnect Diagrams Figure B.6 Ultra5000 to N-Series Motor Configuration (mating connector) 2090-UXNFBN-S 2090-UXNFBN-S xx xx N-Series N-Series Motor Feedback Cable with 15-pin Connector Motor Feedback Cable with 15-pin Connector Ultra5000 Ultra5000 Motor Motor BLACK BLACK A+ A+ A- A- WHT/BLACK WHT/BLACK B+ B+ WHT/RED...
Page 120 Interconnect Diagrams Figure B.7 Ultra5000 to N-Series Motor Configuration (flying leads) 2090-UXNFDN-S 2090-UXNFDN-S xx xx N-Series N-Series Ultra5000 Ultra5000 Motor Feedback Cable with Flying Leads Motor Feedback Cable with Flying Leads Motor Motor BLACK BLACK A+ A+ WHT/BLACK WHT/BLACK A- A- B+ B+ B- B- WHT/RED...
Page 121 Interconnect Diagrams Figure B.8 Ultra5000 to H-, and F-Series Motor Configuration (mating connector) 2090-UXNFBHF-Sxx xx 2090-UXNFBHF-S H/F-Series H/F-Series Ultra5000 Ultra5000 Motor Feedback Cable with 15-pin Connector Motor Feedback Cable with 15-pin Connector Motor Motor A+ A+ BLACK BLACK A- A- WHT/BLACK WHT/BLACK B+ B+...
Page 122 B-10 Interconnect Diagrams Figure B.9 Ultra5000 to H-, and F-Series Motor Configuration (flying leads) 2090-UXNFDHF-S xx xx 2090-UXNFDHF-S H/F-Series H/F-Series Ultra5000 Ultra5000 Motor Feedback Cable with Flying Leads Motor Feedback Cable with Flying Leads Motor Motor A+ A+ BLACK BLACK A- A- WHT/BLACK WHT/BLACK...
Page 123 B-11 Interconnect Diagrams Figure B.10 Ultra5000 to W-Series Motor Configuration (mating connector) 2090-UXNFBHF-S xx xx 2090-UXNFBHF-S W-Series W-Series Ultra5000 Ultra5000 Motor Feedback Cable with 15-pin Connector Motor Feedback Cable with 15-pin Connector Motor Motor BLACK BLACK WHT/BLACK WHT/BLACK WHT/RED WHT/RED GREEN GREEN WHT/GREEN...
Page 124 B-12 Interconnect Diagrams Figure B.11 Ultra5000 to W-Series Motor Configuration (flying leads) 2090-UXNFDHF-S xx xx 2090-UXNFDHF-S W-Series W-Series Ultra5000 Ultra5000 Motor Feedback Cable with Flying Leads Motor Feedback Cable with Flying Leads Motor Motor BLACK BLACK WHT/BLACK WHT/BLACK WHT/RED WHT/RED GREEN GREEN WHT/GREEN...
Page 125 B-13 Interconnect Diagrams Figure B.12 Ultra5000 to Y-Series Motor Configuration (mating connector) 2090-UXNFBY-S 2090-UXNFBY-S xx xx Y-Series Y-Series Ultra5000 Ultra5000 Motor Feedback Cable with 15-pin Connector Motor Feedback Cable with 15-pin Connector Motor Motor BLACK BLACK A+ A+ WHT/BLACK WHT/BLACK A- A- 10 10 B+ B+...
Page 126 B-14 Interconnect Diagrams Figure B.13 Ultra5000 to Y-Series Motor Configuration (flying leads) 2090-UXNFDY-S 2090-UXNFDY-S xx xx Y-Series Y-Series Ultra5000 Ultra5000 Motor Feedback Cable with Flying Leads Motor Feedback Cable with Flying Leads Motor Motor GRAY GRAY +5V DC +5V DC EPWR_5V EPWR_5V 14 14...
Page 127: Ultra5000 Power Wiring Diagrams
B-15 Interconnect Diagrams Ultra5000 Power Wiring This section provides information to assist you with AC input and motor power wiring to your Ultra5000 drive. Diagrams Figure B.14 Typical Power Wiring of Ultra5000 System 2098-IPD-005-xx, -010-xx, and -020-xx Publication 2098-IN001E-EN-P — April 2002...
Page 128 B-16 Interconnect Diagrams Figure B.15 Typical Power Wiring of Ultra5000 System 2098-IPD-030-xx Publication 2098-IN001E-EN-P — April 2002...
Page 129 B-17 Interconnect Diagrams Figure B.16 Typical Power Wiring of Ultra5000 System 2098-IPD-075-xx Publication 2098-IN001E-EN-P — April 2002...
Page 130 B-18 Interconnect Diagrams Figure B.17 Typical Power Wiring of Ultra5000 System 2098-IPD-150-xx Publication 2098-IN001E-EN-P — April 2002...
Page 131 B-19 Interconnect Diagrams Figure B.18 Typical Power Wiring of Ultra5000 System 2098-IPD-HVxxx-xx Publication 2098-IN001E-EN-P — April 2002...
Page 132: Using An Emergency Stop Contactor
B-20 Interconnect Diagrams Using an Emergency Stop Some applications require that a contactor be inserted between the motor and Ultra5000 for emergency stop purposes. To determine if Contactor this is necessary, perform a hazard analysis of the machine. If used, the contactor must not simply break the motor current, it must switch a 3-phase resistive load in parallel with the motor windings.
Page 133 B-21 Interconnect Diagrams Figure B.19 Emergency Stop Contactor Wiring Contactors Resistors Drive Motor Unbraided shield Grounded terminal or stud Isolated terminal Enclosure wall Exposed power wiring conductors that are not shielded are a source of RFI noise. Keep exposed conductors as short as possible and isolated from sensitive devices and wiring.
Page 134: Grounding For Ultra5000 Ce Requirements
B-22 Interconnect Diagrams Grounding for Ultra5000 CE This section provides information to assist you in complying with CE requirements. Figure B.20 briefly outlines Ultra5000 CE requirements. Requirements Refer to Complying with European Union Directives on page 1-1 information on how to determine compliance of specific products. Figure B.20 Ultra5000 CE Requirements Ground Conduit to Enclosure...
Page 135: Ultra5000 Shunt Module Information
B-23 Interconnect Diagrams Ultra5000 Shunt Module This section directs you to information sources for wiring an active or passive shunt module to your Ultra5000 drive. Information 300 Watt Active Shunt Module Use the 2090-UCSR-A300 active shunt module with the Ultra5000 (2098-IPD-005-xx, -010-xx, and -020-xx) drives.
Page 136: 900 Watt Passive Shunt Module
B-24 Interconnect Diagrams 900 Watt Passive Shunt Module Use the 2090-UCSR-P900 passive shunt module with the Ultra5000 drives (2098-IPD-075-xx or 2098-IPD-150-xx). Use shielded, high temperature 75° C (167° F), 600V, 10 mm AWG), 3.05 m (10 ft) maximum, copper wire. Follow one of the methods given below to reduce the effects of EMI noise: •...
Page 137: Ultraware Software
Appendix Catalog Numbers and Accessories Chapter Objectives This appendix lists the Ultra5000 drives and accessory items in tables by catalog number providing detailed descriptions of each component. This appendix describes catalog numbers for: • Ultra5000 Drives • Ultraware Software • AC Line Filters •...
Page 138 Catalog Numbers and Accessories Ultra5000 Drives Use the following table to identify Ultra5000 240V drives with ratings of 500W, 1 kW, and 2 kW. Description Catalog Number Ultra5000 Intelligent Positioning Drives 2098-IPD-005, 2098-IPD-010, 2098-IPD-020 Ultra5000 Intelligent Positioning Drives with DeviceNet 2098-IPD-005-DN, 2098-IPD-010-DN, 2098-IPD-020-DN...
Page 139 Catalog Numbers and Accessories AC Line Filters Use the following table to identify the AC Line Filter for your application. Description AC Line Roxburgh Catalog Number Filter Fuse Part Block Number AC Line Filter (6 Amp, Single phase) 6 Amp MIF06 2090-UXLF-106 AC Line Filter (10 Amp, Single phase)
Page 140: External Shunt Kits
Catalog Numbers and Accessories External Shunt Kits External shunts are available for use with Ultra5000 drives. Refer to Related Documentation on page P-3 to locate Installation Instructions for these shunts. Use the following tables to identify external shunt kits available for Ultra5000 drives.
Page 141: 300 Watt Active Shunt Ferrites
Catalog Numbers and Accessories 300 Watt Active Shunt Ferrites Ferrites are used at both ends of the DC Bus wires for CE radiated emissions compliance. Use the following table to select a ferrite assembly. Box shaped ferrite assembly in fully enclosed nylon case.
Page 142: Cables
Catalog Numbers and Accessories Cables Use the following tables to identify motor power, feedback, interface, and brake cables for your Ultra5000. Length of cable xx is in meters (01, 03, 09, 15, and 30) unless otherwise noted. Motor Power Cables Applicable Drive(s) Description Catalog Number...
Page 143: Motor Feedback Cables
Catalog Numbers and Accessories Motor Feedback Cables Applicable Drive(s) Description Catalog Number All 2098-IPD-xxx and H, F and W-Series Motor Feedback Cable, non-flex, connector at both ends, right angle, 2090-UXNFBHF-Kxx -HVxxx skewed H, F and W-Series Motor Feedback Cable, non-flex, connector at both ends, right angle 2090-UXNFBHF-Rxx H, F and W-Series Motor Feedback Cable, non-flex, connector at both ends, straight 2090-UXNFBHF-Sxx...
Page 144: Mp-Series Motor Brake Cable
Catalog Numbers and Accessories MP-Series Motor Brake Cable Description Catalog Number MP-Series and 1326AB-Bxxxx-M2L or -S2L motor brake cable, 2090-UXNBMP-18Sxx 0.75 mm (18 AWG) Ultra5000 Interface Cables Description Catalog Number Interface cable, PanelView to Ultra5000 2090-U5PV-D09xx Serial Interface Cable, 9-pin D-shell, CN3 to personal computer. 2090-UXPC-D09xx Break Out Boards, Cables, Use the following table to identify your break out board components.
Page 145: Mating Connector Kits
Mating Connector Kit (15-pin high density D-shell) 2090-UXCK-D15 Mating Connector Kit (Terminal Block) 2090-UXCK-TB The following table lists mating connectors that are not available from Rockwell Automation. Please contact Amp at 1-800-522-6752 or a distributor for additional information. Connector Components Motor Feedback Serial...
Page 146 C-10 Catalog Numbers and Accessories Publication 2098-IN001E-EN-P — April 2002...
Page 147: Wiring Three Phase Power To A
Appendix Wiring Three Phase Power to a Single Phase Ultra5000 Objectives This appendix discusses connecting single phase Ultra5000 drives to a star (Y) connected three phase power source. The three main aspects of installation are: • Mandatory Neutral Connection of Isolation Transformer •...
Page 148 Wiring Three Phase Power to a Single Phase Ultra5000 Mandatory Neutral A neutral must be connected (shown in the upper diagram of Figure D.1) when single phase drives are attached to a three phase isolating Connection of Isolation transformer secondary. It is not necessary that all three phases be Transformer loaded with drives, but each drive must have its power return via the neutral connection.
Page 149: Adding A Safety Ground To The Isolation Transformer
Wiring Three Phase Power to a Single Phase Ultra5000 Adding a Safety Ground to the Isolation Transformer Provided that the transformer used is an isolating transformer, it is a good idea to fit a safety ground to the neutral connection. This will do two things: 1.
Page 150: Voiding Of Ce Compliance
The three phase and neutral in line filter applications described above may not be adequate from an EMC aspect for CE compliance. Therefore EMC validity and CE marking by Rockwell Automation is voided when three phase and neutral in line filters are used.
Page 151 Index Numerics 460V drive cables 3-14 230V input implications break out board cable building your own cables drive and motor combinations interface cables Input current motor feedback cables input current motor power 3-14 power MP-series brake cables address to 1326AB motor logically assigned to H/F-series motor physically assigned...
Page 152 Index A-14 configuring 2098-IPD-HV050-DN A-15 drive detection 2098-IPD-HV100 3-12 A-15 drive with DeviceNet 2098-IPD-HV100-DN A-15 firmware upgrade 2098-IPD-HV150 A-15 HV drive for 230V motor input 2098-IPD-HV150-DN 3-14 A-16 power 2098-IPD-HV220 A-16 Ultra5000 2098-IPD-HV220-DN Ultraware software documentation connecting your Ultra5000 on-line and print 5-10 drop length design connector...
Page 153 Index 2-24 excess position error analog outputs 2-20 excess velocity error digital inputs 2-22 external devices digital outputs 2-19 2-19 digital I/O power supply external power supply 2-19 shunt kit internal power supply I/O connector Ultra5000 illegal hall state B-22 filter, AC power input power firmware upgrade...
Page 154 Index periodic Continuous (peak) troubleshooting output current mating connectors continuous (peak) module status LED peak 3-14 motor overload protection B-20 overload protection overspeed fault motor encoder error motor encoder connector pin-outs motor encoder specifications 2-14 DeviceNet connector 2-25 AM, BM, and IM inputs I/O connectors 2-32 auxiliary encoder...
Page 155 Index control of electrical noise auxiliary feedback DeviceNet cable system connectors planning and installation control 3-10 manual DeviceNet communications on-line and printed 2-19 documentation digital I/O power supply Ultra5000 C programming manual general power Ultra5000 DeviceNet reference 2098-IPD-005-xx, manual -010-xx, and -020-xx Ultraware CD installation 2098-IPD-030-xx, -075-xx, and -150-xx...
Page 156 Index minimum clearances frequency exceeded preparation excess cpu load spacing excess position error transformer sizing excess velocity error ventilation illegal hall state IPM fault IPM thermal protection fault tee tap motor encoder error terminal block motor jumps when 3-18 connections enabled 2098-IPD-005-xx, motor overtemperature...
Page 157 Index 3-15 input power 3-14 power connections wire gauge power wiring diagram 3-10 DeviceNet 2098-IPD-005, -010, -020 I/O connector B-15 1-11 subpanel bonding B-16 2098-IPD-030-xx wiring B-17 2098-IPD-075-xx building your own cables B-18 2098-IPD-150-xx 3-15 CE ground clamp B-19 2098-IPD-HVxxx-xx 3-18 connecting cable shield requirements...
Page 158 Index Publication 2098-IN001E-EN-P — April 2002...

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Ab quality allen-bradley ultra5000 2098-ipd-005-dnAb quality allen-bradley ultra5000 2098-ipd-010Ab quality allen-bradley ultra5000 2098-ipd-010-dnAb quality allen-bradley ultra5000 2098-ipd-020Ab quality allen-bradley ultra5000 2098-ipd-020-dnAb quality allen-bradley ultra5000 2098-ipd-030 ... Show all

Rockwell Automation AB Quality Allen-Bradley Ultra5000 2098-IPD-005 Installation Manual

Preface

Introduction

Appendix A Objectives

Chapter 1 Chapter Objectives

Installing Your Ultra5000

Chapter 2

Ultra5000 Connector

Connecting Your Ultra5000

Chapter 3

Chapter 4

Commissioning Your Ultra5000

Chapter 5

Maintaining Your Ultra5000

Appendix B

Interconnect Diagrams

Appendix C

Appendix D

Wiring Three Phase Power to a

Quick Links

Troubleshooting

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Summary of Contents for Rockwell Automation AB Quality Allen-Bradley Ultra5000 2098-IPD-005

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Table of Contents