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Rockwell Automation Allen-Bradley Ultra3000 Integration Manual

Rockwell Automation Allen-Bradley Ultra3000 Integration Manual

Digital servo drives
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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

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Summary of Contents for Rockwell Automation Allen-Bradley Ultra3000

  • Page 1 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...
  • Page 2 In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

  • Page 3: Table Of Contents

    Table of Contents Preface About This Publication......7 Who Should Use This Manual ......7 Conventions Used in This Manual .
  • Page 4 Table of Contents Understanding Drive Fault Behavior ....105 Troubleshooting for DeviceNet Drives ....109 Node Problems .
  • Page 5 Table of Contents Observe the Default Position Error Tolerance Limit Setting ......156 Trending Excursion Limits of the Position Error Parameter .
  • Page 6 Table of Contents Publication 2098-IN005C-EN-P — March 2008...

  • Page 7: Preface

    Manual Ultra3000 servo drives. If you do not have a basic understanding of the Ultra3000 drives, contact your local Rockwell Automation sales representative before using this product for information on available training courses. Conventions Used in This The following conventions are used throughout this manual: Manual •...

  • Page 8: Additional Resources

    (DXF) drawings. Rockwell Automation Product Certification link, website http://ab.com Declarations of conformity currently available from Rockwell Automation. National Electrical Code, published by the National Fire Protection Article on wire sizes and types for grounding electrical equipment. Association of Boston, MA Rockwell Automation Industrial Automation Glossary, publication AG-7.1...

  • Page 9: Commissioning Your Ultra3000 Drive

    Chapter Commissioning Your Ultra3000 Drive This chapter provides you with information to apply power and configure your Ultra3000 servo drive. Topic Page Introduction General Startup Precautions Understanding the Serial Connection Configuring Your Ultra3000 Drive and Ultra3000 Drive with Indexing Configuring Your Ultra3000 Drive with RSLogix 5000 Software Configuring Your Ultra3000 Drive with SERCOS Configuring Your Ultra3000 Drive with DeviceNet Introduction...

  • Page 10: General Startup Precautions

    Commissioning Your Ultra3000 Drive General Startup These precautions apply to all of the procedures in this chapter. Be sure to read and thoroughly understand them before proceeding. Precautions This product contains stored energy devices. To avoid hazard of ATTENTION electrical shock, verify that all voltages on the system bus network have been discharged before attempting to service, repair, or remove this unit.

  • Page 11: Configuring Your Ultra3000 Drive And Ultra3000 Drive With Indexing

    Commissioning Your Ultra3000 Drive Configuring Your Ultra3000 The procedures in this section are listed in this table and apply to Ultra3000 drives and Ultra3000 drives with indexing. Drive and Ultra3000 Drive with Indexing Ultra3000 Drive Configuration Procedures Procedure Page Apply Power To Your Ultra3000 Drive Detect Your Ultra3000 Drive Understanding the Workspace and Drive Branches Select a Motor...
  • Page 12 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000 230V drives (3 kW). Front Panel Connections for 2098-DSD-030 and 2098-DSD-030X Drives 9-pin CN3 Seven-segment Serial Connector Status Indicator Passive Shunt Internal Logic Power Status Indicator Resistor Connections Pin 5 Pin 9...
  • Page 13 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000 230V drives (7.5 and 15 kW). Front Panel Connections for 2098-DSD-075, 2098-DSD-075X, 2098-DSD-150, and 2098-DSD-150X Drives 9-pin CN3 Serial Connector Seven-segment Status Indicator Pin 5 Passive Shunt Pin 9 Internal...
  • Page 14 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000 460V drives (3 W, 5 kW, 10 kW, 15 kW, and 22 kW). Front Panel Connections for 2098-DSD-HVxxx and 2098-DSD-HVxxxX Drives Seven-segment Status Indicator 9-pin CN3 Serial Connector Logic Power Status Indicator...

  • Page 15: Apply Power To Your Ultra3000 Drive

    Commissioning Your Ultra3000 Drive Apply 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. High voltage exists in ac line filters. The filter must be grounded ATTENTION properly before applying power.

  • Page 16: Detect Your Ultra3000 Drive

    Commissioning Your Ultra3000 Drive Detect Your Ultra3000 Drive This procedure assumes you have successfully applied power to your drive. These steps are designed to make sure that your Ultra3000 drive is communicating with your Ultraware software. Follow these steps to detect your Ultra3000 drive. 1.

  • Page 17: Understanding The Workspace And Drive Branches

    Commissioning Your Ultra3000 Drive Understanding the Workspace and Drive Branches This section provides a description of the Ultraware workspace and various drive branches. Click the [+] next to 3k Drive to expand the parameter group. Double-click the 3k Drive icon in the Ultraware workspace to display the various drive branches.
  • Page 18 Commissioning Your Ultra3000 Drive Motor Branch Use the Motor Branch to: • select a motor for the associated online or offline Ultra3000 drive. Once you select a motor, the status values associated with the selected motor appear in the Status pane of this dialog. •...
  • Page 19 Commissioning Your Ultra3000 Drive 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 dialogs where you can override the state of digital outputs and the relay.
  • Page 20 Commissioning Your Ultra3000 Drive Faults Branch Use the Faults Branch to: • set fault limits. • monitor fault status. • execute the Clear Faults command. • open a dialog where you can review the drive's fault history. • enable or disable faults. For more information on setting fault limits, refer to Appendix C, Minimizing the Effects of Feedback Signal Loss on page 141.

  • Page 21: Select A Motor

    Commissioning Your Ultra3000 Drive Select a Motor This procedure assumes you have power applied to your drive and the drive is detected by the Ultraware software. Refer to the Ultraware User Manual, publication 2098-UM001, for more information on selecting a motor. Follow these steps to select a motor.

  • Page 22: Tune Your Motor

    Commissioning Your Ultra3000 Drive Assign Digital Inputs Follow these steps to assign Digital Inputs 1 and 2. 1. Double-click the Digital Inputs branch. The Digital Inputs properties dialog opens. 2. Verify that Input 1 value is set to Drive Enable (this is default). To avoid fault action or damage to the drive due to ATTENTION improper sequencing of input power and the Drive Enable...

  • Page 23: Configure Displayed Units

    Commissioning Your Ultra3000 Drive 3. Apply 12…24V to input 1. Input 1 was configured as Drive Enable in a previous step (Drive Enabled light turns yellow). To avoid damage to the drive due to improper sequencing ATTENTION of input power and the Drive Enable signal, do not apply Drive Enable signal without first applying input power.
  • Page 24 Commissioning Your Ultra3000 Drive The Ultra3000 Drive properties dialog opens. 2. Click the Value field next to Display Units and choose User. 3. Click the [+] next to Motor Encoder Units. Use these parameter settings for an incremental encoder. To display velocity in rpm divide 8000 counts/rev by 60 seconds/ minute or 133.333.

  • Page 25: Test Your Motor (Non-Indexing Move)

    Commissioning Your Ultra3000 Drive Test 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.

  • Page 26: Test Your Motor (Indexing Move)

    Commissioning Your Ultra3000 Drive 7. Observe the Status table. • Drive Enable status = lamp is on (yellow) • Velocity - Motor Feedback status = the value you entered in step 5 8. Click Disable Drive. The motor stops. 9. Close the velocity control panel. The drive is software disabled and the enable icon in the toolbar is no longer illuminated.
  • Page 27 Commissioning Your Ultra3000 Drive The drive properties dialog opens. 2. Expand the Mode Configuration branch and double-click Indexing. The Indexing Setup dialog opens. 3. Expand Index 0 Setup. 4. Configure your incremental move with the following values for Index 0. •...
  • Page 28 Commissioning Your Ultra3000 Drive is 1024 ppr (pulses per revolution). However, the interpolation factor, as set in the Encoders tab of the Workspace, determines the counts per revolution. Default interpolation is x256 which totals 1024 x 256 or 262,144 counts per revolution. These settings may not be appropriate for your application.

  • Page 29: Indexing And Non-Indexing Move Examples

    Commissioning Your Ultra3000 Drive 8. Close the indexing control panel dialog. The drive is software disabled and the toolbar Enable icon is no longer on. 9. Close the Indexing mode dialog. Indexing and Non-indexing Move Examples This section provides examples of indexing and non-indexing moves you can make with your Ultra3000 drive by using Ultraware software.
  • Page 30 Commissioning Your Ultra3000 Drive 3. Close the Drive Branch dialog. 4. Expand the Mode Configuration branch and double-click Analog. The Analog Setup dialog opens. 5. In the Velocity Scale box, enter 300.0 and verify Velocity Offset is set to 0. 6.
  • Page 31 Commissioning Your Ultra3000 Drive 7. Double-click the Monitor branch. The (default) Drive Status parameters display. 8. Click Setup. The Monitor Setup dialog opens. 9. In the Monitor Setup dialog, check Velocity Signals. 10. Click OK. The Monitor Status dialog closes. 11.

  • Page 32: Analog Position Mode (Non-Indexing)

    Commissioning Your Ultra3000 Drive Analog Position Mode (non-indexing) 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 Position mode.
  • Page 33 Commissioning Your Ultra3000 Drive 6. Double-click the Digital Inputs branch. a. Verify that Input 1 is configured as Drive Enable input (factory default). b. Verify that Input 2 is configured as the Fault Reset input. If more digital inputs are required for an application than are available in Ultraware software, you can combine inputs for multiple assignments.

  • Page 34: Preset Velocity Control (Non-Indexing)

    Commissioning Your Ultra3000 Drive 8. Click Setup. The Monitor Setup dialog opens. 9. In the Monitor Setup dialog, check Position Signals. 10. Click OK. The Monitor Status dialog closes. 11. Apply 12…24V dc to input 1. Input 1 was configured as Drive Enable in a previous step. Make sure the Enable icon in the toolbar is active.
  • Page 35 Commissioning Your Ultra3000 Drive 3. Click the current setting and use the pull-down menu to change the Operation Mode to Preset Velocity. 4. Close the Drive Branch dialog. 5. Expand the Mode Configuration branch and double-click Preset. The Preset setup dialog opens. 6.
  • Page 36 Commissioning Your Ultra3000 Drive 11. Using this table, determine the sequence of these three inputs that correspond to the preset velocity entered. Binary Code Preset Selects Selected Preset or Index Preset 0 or Index 0 is selected. Preset 1 or Index 1 is selected. Preset 2 or Index 2 is selected.

  • Page 37: Preset Position Control (Indexing Move)

    Commissioning Your Ultra3000 Drive 14. Click Setup. The Monitor Setup dialog opens. 15. In the Monitor Setup dialog, check Velocity Signals. 16. Click OK. The Monitor Status dialog closes and the setup changes take affect. 17. Observe that Velocity - Command matches what was entered in Preset Velocity 0.
  • Page 38 Commissioning Your Ultra3000 Drive 3. Click the current setting and use the pull-down menu to change the Operation Mode to Preset Position. 4. Close the Drive Branch dialog. 5. Expand the Mode Configuration branch and double-click Preset. The Preset setup dialog opens. 6.
  • Page 39 Commissioning Your Ultra3000 Drive 9. Using this table, determine the sequence of these three inputs that correspond to the preset positions entered. Binary Code Preset Selects Selected Preset or Index Preset 0 or Index 0 is selected. Preset 1 or Index 1 is selected. Preset 2 or Index 2 is selected.

  • Page 40: Master Follower And Preset Gear Ratios (Non-Indexing Move)

    Commissioning Your Ultra3000 Drive 12. In the Monitor Setup dialog, check Position Signals. 13. Click OK. The Monitor Status dialog closes and the setup changes take affect. 14. Apply 12…24V dc to input 1. Input 1 was configured as Drive Enable in a previous step. a.
  • Page 41 Commissioning Your Ultra3000 Drive 3. Click the current setting and use the pull-down menu to change the Operation Mode to Follower: Auxiliary Encoder. 4. Close the Drive Branch dialog. 5. Expand the Mode Configuration branch. 6. Double-click Follower. 7. Enter the Gear Ratio preset values as shown in the table below or according to your specific application.
  • Page 42 Commissioning Your Ultra3000 Drive 11. Using this table, determine the sequence of these three inputs that correspond to the preset gear ratios entered. Binary Code Preset Selects Selected Preset or Index Preset 0 or Index 0 is selected. Preset 1 or Index 1 is selected. Preset 2 or Index 2 is selected.
  • Page 43 Commissioning Your Ultra3000 Drive 15. Click OK. The Monitor Status dialog closes and the setup changes take affect. 16. Apply 12…24V dc to input 1. Input 1 was configured as Drive Enable in a previous step. a. Verify the toolbar Enable icon is active, indicating the drive is enabled.

  • Page 44: Incremental Indexing (Indexing Move)

    Commissioning Your Ultra3000 Drive 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.
  • Page 45 Commissioning Your Ultra3000 Drive 10. Use the pull-down menu to change the input values. 11. Close the Digital Inputs dialog. 12. Double-click the Digital Outputs branch. 13. Use the pull-down menu to change the output values. 14. Close the Digital Outputs dialog. Publication 2098-IN005C-EN-P —...
  • Page 46 Commissioning Your Ultra3000 Drive Follow these steps to verify the number of indexing moves by using drive signals. 1. Double-click the Monitor branch. 2. Click Setup. 3. Expand the Mode Configuration branch/the Indexing branch/and check Batch Count. 4. Click OK. 5.
  • Page 47 Commissioning Your Ultra3000 Drive Follow these steps 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.

  • Page 48: Absolute Indexing (Indexing Move)

    Commissioning Your Ultra3000 Drive 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.
  • Page 49 Commissioning Your Ultra3000 Drive 8. Enter the Index 1 parameter values as shown in the table below. 9. Close the Indexing Parameters dialog. 10. Expand the Mode Configuration branch. 11. Double-click Homing. 12. Enter the Homing parameter values as shown in the table below. 13.
  • Page 50 Commissioning Your Ultra3000 Drive Follow these steps to use digital outputs to indicate an event has occurred. 1. Double-click the Digital Outputs branch. 2. Use the pull-down menu to change the output values. 3. Close the Digital Outputs dialog. 4. Apply 12…24V dc to input 1. Input 1 was configured as Drive Enable in a previous step.
  • Page 51 Commissioning Your Ultra3000 Drive 11. Turn off input 5. 12. Apply 12…24V dc to input 4 (momentarily again) to restart the indexing move. 13. Turn off input 4. 14. Apply 12…24V dc to input 7 to pause the indexing move. 15.

  • Page 52: Configuring Your Ultra3000 Drive With

    Commissioning Your Ultra3000 Drive Configuring Your Ultra3000 In this section you will configure your Ultra3000 drive by using Ultraware software, configure the Logix analog motion module by Drive with RSLogix 5000 using RSLogix 5000 software, and test/tune your axis. Software Configure Your Ultra3000 Drive Follow these steps to configure your Ultra3000 drive.

  • Page 53: Configuring Your Logix Analog Motion Module

    Commissioning Your Ultra3000 Drive Configuring Your Logix Analog Motion Module This procedure assumes that you have finished configuring your Ultra3000 drive. For help using RSLogix 5000 software as it applies to configuring the Logix analog modules, refer to Additional Resources on page 8. Configure Your Logix Controller Follow these steps to configure your Logix controller.
  • Page 54 Commissioning Your Ultra3000 Drive The Controller Properties dialog opens. 6. Click the Date/Time tab. 7. Check the Make this controller the Coordinated System Time master checkbox. Only one Logix processor can be assigned as the IMPORTANT Coordinated System Time master. 8.
  • Page 55 Commissioning Your Ultra3000 Drive Configure Your Logix Module Follow these steps to configure your Logix module. 1. In the Explorer dialog, right-click I/O Configuration and choose New Module. The Select Module dialog opens. 2. Expand the Motion category and select 1756-M02AE, 1756-HYD02, 1756-M02AS, or 1784-PM02AE as appropriate for your actual hardware configuration.
  • Page 56 Commissioning Your Ultra3000 Drive 6. Click the Associated Axes tab. 7. Click New Axis. The New Tag dialog opens. 8. Configure the new tag. a. In the Name box, enter your axis name. b. From the Data Type pull-down menu, choose AXIS_SERVO. 9.
  • Page 57 Commissioning Your Ultra3000 Drive Configure the Motion Group Follow these steps to configure the motion group. 1. In the Explorer dialog, right-click Motion Groups and choose New Motion Group. The New Tag dialog opens. 2. In the Name box, enter your motion group name. 3.

  • Page 58: Download Your Program

    Commissioning Your Ultra3000 Drive Configure Axis Properties Follow these steps to configure axis properties. 1. In the Explorer dialog, right-click an axis and choose Properties. The Axis Properties dialog opens. 2. Click the Servo tab. a. From the External Drive Configuration pull-down menu choose Torque.

  • Page 59: Testing And Tuning Your Axis

    Commissioning Your Ultra3000 Drive Testing and Tuning Your Axis This procedure assumes that you have configured your Ultra3000 drive and the analog motion module. Before proceeding with testing and tuning your axis, verify that IMPORTANT the seven-segment status indicator is actively cycling in a full circle.
  • Page 60 Commissioning Your Ultra3000 Drive 4. In the Test Increment box, enter 2.0 as the number of revolutions for the test (or another number more appropriate for your application). Test Description Verifies marker detection capability as you rotate the Test Marker motor shaft.
  • Page 61 Commissioning Your Ultra3000 Drive 9. Determine if your test completed successfully. Then Your test completes successfully, this dialog appears. 1. Click OK. 2. Remove Drive Enable signal (CN1-31). 3. Go to Tune Your Axis. Your test failed, this dialog appears. 1.
  • Page 62 Commissioning Your Ultra3000 Drive Tune Your Axis Follow these steps to tune your axis. 1. Verify that the load is still removed from the axis being tuned. To reduce the possibility of unpredictable motor response, ATTENTION tune your motor with the load removed first, then reattach the load and perform the tuning procedure again to provide an accurate operational response.
  • Page 63 Commissioning Your Ultra3000 Drive 7. Click Start Tuning to auto-tune your axis. The Online Command - Tune Servo dialog opens. When the test completes, the Command Status changes from Executing to Command Complete. 8. Click OK. The Tune Bandwidth dialog opens. Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.
  • Page 64 Commissioning Your Ultra3000 Drive Then Your test completes successfully, this dialog appears. 1. Click OK. 2. Remove Drive Enable (Input 1) signal (CN1-31) applied earlier. 3. You are finished tuning your Ultra3000 drive. Your test failed, this dialog appears. 1. Click OK. 2.

  • Page 65: Configuring Your Ultra3000 Drive With Sercos

    Commissioning Your Ultra3000 Drive Configuring Your Ultra3000 The procedures in this section are listed in this table and apply to Ultra3000-SE drives with SERCOS interface. Drive with SERCOS Ultra3000 Drive Configuration Procedures Procedure Page Configure Your Ultra3000-SE Drive Configuring Your Logix SERCOS interface Module Download Your Program Apply Power to Your Ultra3000 Drive with SERCOS Testing and Tuning Your Axis...
  • Page 66 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-SE 230V drives (500W, 1 kW, and 2 kW). Front Panel Connections for 2098-DSD-005-SE, 2098-DSD-010-SE, and 2098-DSD-020-SE Drives 9-pin CN3 Serial Connector Module Status Indicator Seven-segment Pin 5 Pin 9...
  • Page 67 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-SE 230V drive (3 kW). Front Panel Connections for 2098-DSD-030-SE Drive 9-pin CN3 Seven-segment Serial Connector Status Indicator Passive Shunt Internal Logic Power Status Indicator Resistor Connections Pin 5 Pin 9...
  • Page 68 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-SE 230V drives (7.5 and 15 kW). Front Panel Connections for 2098-DSD-075-SE and 2098-DSD-150-SE Drives 9-pin CN3 Seven-segment Serial Connector Status Indicator Passive Shunt Internal Logic Power Status Indicator Pin 5 Resistor Connections...
  • Page 69 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-SE 460V drives (3 kW, 5 kW, 10 kW, 15 kW, and 22 kW). Front Panel Connections for 2098-DSD-HVxxx-SE Drives Seven-segment Status Indicator 9-pin CN3 Serial Connector Logic Power Status Indicator Module Status Indicator...

  • Page 70: Configure Your Ultra3000-Se Drive

    Commissioning Your Ultra3000 Drive Configure Your Ultra3000-SE Drive Follow these steps to configure your Ultra3000-SE drive. 1. Verify that there is no power applied to the drive and that the SERCOS fiber-optic cables are correctly plugged into the Tx and Rx connectors.
  • Page 71 Commissioning Your Ultra3000 Drive 5. If using Overtravel inputs, verify that 12…24V dc is tied to CN1-37 and CN1-38. Without CN1-37 and CN1-38 inputs applied, the drive/ IMPORTANT system will fault. Fiber-optic Ring Connections Logix Platform (SoftLogix 1784-PM16SE SERCOS PCI Card is shown) Transmit Receive SERCOS Fiber-optic Ring...

  • Page 72: Configuring Your Logix Sercos Interface Module

    Commissioning Your Ultra3000 Drive Configuring Your Logix SERCOS interface Module This procedure assumes that you have configured the Ultra3000-SE communication rate. In order for the Ultra3000 drive to communicate with the IMPORTANT SERCOS interface module (indicated by the three status indicators on the module going solid green), your RSLogix 5000 software must be version 11.0 or later.
  • Page 73 Commissioning Your Ultra3000 Drive 4. Click OK. 5. From the Edit menu, choose Controller Properties. The Controller Properties dialog opens. 6. Click the Date/Time tab. 7. Check the Make this controller the Coordinated System Time master checkbox. Only one Logix processor can be assigned as the IMPORTANT Coordinated System Time master.
  • Page 74 Commissioning Your Ultra3000 Drive The New Module dialog opens. 4. Configure the new module. a. In the Name box, name your file. b. In the Slot box, enter the slot where your module resides. c. From the Electronic Keying pull-down menu, choose an electronic keying option (choose Disable Keying if unsure).
  • Page 75 Commissioning Your Ultra3000 Drive 7. Verify that the Data Rate setting matches the Data Rate (communication rate) switch setting on the Ultra3000-SE drive. 8. Set the Cycle Time according to this table. Data Rate Number of Axes Cycle Time Up to 4 1 ms 4 Mbps Up to 8...
  • Page 76 Commissioning Your Ultra3000 Drive The New Module dialog opens. 4. Configure the new module. a. In the Name box, enter your module name. b. In the Node box, enter the node address. Set the node address in the software to match the node address setting on the drive.
  • Page 77 Commissioning Your Ultra3000 Drive The New Tag dialog opens. 8. Configure the new tag. a. In the Name box, enter your module name. b. In the Data Type pull-down menu, choose AXIS_SERVO_DRIVE. 9. Click OK. The axis appears under the Ungrouped Axes folder in the Explorer dialog.
  • Page 78 Commissioning Your Ultra3000 Drive Configure the Motion Group Follow these steps to configure the motion group. 1. In the Explorer dialog, right-click Motion Groups and choose New Motion Group. The New Tag dialog opens. 2. In the Name box, enter the new motion group name. 3.
  • Page 79 Commissioning Your Ultra3000 Drive Configure Axis Properties Follow these steps to configure axis properties. 1. In the Explorer dialog, right-click an axis and choose Properties. The Axis Properties dialog opens. 2. Click the Drive/Motor tab. a. From the Amplifier Catalog Number pull-down menu, choose the Ultra3000 amplifier (2098-DSD-xxx-SE or 2098-DSD-HVxxx-SE).

  • Page 80: Download Your Program

    Commissioning Your Ultra3000 Drive 6. Click the Fault Actions tab. For more information on setting fault limits, refer to Appendix C, Minimizing the Effects of Feedback Signal Loss on page 141. 7. Click the Set Custom Stop Action. The Custom Stop Action Attributes dialog opens. 8.

  • Page 81: Apply Power To Your Ultra3000 Drive With Sercos

    Commissioning Your Ultra3000 Drive Apply Power to Your Ultra3000 Drive with SERCOS This procedure assumes that you have configured your Ultra3000-SE drive and your SERCOS interface module. High voltage exists in ac line filters. The filter must be grounded ATTENTION properly before applying power.
  • Page 82 Commissioning Your Ultra3000 Drive The status indicator cycles through SERCOS phases until final configuration (phase 4) is reached. Seven-segment Status Indicator Status Do This The drive is looking for a closed SERCOS ring. Wait for Actively cycling (phase 0) Check fiber-optic connections. phase 1 or take corrective action until you reach phase 1.

  • Page 83: Testing And Tuning Your Axis

    Commissioning Your Ultra3000 Drive Testing and Tuning Your Axis This procedure assumes that you have configured your Ultra3000-SE drive, your SERCOS interface module, and applied power to the system. Before proceeding with testing and tuning your axis, verify that IMPORTANT the Ultra3000-SE status indicators are as described in this table.
  • Page 84 Commissioning Your Ultra3000 Drive 4. In the Test Increment box, enter 2.0 as the number of revolutions for the test (or another number more appropriate for your application). Test Description Verifies marker detection capability as you rotate the Test Marker motor shaft.
  • Page 85 Commissioning Your Ultra3000 Drive 8. Click OK. 9. Determine if your test completed successfully. Then Your test completes successfully, this dialog appears. 1. Click OK. 2. Remove Drive Enable signal (CN1-31). 3. Go to Tune Your Axis on page 86. Your test failed, this dialog appears.
  • Page 86 Commissioning Your Ultra3000 Drive Tune Your Axis Follow these steps to tune your axis. 1. Verify that the load is still removed from the axis being tuned. To reduce the possibility of unpredictable motor response, ATTENTION tune your motor with the load removed first, then reattach the load and perform the tuning procedure again to provide an accurate operational response.
  • Page 87 Commissioning Your Ultra3000 Drive 7. Click Start Tuning to auto-tune your axis. The Online Command - Tune Servo dialog opens. When the test completes, the Command Status changes from Executing to Command Complete. 8. Click OK. The Tune Bandwidth dialog opens. Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.
  • Page 88 Commissioning Your Ultra3000 Drive Then Your test completes successfully, this dialog appears. 1. Click OK. 2. Remove Drive Enable (Input 1) signal (CN1-31) applied earlier. 3. You are finished tuning your axis. Your test failed, this dialog appears. 1. Click OK. 2.

  • Page 89: Configuring Your Ultra3000 Drive With Devicenet

    Commissioning Your Ultra3000 Drive Configuring Your Ultra3000 The procedures in this section are listed in this table and apply to Ultra3000-DN drives with indexing. Drive with DeviceNet Ultra3000 Drive Configuration Procedures Procedure Page Configure Your Ultra3000 Drive with DeviceNet Apply Power to Your Ultra3000 Drive with DeviceNet These procedures assume you have completed wiring the DeviceNet interface connector on your Ultra3000-DN drive.
  • Page 90 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-DN 230V drives (3 kW). Front Panel Connections for 2098-DSD-030-DN and 2098-DSD-030X-DN Drives 9-pin CN3 Seven-segment Serial Connector Status Indicator Passive Shunt Internal Logic Power Indicator Resistor Connections Pin 5 External...
  • Page 91 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-DN 230V drives (7.5 and 15 kW). Front Panel Connections for 2098-DSD-075-DN, 2098-DSD-075X-DN, 2098-DSD-150-DN, and 2098-DSD-150X-DN Drives 9-pin CN3 Serial Connector Seven-segment Status Indicator Passive Shunt Internal Logic Power Indicator Pin 5...
  • Page 92 Commissioning Your Ultra3000 Drive Use this figure to locate the front panel connections on the Ultra3000-DN 460V drives (3 kW, 5 kW, 10 kW, 15 kW, and 22 kW). Front Panel Connections for 2098-DSD-HVxxx-DN and 2098-DSD-HVxxxX-DN Drives Seven-segment 9-pin CN3 Status Indicator Serial Connector Logic Power Indicator...

  • Page 93: Configure Your Ultra3000 Drive With Devicenet

    Commissioning Your Ultra3000 Drive Configure Your Ultra3000 Drive with DeviceNet Follow these steps to configure your Ultra3000-DN drive. 1. Verify that there is no power applied to the drive and that the DeviceNet cable is connected. Refer to the figures on pages 89…92 for switch locations. 2.

  • Page 94: Apply Power To Your Ultra3000 Drive With Devicenet

    Commissioning Your Ultra3000 Drive Apply Power to Your Ultra3000 Drive with DeviceNet This procedure assumes you have wired your Ultra3000-DN system, verified the wiring, and are ready to begin using Ultraware software. High voltage exists in ac line filters. The filter must be grounded ATTENTION properly before applying power.
  • Page 95 Commissioning Your Ultra3000 Drive 4. Observe the module status indicator. Module Status Indicator Status Do This Steady green The drive is ready. Go to step 5. Go to DeviceNet Module Status Not steady green The drive is faulted. Indicator on page 109. 5.
  • Page 96 Commissioning Your Ultra3000 Drive Publication 2098-IN005C-EN-P — March 2008...

  • Page 97: Troubleshooting Your Ultra3000 Servo Drive

    Chapter Troubleshooting Your Ultra3000 Servo Drive Introduction This chapter provides troubleshooting tables for your Ultra3000 servo drive. Topic Page Safety Precautions General Troubleshooting Troubleshooting for SERCOS Drives Troubleshooting for DeviceNet Drives Safety Precautions Observe the following safety precautions when troubleshooting your Ultra3000 servo drive.

  • Page 98: 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 Rockwell Automation sales representative for further assistance. Determine Ultra3000 Drive Status Ultra3000 Drives with the...
  • Page 99 Troubleshooting Your Ultra3000 Servo Drive Error Problem or Symptom Possible Cause Action/Solution Code The velocity command or feedback exceeds half the machine cycle length per Increase machine cycle size or reduce Velocity Exceeds Position Rollover /2 millisecond (applies only when the velocity profile.
  • Page 100 Troubleshooting Your Ultra3000 Servo Drive Error Problem or Symptom Possible Cause Action/Solution Code • Change the deceleration or motion Excessive regeneration of power. profile. • Use a larger system (motor and When the motor is driven by an external Ultra3000). mechanical power source, it may Bus Overvoltage regenerate too much peak energy through...
  • Page 101 Troubleshooting Your Ultra3000 Servo Drive Error Problem or Symptom Possible Cause Action/Solution Code • 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 The motor encoder encountered an illegal CN1 cable.
  • Page 102 Troubleshooting Your Ultra3000 Servo Drive Error Problem or Symptom Possible Cause Action/Solution Code • Select a different motor through the Parameter loaded from smart encoder or SERCOS controller. Motor Parameter Error received from SERCOS controller is • Select a different motor. incompatible with the drive.
  • Page 103 Troubleshooting Your Ultra3000 Servo Drive Error Problem or Symptom Possible Cause Action/Solution Code • Verify that there are no impediments to motion at startup, such as hard limits. • Increase self-sensing current if high Motion required for self-sensing startup Self-sensing Commutation Startup Error commutation was obstructed.

  • Page 104: Troubleshooting For Sercos Drives

    Troubleshooting Your Ultra3000 Servo Drive Troubleshooting for These troubleshooting tables apply to Ultra3000-SE drives (2098-DSD-xxx-SE and 2098-DSD-HVxxx-SE). SERCOS Drives SERCOS Module Status Indicator SERCOS Module Status Potential Cause Possible Resolution Status Indicator Steady green Normal Drive is enabled. Normal operation when drive is enabled. Flashing green Standby Drive is not enabled.

  • Page 105: Understanding Drive Fault Behavior

    Troubleshooting Your Ultra3000 Servo Drive Understanding Drive Fault Behavior The following RSLogix 5000 fault actions are configurable from the Axis Properties dialog, Fault Actions tab. RSLogix 5000 Drive Fault Action Definitions Drive Fault Action Definition The drive disables and the contactor enable relay opens. Uncontrolled stop, Shutdown motor coasts to a stop.
  • Page 106 Troubleshooting Your Ultra3000 Servo Drive When a fault is detected, the seven-segment status indicator displays E followed by the flashing two-digit error code, one digit at a time. This is repeated until the fault is cleared. Drive Fault Behavior Software Fault Message RSLogix 5000 Error Drive Fault...
  • Page 107 Troubleshooting Your Ultra3000 Servo Drive Software Fault Message RSLogix 5000 Error Drive Fault Description Programmable RSLogix 5000 Code Action/Attribute Fault Action? (Ultraware) DriveHardFault User-specified average current level has been exceeded. DISABLE (User-specified Current Fault) OverspeedFault Motor speed has exceeded 125% of maximum rated speed. DISABLE (Overspeed Fault) PositionErrorFault...
  • Page 108 Troubleshooting Your Ultra3000 Servo Drive Software Fault Message RSLogix 5000 Error Drive Fault Description Programmable RSLogix 5000 Code Action/Attribute Fault Action? (Ultraware) DriveHardFault The converter pre-charge cycle has failed. DISABLE (Precharge Fault) DriveHardFault Excessive heat exists in the power circuitry. DISABLE (Power Circuitry Overtemperature)

  • Page 109: Troubleshooting For Devicenet Drives

    Troubleshooting Your Ultra3000 Servo Drive Troubleshooting for These troubleshooting tables apply to Ultra3000-DN drives (2098-DSD-xxx-DN, 2098-DSD-xxxX-DN, 2098-DSD-HVxxx-DN, or DeviceNet Drives 2098-DSD-HVxxxX-DN). DeviceNet Module Status Indicator Module Status Status Potential Cause Possible Resolution Indicator Not powered No power There is no power going to the device. Steady-green Operational Normal operation...

  • Page 110: Node Problems

    Troubleshooting Your Ultra3000 Servo Drive 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.

  • Page 111: Scanner Problems

    Troubleshooting Your Ultra3000 Servo Drive 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 these issues.

  • Page 112: Cable Installation And Design Problems

    Troubleshooting Your Ultra3000 Servo Drive 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. Make sure you have a diagram of the physical layout and a record of the information in these tables.

  • Page 113: Interconnect Diagrams

    Appendix Interconnect Diagrams Introduction This appendix provides you with interconnect diagrams for your Ultra3000 servo drive. Topic Page Introduction Wiring Examples Power Interconnect Diagrams Shunt Module Interconnect Diagrams Ultra3000 Drives/Rotary Motors and Actuators Wiring Examples Ultra3000 Drives/Linear Actuators Wiring Examples Control String Examples (120V ac) Controlling a Brake Example Ultra3000 Drive to Logix Analog Module Diagrams...

  • Page 114: Wiring Examples

    Interconnect Diagrams Wiring Examples This appendix provides wiring examples to assist you in wiring the Ultra3000 drive system. The notes in this table apply to the power, shunt, motor, actuator, and control string interconnect diagrams. The National Electrical Code and local electrical codes ATTENTION take precedence over the values and methods provided.

  • Page 115: Power Interconnect Diagrams

    Interconnect Diagrams Power Interconnect Diagrams This is the power wiring diagram with 24V dc control string for 2098-DSD-005x-xx, 2098-DSD-010x-xx, and 2098-DSD-020x-xx Ultra3000 drives (non-SERCOS drives only). To avoid a separate 5V dc auxiliary logic power supply, the 24V to 5V converter breakout board (catalog number 2090-U3CBB-DMxx) is used to wire the control interface (CN1) connector.
  • Page 116 Interconnect Diagrams This is the power wiring diagram with 24V dc control string for the 2098-DSD-030x-xx drive (non-SERCOS drives only). For the control string diagram with 120V ac input refer to the figure on page 129. For SERCOS drives, input line contactor is part of the PLC program and output control.
  • Page 117 Interconnect Diagrams This is the power wiring diagram with 24V dc control string for 2098-DSD-075x-xx and 2098-DSD-150x-xx Ultra3000 drives (non-SERCOS drives only). For the control string diagram with 120V ac input refer to the figure on page 130. For SERCOS drives, input line contactor is part of the PLC program and output control.
  • Page 118 Interconnect Diagrams This is the power wiring diagram with 24V dc control string for 2098-DSD-HVxxx-xx and 2098-DSD-HVxxxX-xx Ultra3000 drives. For the control string diagram with 120V ac input refer to the figure on page 130. Typical Power Wiring of Ultra3000 (460V) System 2098-DSD-HVxxx-xx and 2098-DSD-HVxxxX-xx Ultra3000...

  • Page 119: Shunt Module Interconnect Diagrams

    Interconnect Diagrams Shunt Module Interconnect Diagrams This section contains the interconnect diagrams for Ultra3000 drives with active and passive shunt modules. External Active Shunt Module Interconnect Diagram 2098-DSD-005x-xx, 2090-UCSR-A300 2098-DSD-010x-xx, and External Active 2098-DSD-020x-xx Shunt Module Ultra3000 Digital Servo Drives DC Bus Connections for Active Shunt Module AC Input Power...
  • Page 120 Interconnect Diagrams External Passive Shunt (single-shunt) Diagram 2098-DSD-030x-xx, 2098-DSD-075x-xx, 2098-DSD-150x-xx, 2098-DSD-HVxxx-xx, and 2098-DSD-HVxxxX-xx Ultra3000 Digital Servo Drives External Passive Shunt Module External Passive Shunt Resistor Connections In this figure, the 2098-DSD-150x-xx Ultra3000 drive is wired with two external passive shunt resistors. When two 900 W shunt modules are connected in parallel, the shunt capacity is doubled for a total of 1800 W of continuous power dissipation.
  • Page 121 Interconnect Diagrams In this figure, the 2098-DSD-HV150x-xx or 2098-DSD-HV220x-xx Ultra3000 drive is wired to a Bonitron shunt module. External Passive Shunt (Bonitron shunt) Diagram 2098-DSD-HV150x-xx 2098-DSD-HV220x-xx Ultra3000 Digital Servo Drives External Passive Shunt Resistor Connections Shunt Wiring Methods: Twisted pair in conduit (1st choice). Shielded twisted pair (2nd choice).

  • Page 122: Ultra3000 Drives/Rotary Motors And Actuators Wiring Examples

    Interconnect Diagrams Ultra3000 Drives/Rotary Motors and Actuators Wiring Examples Wiring Examples with MPL-A and MPG-A (MP-Series) Motors/Actuators 2090-XXNPMP-xxSxx MPL-A3xx…MPL-A5xx, Motor Power Cable and MPG-Axxx Note 12 (230V) Servo Motors with High Resolution Feedback Motor Feedback Green/Yellow Ultra3000 230V Drive (CN2) Connector Note 13 Blue Black...
  • Page 123 Interconnect Diagrams Wiring Examples with MPL-B, MPG-B, and 1326AB Motors/Actuators MPL-B3xx…MPL-B9xx, 2090-XXNPMP-xxSxx MPG-Bxx, or 1326AB (M2L/S2L) Motor Power Cable (460V) Servo Motors with Note 12 High Resolution Feedback Motor Feedback Green/Yellow Ultra3000 460V Drive (CN2) Connector Note 14 Blue Black Three-phase SIN+ Brown...
  • Page 124 Interconnect Diagrams Wiring Examples with MPL-A/B, MPF-A/B, and MPS-A/B (MP-Series) Motors MPL-A/B15xx and MPL-A/B2xx, 2090-XXNPMF-xxSxx MPF-A/Bxxx and MPS-A/Bxxx Motor Power Cable Servo Motors with Note 12, 16, 20 High Resolution Feedback Motor Feedback Green/Yellow Ultra3000 Drive (CN2) Connector Notes 13, 14 Blue Black Three-phase...
  • Page 125 Interconnect Diagrams Wiring Example with TLY-A (TL-Series) Motors Ultra3000 (230V) Drive TLY-Axxxx-H (230V) Note 13 Servo Motors with Motor Feedback Incremental Feedback (CN2) Connector Green/Yellow BLACK Blue WHT/BLACK Motor Power Black (TB1) Connector Three-phase WHT/RED Brown Motor Power 2090-CPBM6DF-16AAxx GREEN Motor Feedback Motor Power Cable WHT/GREEN...
  • Page 126 Interconnect Diagrams Wiring Examples with F-Series (230V) Motors 2090-XXNPHF-xxSxx or 2090-UXNPAHF-xxSxx F-Series (230V) Motor Power Cable Note 12 Servo Motors with Incremental Feedback Motor Feedback Green/Yellow Ultra3000 230V Drive (CN2) Connector Note 13 Blue Black Three-phase Brown Motor Power BLACK Motor Feedback WHT/BLACK (15-pin) Connector...

  • Page 127: Ultra3000 Drives/Linear Actuators Wiring Examples

    Interconnect Diagrams Ultra3000 Drives/Linear Actuators Wiring Examples Wiring Example with MPAS-A/B (MP-Series) Linear Stages MPAS-A/Bxxxxx-VxxSxA 2090-XXNPMF-xxSxx Ballscrew Linear Stages Motor Power Cable with Note 12, 16 High Resolution Feedback Motor Feedback Green/Yellow Ultra3000 Drive (CN2) Connector Notes 13, 14 Blue Black Three-phase SIN+...

  • Page 128: Control String Examples (120V Ac)

    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. In this example, the 2098-DSD-005x-xx, 2098-DSD-010x-xx, or 2098-DSD-020x-xx Ultra3000 drive is wired to the 120V ac control string.
  • Page 129 Interconnect Diagrams In this example, the 2098-DSD-030x-xx Ultra3000 drive is wired to the 120V ac control string. Implementation of safety circuits and risk assessment is the ATTENTION responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories.
  • Page 130 Interconnect Diagrams In this example, the 2098-DSD-075x-xx, 2098-DSD-150x-xx, 2098-DSD-HVxxx-xx, and 2098-DSD-HVxxxX-xx Ultra3000 drive is wired to the 120V ac control string. Implementation of safety circuits and risk assessment is the ATTENTION responsibility of the machine builder. Please reference international standards EN1050 and EN954 estimation and safety performance categories.

  • Page 131: Controlling A Brake Example

    Interconnect Diagrams Controlling a Brake The relay output of the Ultra3000 drive (pins CN1-43 and CN1-44) is suitable for directly controlling a motor brake, subject to the relay Example voltage limit of 30V dc, and the relay current limit of 1 A dc. For brake requirements outside of these limits, an external relay must be used.
  • Page 132 Interconnect Diagrams A separate power source is required to disengage the brake. Removing power causes the brake to engage, but may also cause electrical arcing to occur at the relay contacts until the brake power dissipates. A customer-supplied diode or metal oxide varistor (MOV) is recommended to prevent arcing.

  • Page 133: Ultra3000 Drive To Logix Analog Module Diagrams

    Interconnect Diagrams Ultra3000 Drive to Logix This section provides information to assist you in wiring the Ultra3000 drive CN1 (44-pin) cable connector with either the ControlLogix Analog Module Diagrams 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.
  • Page 134 Interconnect Diagrams Ultra3000 Drive to ControlLogix Servo Module Interconnect Diagram WHT/ORG 22GA RELAY + RELAY + WHT/ORG 22GA WHT/YEL 22GA RELAY - RELAY - RELAY WHT/YEL 22GA RELAY DRAIN (user configured) (user configured) DRAIN IO PWR WHT/RED 22GA IO PWR WHT/RED 22GA WHT/BLACK 22GA IO COM...
  • Page 135 Interconnect Diagrams Ultra3000 Drive to SoftLogix PCI Card Interconnect Diagram WHT/ORG 22GA RELAY + RELAY + WHT/ORG 22GA WHT/YEL 22GA RELAY - RELAY - RELAY WHT/YEL 22GA RELAY DRAIN DRAIN (user configured) (user configured) IO PWR WHT/RED 22GA IO PWR WHT/RED 22GA WHT/BLACK 22GA IO COM...

  • Page 136: Ultra3000 Drive To Imc-S Compact Controller Diagram

    Interconnect Diagrams Ultra3000 Drive to IMC-S This section provides information to assist you in wiring the IMC-S/23x-xx Compact Controller when connecting the 4100-CCS15F Compact Controller feedback cable and 4100-CCA15F I/O cable to your Ultra3000 drive. Diagram Ultra3000 Drive to IMC-S/23x-xx Compact Controller Configuration Ultra3000 Drive 44-pin Breakout Board IMC S Class Compact Controller...

  • Page 137: Understanding Motor Feedback Signals And Outputs

    Appendix Understanding Motor Feedback Signals and Outputs Introduction This appendix provides you with motor encoder input signal information and drive encoder output information specific to the Ultra3000 servo drives. Topic Page Introduction Unbuffered Encoder Outputs Incremental Encoder Outputs High Resolution Encoder Outputs The Ultra3000 drive is compatible with motors equipped with both incremental A quad B or high resolution (Stegmann Hiperface) SIN/COS encoders.

  • Page 138: Unbuffered Encoder Outputs

    Understanding Motor Feedback Signals and Outputs Unbuffered Encoder The unbuffered outputs available from the drive (CN1-10 through CN1-15) are tied directly to the incoming (incremental or high Outputs resolution) encoder signals (CN2-1 through CN2-6). The unbuffered outputs are not filtered or conditioned. Incremental Encoder 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...

  • Page 139: High Resolution Encoder Outputs

    Understanding Motor Feedback Signals and Outputs High Resolution Encoder When the incoming encoder feedback on CN2 is a high resolution (SIN/COS) signal, the drive is capable of generating more than just 4 Outputs 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.
  • Page 140 Understanding Motor Feedback Signals and Outputs Interpolated and Divided Absolute High Resolution Encoder Counts Cycle CN1-10 (SIN/AM+) Unbuffered encoder feedback signal to drive, 1024 cycles/rev. Voltage CN1-12 (COS/BM+) Unbuffered encoder feedback signal to drive, 1024 cycles/rev. CN1-16 (SIN/AMOUT+) x8 Interpolated output from drive Voltage CN1-18 (COS/BMOUT+) x8 Interpolated...

  • Page 141: Minimizing The Effects Of Feedback Signal Loss

    Appendix Minimizing the Effects of Feedback Signal Loss Introduction This appendix contains information on how to reduce unexpected motion as a result of feedback signal loss. Topic Page Introduction Setting Position Error Limits in Ultraware and RSLogix 5000 Software Setting Velocity Error Limits in Ultraware Software Configuring Fault Actions in RSLogix 5000 Software Position and Velocity Error Limit Adjustment Example with Ultraware Software Position Error Limit Adjustment Example with RSLogix 5000 Software...

  • Page 142: Rslogix 5000 Software

    Minimizing the Effects of Feedback Signal Loss Setting Position Error Parameters for setting the position and velocity error limits according to the specific needs of the user application exist in both the Limits in Ultraware and Ultraware and the RSLogix 5000 software. Adjust these limit settings to RSLogix 5000 Software be as close to the maximum position and velocity error excursion limit values of the application as possible, but wide enough to avoid...
  • Page 143 Minimizing the Effects of Feedback Signal Loss units by using the Conversion ratio constant found in the Conversion tab of the Axis Properties dialog. The Position Error Tolerance parameter ride-through time setting is fixed at 10 ms and is not adjustable through RSLogix 5000 software. This setting defines the duration of time for which the position error limit setting must be reached or exceeded before an Excess Position Error (E19) is asserted.

  • Page 144: Setting Velocity Error Limits In Ultraware Software

    Minimizing the Effects of Feedback Signal Loss for the Following Error Time parameter is 0…65,535 ms, with a default value of 100 ms. Ultraware Following Error Parameters Setting Velocity Error Limits The position error limit and time parameters let you define a tight window of error tolerance for the system.

  • Page 145: Configuring Fault Actions In Rslogix 5000 Software

    Minimizing the Effects of Feedback Signal Loss routines. This technique lets you specify velocity error limit settings in cases where the default settings do not suit the application. To make use of the VelocityError attribute, you must select it as IMPORTANT one of the two RealTimeAxis Information attributes under the Drive/ Motor tab in the Axis Properties dialog.
  • Page 146 Minimizing the Effects of Feedback Signal Loss When configuring the fault actions to minimize unexpected motion, you can select Shutdown or Disable Drive for the Position Error attribute found in the Fault Actions tab of the Axis Properties dialog. In the event of feedback signal loss, either of these settings will result in the drive disabling and the axis coasting to a stop.

  • Page 147: Position And Velocity Error Limit Adjustment Example With Ultraware Software

    Minimizing the Effects of Feedback Signal Loss Position and Velocity Error This example uses Ultraware software and an Ultra3000 indexing drive (catalog number 2098-DSD-030X) with an MP-Series (230V) Limit Adjustment Example motor (catalog number MPL-A330P-S) and appropriate power and with Ultraware Software feedback cables to illustrate position and velocity error limit setting optimization.
  • Page 148 Minimizing the Effects of Feedback Signal Loss For this example, the default values were replaced with the values shown. 4. Click the Drive Enable icon to enable the Ultra3000 drive. 5. Click Indexing Control Panel. The indexing control panel dialog opens. To avoid injury or damage caused by unexpected motion, ATTENTION make sure that all system and user safety measures are...

  • Page 149: Understanding Error Limit Settings In Ultraware Software

    Minimizing the Effects of Feedback Signal Loss Understanding Error Limit Settings in Ultraware Software With the motion application configured and operational, observe the default Following Error and Velocity Error Fault limit settings in Ultraware software to understand the significance of their values and units.

  • Page 150: Use The Oscilloscope Feature

    Minimizing the Effects of Feedback Signal Loss Use the Oscilloscope Feature Once the system is running, the default position and velocity error limit values can be monitored and optimized via the oscilloscope branch. Since RSLogix 5000 software already provides an efficient IMPORTANT plotting utility, do not use this feature with a SERCOS drive.
  • Page 151 Minimizing the Effects of Feedback Signal Loss 3. Click OK. 4. Click the Scale Type default value and select Auto. 5. Click the Run Continuous trigger setting and observe the main dialog. The Position Error signal of the running system is displayed. It is likely that the signal is highly dynamic, and the auto-scaling feature of Ultraware automatically adjusts the dialog scaling to fit the signal for every sampling and trigger instance.
  • Page 152 Minimizing the Effects of Feedback Signal Loss 9. Enter values (in counts) in the Scale and a Offset fields that results in the entire periodic Position Error signal waveform visible in the oscilloscope window. Steps 8 and 9 are purely for the purpose of visualization. Fixing the vertical scale of the oscilloscope window lets you observe the amplitude excursion limits of the Position Error signal from a fixed range of reference.

  • Page 153: Interpreting The Results

    Minimizing the Effects of Feedback Signal Loss Interpreting the Results Once the actual position and velocity error excursion limit values are known, you can adjust the default Following Error Limit/Time and Velocity Error Fault Limit/Time settings to be just above these actual application extremes.

  • Page 154: Position Error Limit Adjustment Example With

    Minimizing the Effects of Feedback Signal Loss Position Error Limit This example uses RSLogix 5000 software, a ControlLogix controller (catalog number 1756-L63), and an Ultra3000i indexing drive (catalog Adjustment Example with number 2098-DSD-030X) with a 230V MP-Series motor (catalog RSLogix 5000 Software number MPL-A330P-S) and appropriate power and communication cables to illustrate position error limit setting optimization.

  • Page 155: Run The Rslogix 5000 Software Example Program

    Minimizing the Effects of Feedback Signal Loss In the ladder logic example diagram, the Start input (when activated) enables the axis for motion. The Stop input disables the axis. A repeating sequence of two MAM commands is performed to move the axis an incremental distance in one direction and then return the axis to its original position.

  • Page 156: Observe The Default Position Error Tolerance Limit Setting

    Minimizing the Effects of Feedback Signal Loss Observe the Default Position Error Tolerance Limit Setting To understand the significance of the default Position Error Tolerance limit setting, observe the default value in RSLogix 5000 software. The Position Error Tolerance limit setting, units and conversion settings, and real-time axis attribute settings are accessible through the Axis Properties dialog.
  • Page 157 Minimizing the Effects of Feedback Signal Loss 3. Click the Motor Feedback tab. 4. Observe the Cycles, Interpolation Factor, and Feedback Resolution values. 5. Click the Drive/Motor tab. 6. Observe the Drive Resolution value. For the MPL-A330P-S motor used in this example, 1024 raw feedback counts per 1 axis revolution are used to generate 2097152 (1024 x 2048) interpolated feedback counts per 1 axis revolution by using an interpolation factor of 2048.
  • Page 158 Minimizing the Effects of Feedback Signal Loss 7. Click the Conversion tab. 8. Observe the Conversion Constant value. The Conversion tab shows how the user-defined position units relate to drive resolution counts, and, therefore, to raw and interpolated feedback counts and axis revolutions. Summary In this example, the Position Error Tolerance limit setting of 0.77312005 position units at 200,000 drive resolution counts per 1...

  • Page 159: Trending Excursion Limits Of The Position Error

    Minimizing the Effects of Feedback Signal Loss Trending Excursion Limits of the Position Error Parameter With the motion application running, you can trend the position error parameter. The trending feature of RSLogix 5000 software lets you plot drive parameters in real-time and view them in graphical form. Before trending of any drive parameter is possible, the Real Time Axis Attribute field, found under the Axis Properties dialog, Drive/Motor tab, must be configured to specify which of the numerous drive...
  • Page 160 Minimizing the Effects of Feedback Signal Loss 4. From the Attribute 1 pull-down menu, choose the Position Error parameter. This configures the Logix controller to receive the position error parameter data from the drive. 5. Click OK. Locate the Position Error Parameter Tag and Configure It for Trending Once the system is running and the Logix controller is configured to receive position error parameter data from the drive, the position error characteristics of the Ultra3000 drive and motor system can be...
  • Page 161 Minimizing the Effects of Feedback Signal Loss 6. Right-click the PositionError parameter tag and choose Trend Axis_x.PositionError. The RSLogix 5000 trending window opens and the position error signal of the running Ultra3000 drive/motor system becomes visible. The default trending dialog settings are sufficient to display the position-error waveform.
  • Page 162 Minimizing the Effects of Feedback Signal Loss Change the Default Trending Dialog Settings You can change the X or Y scales of the trending dialog (time base and amplitude, respectively) or the sampling period of the acquisition cycle by using the RSTrendX chart properties control panel. Follow these steps to change the default trending dialog settings.

  • Page 163: Set The New Position Error Limit

    Minimizing the Effects of Feedback Signal Loss 10. Click OK to accept the new trending dialog settings. In this example, the Y-Axis scaling was adjusted to show a range of -0.10 (min) to 0.10 (max) position units, with 3 decimal places of resolution.

  • Page 164: Verify The New Position Error Limit

    Minimizing the Effects of Feedback Signal Loss Verify the New Position Error Limit You can use the RSLogix 5000 trigger feature to detect parameter tag events which meet or exceed your new Position Error Tolerance limit setting. After configuring the trigger feature, you can verify that the new settings are not exceeded by the system under normal operating conditions.
  • Page 165 Minimizing the Effects of Feedback Signal Loss 4. Click the Start Trigger tab. 5. Uncheck the No Trigger checkbox. 6. From the Tag pull-down menu, choose axis_x.PositionError. 7. From the Operation pull-down menu, choose Greater Than (Tag≥Target). The trigger is now set to when the parameter exceeds the target value.

  • Page 166: Visualize The New Position Error Limit

    Minimizing the Effects of Feedback Signal Loss Visualize the New Position Error Limit Follow these steps to visualize the new position error limit. 1. Set the Logix processor to online operation. 2. Download the program to the controller when prompted. 3.

  • Page 167: Exporting And Importing Drive Setup Files

    Appendix Exporting and Importing Drive Setup Files This appendix provides you with procedures for exporting and importing drive setup files used with Ultra3000, Ultra3000X with indexing, Ultra3000-DN DeviceNet, and Ultra3000X-DN DeviceNet with indexing servo drives. Topic Page Introduction Export a Drive Setup File Import a Drive Setup File Introduction Drive setup files contain all the configuration data used by Ultraware...
  • Page 168 Exporting and Importing Drive Setup Files 3. Choose Export from the File menu. If Export is grey and cannot be chosen, then you haven’t selected a file to export. The Export To: dialog opens. 4. Browse to a location to temporarily store the drive setup file. 5.

  • Page 169: Import A Drive Setup File

    Exporting and Importing Drive Setup Files Import a Drive Setup File Follow these steps to import a drive setup file. 1. Open your Ultraware software and go online with the replacement Ultra3000 drive. Refer to Detect Your Ultra3000 Drive on page 16, for more information on starting the Ultraware software and detecting your drive.
  • Page 170 Exporting and Importing Drive Setup Files 3. Select the Off-line: Unsaved folder. 4. From the File menu, choose Import. If Import is grey and cannot be chosen, then you haven’t selected the Off-line: Unsaved folder. The Import From: dialog opens. 5.
  • Page 171 Exporting and Importing Drive Setup Files The drive setup file appears under the Off-line: Unsaved folder. 6. Drag and drop the drive setup file onto the online drive. This Ultraware dialog opens. 7. Click OK. The file loads and you are ready to restart the application. Publication 2098-IN005C-EN-P —...
  • Page 172 Exporting and Importing Drive Setup Files Publication 2098-IN005C-EN-P — March 2008...
  • Page 173 Index Numerics CompactLogix 65 configuring 2090-U3AE-D44 analog drive with logix 52 cable 133 axis properties 58 interconnect diagram 134 drive 75 2090-U3CC-D44 drive detection 16 cable 133 drive with DeviceNet 93 interconnect diagram 135 drive with SERCOS 70 fault actions 105 logix controller 53 logix module 55 abbreviations 7...
  • Page 174 Index encoder communication fault 102 hardware overtravel 99 encoder data 102 high resolution encoders 139 encoder output frequency home position in limit 100 exceeded 102 home search failed 100 encoders hookup tab 59 absolute 139 buffered 137 high resolution 137 illegal hall state 100 incremental 137 incremental encoders 138...
  • Page 175 Index troubleshooting 98 position error 142 master follower 40 velocity error 144 position error 141 minor fault 104 examples mode configuration 17 oscilloscope 150 module properties RSLogix 5000 154 SERCOS module 74 Ultraware 147 module status LED 104 power DeviceNet 95 applying power 15 SERCOS 82 power (PWR) indicator not on 98...
  • Page 176 Index sine/cosine encoder frequency length 100 ground fault 102 limit exceeded 102 hardware overtravel 99 SoftLogix 65 home position in limit 100 software overtravel 100 home search failed 100 start-up procedure 9 illegal hall state 100 status LEDs 98 IPM fault 99 status only 105 IPM thermal protection fault stop motion 105...
  • Page 177 Index Ultra3000 with DeviceNet unrecoverable fault 104 Reference Manual 95 user-specified current fault 100 Ultraware software 16 user-specified velocity fault 101 analog outputs branch 19 digital inputs branch 18 digital outputs branch 19 velocity error 141 encoders branch 18 examples faults branch 20 oscilloscope 150 mode configuration 17...
  • Page 178 Index Publication 2098-IN005C-EN-P — March 2008...
  • Page 180 Outside United Please contact your local Rockwell Automation representative for States return procedure. Publication 2098-IN005C-EN-P — March 2008 Supersedes Publication 2098-IN005B-EN-P — August 2004 Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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