Installation Manual User guide

ManualsBrandsRockwell Automation ManualsEquipment1398-DDM-xxx ULTRA 100 Series Drives

Installation

Manual

ULTRA

100 Series

Drives

(Cat. No. 1398-5.2)

Allen-Bradley

Summary of content (300 pages)

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Allen-Bradley ULTRA 100 Series Drives (Cat. No. 1398-5.
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Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
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Table of Contents IntroTable of Contents Table of Contents Intro-3 List of Figures Intro-9 List of Tables Intro-13 Preface Intro-17 Who Should Use this Manual . . . . . . . . . . . . . . . . . . .Intro-17 ULTRA 100 Series Product Receiving and Storage Responsibility. . Intro-17 Rockwell Automation Support . . . . . . . . . Local Product Support. . . . . . . . . . . . . . Technical Product Assistance . . . . . . . . . Purpose and Contents of this Manual . . . . .
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Intro-4 Table of Contents ULTRA 100 Series Features . . . . . . . . . . . . . Drive Power Ratings . . . . . . . . . . . . . . . . High Performance Microcontroller Technology . IPM Technology . . . . . . . . . . . . . . . . . . . Analog and Digital Interfaces . . . . . . . . . . . Encoder Control . . . . . . . . . . . . . . . . . . . Encoder Output . . . . . . . . . . . . . . . . . . . Digital I/O . . . . . . . . . . . . . . . . . . . . . . Analog I/O . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents Intro-5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . 5-7 AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Chapter 6 Interfaces J1 – Controller . . . . . . . . . . . . . Digital I/O Power . . . . . . . . . . Digital Inputs . . . . . . . . . . . . Input Interface Circuit Examples Auxiliary Encoder Input Types . . Interface Cable Examples . . . . .
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Intro-6 Table of Contents Tuning . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . Position Follower (Step/Direction) . . . Hardware Set Up . . . . . . . . . . . Connection Diagram . . . . . . . . . Configuration . . . . . . . . . . . . . Tuning . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . Position Follower (Step Up/Down) . . . Hardware Set Up . . . . . . . . . . . Connection Diagram . . . . . . . . . Configuration . . . . . . . . . . . . . Tuning .
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Table of Contents Manual Tune Mode . . . . . . . . . Filters . . . . . . . . . . . . . . . Gains . . . . . . . . . . . . . . . Manual Tuning . . . . . . . . . . Velocity Loop Tuning Examples Chapter 10 . . . . . . . . . . . . . . . . . . 9-6 . . . . . . . . . . . . . . . . . . 9-6 . . . . . . . . . . . . . . . . . . 9-6 . . . . . . . . . . . . . . . . . . 9-6 . . . . . . . . . . . . . . . . . . 9-9 Status Display Status Indicator . . . . . . . Error Messages . . . . . . . Run Time Error Codes .
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Intro-8 Table of Contents Appendix C TouchPad Instructions Installation and Operation . . TouchPad Commands . . . . Supplemental Instructions Motor Selection . . . . . . Analog Output Scaling . . Displays . . . . . . . . . . Motor Table . . . . . . . . . . TouchPad Options and Lists . TouchPad Lists . . . . . . . . Appendix D . . . . . . . . . . . . . . . . . . . . . .C-1 . . . . . . . . . . . . . . . . . . . . . .C-3 . . . . . . . . . . . . . . . . . . . . . .C-6 . . . . . . . . . . . . . . . . . . .
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List of Figures IntroList of Figures Product Parts Explained . . . . . . . . . . . . . . . . . . . . . Intro-25 Chapter 1 Safety Chapter 2 Unpacking, Inspecting and Storing Host Mode Connection Diagram . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Selecting Other System Components Chapter 4 ULTRA Master Installation Chapter 5 Installation 1398-DDM-005 and -005X Mounting Dimensions . . . . . . . . . .
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Intro-10 List of Figures J2 Breakout Board Assembly – European Union EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Encoder Inputs . . . . . . . . . . . . . . . . . . . . . Auxiliary Encoder Input Circuit . . . . . . . . . . . . . . . . . External Encoder Interface via TTL Differential Line Drivers . Complementary Encoder Interface via 7406 Line Drivers with Pull-up Resistors . . . . . . . . . . . . . . . . . . . . . . Complementary Encoder Interface via Standard TTL Logic . .
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List of Figures Registration Indexing Connection Diagram Absolute Indexing Examples . . . . . . . . . Absolute Indexing Connection Diagram . . PC Display Units – Default Dialog . . . . . . Chapter 9 Intro-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38 8-43 8-45 8-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 .
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Intro-12 List of Figures F- or H-Series Motors to ULTRA 100 Series Drive using P2 Terminal Strip . . . . . . . . . . . . . . . . . . . . . . .B-25 Y-Series Motors to ULTRA 100 Series Drive . . . . . . . . . . . . .B-26 Y-Series Motors to ULTRA 100 Series Drive using P2 Terminal Strip . . . . . . . . . . . . . . . . . . . . . . .B-27 Appendix C TouchPad Instructions TouchPad Connection and Pinouts . . . . . . . . . . . . . . . . . . C-1 TouchPad Version Number Display . . . . . . . . . . . . . . . . .
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List of Tables IntroList of Tables Chapter 1 Safety Chapter 2 Unpacking, Inspecting and Storing Chapter 3 Selecting Other System Components Chapter 4 ULTRA Master Installation Chapter 5 Installation 1398-DDM-005 and -005X Mounting Dimensions . . . . . . . . . . 5-3 1398-DDM-009and-009X,1398-DDM-019and-019XMountingDimensions 5-4 AC Line Filters for ULTRA 100 Series drives . . . . . . . . . . . . . 5-8 MIF Single Phase AC Line Filter Engineering Specifications . . . .
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Intro-14 List of Tables Chapter 7 Power Connections TB1 - DC Bus and AC Power Terminal Block Connections. Motor Power Contact and Wire Size Recommendations . . TB1 - AC Power Terminals . . . . . . . . . . . . . . . . . . . AC Input Power Sizing Requirements . . . . . . . . . . . . Chapter 8 . . . . . . . . . . . . . . . . 7-1 7-4 7-7 7-8 Application and Configuration Examples Preset Binary Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Chapter 9 Tuning Velocity Loop Gains. . . .
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List of Tables Intro-15 Output Flags Parameter List for TouchPad . . . . . . . . . . . . . C-21 Appendix D Creating Custom Motor Files Appendix E Electromagnetic Compatibility Guidelines for Machine Design Appendix F Dynamic Braking Resistor Selection Dynamic Braking Resistor Parameters . . . . . . . . . . . . . . . . . F-1 Appendix G Specifications Publication 1398-5.
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Intro-16 List of Tables Publication 1398-5.
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Preface IntroPreface Read this preface to familiarize yourself with the rest of the manual.
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Intro-18 Preface ● ● in an area where it cannot be exposed to a corrosive atmosphere in a non-construction area The “Drive Checkout Test” on page 2-3 is useful to verify that the unit is operating correctly after delivery. Rockwell Automation Support Publication 1398-5.2 – PDF 1997 Rockwell Automation offers support services worldwide.
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Preface Local Product Support Intro-19 Contact your local Allen-Bradley representative for: ● ● ● ● sales and order support product technical training warranty support support service agreements Technical Product Assistance If you need to contact Rockwell Automation for technical assistance, please review the information in the Troubleshooting chapter first. Then call your local Allen-Bradley distributor.
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Intro-20 Preface Title Unpacking, Inspecting and Storing Installation Interfaces Description Lists what should be included with your ULTRA 100 Series drive and instructs you on how to perform a basic functional test before installing or storing the drive. Instructs you on how to physically install your ULTRA 100 Series drive. Each signal or set of signals is identified by: Power requirements for driving the signal. Functions performed by the signal. Specifications, including ON and OFF states.
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Preface Title Electromagnetic Compatibility Guidelines for Machine Design Dynamic Braking Resistor Selection Specifications Intro-21 Description Describes common electrical noise problems and suggests methods to ensure ElectroMagnetic Compatibility. Provides equations to assist in sizing resistors for dynamic braking. Details the design and operational specifications for the ULTRA 100 Series drives in a tabular format.
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Intro-22 Preface Additional Instructions and Manuals Host Commands and ULTRA Master All ULTRA 100 Series drives are setup through serial Host Commands. The drives can be configured directly through the Host Command language or indirectly through the ULTRA Master software. ULTRA Master is a graphical user interface that provides a visual method of accessing the Host Command language through the Microsoft Windows Operating System. All documentation for both the Host Commands and ULTRA Master is online.
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Preface Symbols and Conventions Intro-23 Typographical and Wording Conventions This manual uses the following typographical and wording conventions: Example Drive Set Up Description Text shown in this font and underlined indicates a Hot Key (keystroke combination) to quickly access a command. For example, Choose Drive Set Up. ULTRA Master indicates typing ALT+D followed by ENTER accesses this command. Text shown in this font is information to enter in a window or dialog box.
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Intro-24 Preface Graphical Symbols This manuals uses the following graphic symbols. Example Description Protective conductor terminal (Earth ground) Chassis terminal (not a protective ground) ! Publication 1398-5.2 – PDF 1997 Symbol plus ATTENTION: These notices provide information intended to prevent potential personal injury and equipment damage.
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Preface Pictorial Index Intro-25 Shown here is a face view of the product, with pointers to where individual parts are discussed. Product Parts Explained page 10-1, 11-3 page 6-31 page 7-9 page 6-29 page 7-7 page 6-1 page 7-2 Publication 1398-5.
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Intro-26 Preface Publication 1398-5.
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Chapter 1 Safety Installing and Using the ULTRA 100 Series Drive Chapter 1 Read the complete manual before attempting to install or operate the drive. By reading the manual you will become familiar with practices and procedures that allow you to operate the drive safely and effectively. You should always adhere to the “General Safety Guidelines” on page 1-3. Specific Warnings and Cautions appear throughout the manual.
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1-2 Safety Voltage Potentials Intro ! ATTENTION: DC bus capacitors may retain hazardous voltages for several minutes after input power has been removed, but will normally discharge in several seconds. Measure the DC bus voltage to verify it has reached a safe level each time power is removed before working on the drive; or wait for the time indicated in the warning on the front of the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.
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Safety General Safety Guidelines 1-3 This section covers general safety guidelines for electronic devices. Safety information specific to ULTRA 100 Series drives begins on page 1-1. Hazards which can be encountered in the use of this equipment are: ● ● ● ● Electric Shock Electric Fire Mechanical Stored Energy There are no chemical or ionizing radiation hazards.
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1-4 Safety ● ● ● ● ● ● ● ● ● ● ● ● Publication 1398-5.2 – PDF 1997 All non-qualified personnel should maintain a safe distance from the equipment. The system must be installed in accordance with local regulations. The equipment is intended for permanent connection to a main power input. It is not intended for use with a portable power input. Do not power up the unit without the covers in place and the protective conductor connected.
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Chapter 2 Unpacking, Inspecting and Storing Chapter 2 This chapter describes the steps which ensure that the drive will function as specified. The steps include: ● ● ● ● Unpacking the Drive Unpacking the ULTRA 100 Series drive Inspecting the drive for shipping damage Testing the basic functionality of the drive Guidelines for storing the drive. 1. Remove the ULTRA 100 Series drive from the shipping carton and remove all packing materials from the unit.
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2-2 Unpacking, Inspecting and Storing Testing the Unit Drives are burned-in and individually tested before they leave the factory. However, damage may occur during shipping. Perform the procedures below to ensure the ULTRA 100 Series drive is operational and undamaged. Abbreviated directions for connecting the drive to a motor and a PC are provided.
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Unpacking, Inspecting and Storing 2-3 2. Connect an RS-232 cable between the serial port on the PC and the J5 connector on the ULTRA 100 Series drive. A simple 3 wire cable is depicted in the figure below. 3. Connect a Motor/Feedback cable from the motor to the J2 connector on the ULTRA 100 Series drive. 4. Connect a jumper wire with a toggle switch with a toggle switch between the following pins: • J1-20 (ENABLE) and J1-26 (I/O PWR). • J1-21 (FAULT RESET) and J1-26 (I/O PWR).
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2-4 Unpacking, Inspecting and Storing ● ● ● Drive power wiring is correct and start-up logic is functioning. The drive and motor are correctly wired Drive serial communications are operational Before beginning the “Initial Power-up”, please check the following: ● ● Publication 1398-5.2 – PDF 1997 All wiring and mounting to verify correct installation Input voltages to ensure they do not exceed specifications for the drive or motor.
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Unpacking, Inspecting and Storing 2-5 Initial Power-up 1. Verify the AC power is within specifications at the terminal strip. 2. Switch the AC Power to ON and verify the Status LED is green 3. Switch the power OFF and wait until the DC Bus Voltage is below 30 Volts. 4. Connect the motor windings to: • R (TB1-6)for the Phase R winding • S (TB1-7) for the Phase S winding • T (TB1-8) for the Phase T winding • (TB1-9) for the Ground connection. 5.
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2-6 Unpacking, Inspecting and Storing 13. Select Read Drive Parameters from the Communications menu in ULTRA Master. 14. Select OK in the Drive Select dialog box. A dialog box indicating that the PC is reading drive parameters should appear. If this dialog box does not appear, a message appears that advises you to check the COM settings and the communication cable. If necessary, refer to “Troubleshooting” on page 11-3 for instructions on how to perform these checks. Publication 1398-5.
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Unpacking, Inspecting and Storing 2-7 Initial Drive Operation 1. When the message appears that a motor must be selected, choose OK. The Drive Set Up dialog box is selected with Motor Model active. 2. Select the appropriate motor from the drop-down Motor Model box. 3. Choose OK when the message appears advising that the drive must reset. A change in motor parameters requires reselection of the firmware based drive/motor tables. The software reset prevents improper sequencing of these table parameters. 4.
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2-8 Unpacking, Inspecting and Storing A drive completing these steps is functional. If the ULTRA 100 Series drive did not pass the steps above, refer to “Troubleshooting” on page 11-3. Note: For information on testing the digital and analog signals refer to “Testing Digital Outputs” on page 11-9, “Testing Digital Inputs” on page 11-11, “Testing Analog Output” on page 11-11 and “Testing Analog Input” on page 11-12.
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Chapter 3 Selecting Other System Components Chapter 3 This chapter reviews the ULTRA 100 Series 1398-DDM-005 and -005X, 1398-DDM-009 and -009X, 1398-DDM-019 and -019X drives, command sources and interfaces for the drives, and complementary motors and accessory equipment. Selection of complementary servo components allows you to efficiently connect other devices to your microdrive. Pertinent information about each is provided to assist you in planning your servo system.
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3-2 Selecting Other System Components High Performance Microcontroller Technology All digital current, velocity and position loop calculations as well as the motor commutation calculation are performed by a microcontroller. IPM Technology IPM (Intelligent Power Module) technology in the output stage provides a high frequency, digital PWM (Pulse Width Modulation) sine wave that controls the current loop, including overcurrent, short circuit and overtemperature protection.
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Selecting Other System Components ● ● ● 3-3 One dedicated, control (ENABLE), optically isolated, active high input. Two selectable, optically isolated and short circuit protected, active high outputs. Two dedicated (BRAKE/DRIVE ENABLED and DRIVE READY), normally open relay outputs.
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3-4 Selecting Other System Components ● ● ● ● Host computers Programmable Logic Controllers Motion controllers TouchPad. The serial communication interface for the ULTRA 100 Series supports: ● ● ● ● RS-232 and the four wire RS-485 communications standards NRZ (non-return to zero) asynchronous serial format Baud rates: 1200, 2400, 4800, 9600 and 19200 Parity generation and checking: Even, Odd or None.
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Selecting Other System Components 3-5 If this signal is not provided, the peak current of the drive may be set in software through the Drive Parameter window. Analog Output One analog output channel may be defined by the user through software: ● ANALOG is a ±10 Volt signal. The allowable current draw of the load is ±2 mA This analog output is designed for monitoring purposes only. This signal should not be used for control purposes due to the relatively high ripple voltage (1%).
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3-6 Selecting Other System Components If using a motor with the 90VAC brake option, a user-provided relay may be driven by these outputs up to the specified levels. Refer to Figure 6.10 on page 6-10 for information about the necessary hardware connections. Consult the I/O Configuration in the on-line ULTRA Master help for additional information about the software parameters.
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Selecting Other System Components ● ● ● ● ● 3-7 Critical information is available with complete Windows-based on-line help. Serial Host Language commands are explained through on-line help. User defined velocity, acceleration, position and torque parameters. Tuning and diagnosis is aided with an on-screen dual channel digital oscilloscope. On-screen meters and software tools provide rapid debugging and measurement. Autotuning Digital auto tuning allows easy setup.
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3-8 Selecting Other System Components Refer to the Torque/Speed curves in the Allen-Bradley Standard Product Catalog and Handbook (Publication 1398-2.0) or contact your local Allen-Bradley distributor for motor sizing and compatibility assistance. Custom motors or motors not manufactured by Allen-Bradley may be interfaced, refer to “Creating Custom Motor Files” on page D-1 and, if necessary, contact Product Support for assistance. Options ● ● ● ● Publication 1398-5.
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Selecting Other System Components 3-9 European Union Requirements ULTRA 100 Series drives conform to the following European Union Directives: ● ● Low Voltage Directive (72/23/EEC, 93/68/EEC) Electromagnetic Compatibility Directive (89/336/EEC, 92/31/ EEC, 93/68/EEC) Compliance with the EEC Directives is contingent on two conditions: 1. Installation of AC line filters between the power source and the drive, and 2. Use of factory authorized cables to connect motors.
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Chapter 4 ULTRA Master Installation Chapter 4 Installation of ULTRA Master on a PC is covered in this chapter, which: ● ● ● ● Lists the minimum PC hardware and software necessary to run ULTRA Master. Provides step-by-step instructions on how to load ULTRA Master. Shows you how to start and quit ULTRA Master and introduces the Drive Window, the main command window for ULTRA Master. Instructs you on how to access on-line help.
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ULTRA Master Installation 4-2 2. If Windows is not running, type win at the DOS prompt (C:>). If Windows is already running, close any open applications. 3. Insert the ULTRA Master disk into a 1.44MB floppy disk drive, typically drive A:, and close the drive door. 4. Choose Run, from the File menu in Windows Program Manager. 5. Type a:setup and then press ENTER. A message box will appear saying that the setup is initializing.
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4-3 ULTRA Master Installation From Windows 1. Choose the ULTRA Master program group from the Program Manager in Windows. Note: If the ULTRA Master window is not active, hold down ALT and press TAB (ALT+TAB) until the ULTRA Master title bar and icon are highlighted, or select ULTRA Master from the list in the Window menu. 2. Choose the ULTRA Master icon from the ULTRA Master program group. The ULTRA Master start-up screen will open. Publication 1398-5.
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ULTRA Master Installation 4-4 The ULTRA Master Start-Up Screen When ULTRA Master starts for the first time, its default instructions are: ● ● Display the Help menu - Quick Start. Present the Drive Select window. The Drive Select window offers Drive 0, which is the default drive address assigned at the factory. The default ULTRA Master Start-up screen is shown below. The comments point out many of the Windows controls that are available in ULTRA Master.
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4-5 ULTRA Master Installation Miscellaneous Files The readme File A file, titled README, may be included in the ULTRA Master directory. This file contains installation instructions, change notes from previous revisions, and information that became available after this manual was printed. After you install ULTRA Master you can access this file by choosing the Read Me icon in the ULTRA Master window or by using Microsoft Write or an equivalent application program to view the file readme.
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Chapter 5 Installation Mechanical Installation Requirements Chapter 5 1. Mount the unit in an enclosure providing protection to IP54 (protected against dust and splashing water), or IP65 (dust free and protected against water jets) if the work environment is poor. Many NEMA (National Electrical Manufacturers Association) Type 4 cabinets provide this level of protection. Minimum cabinet requirements are: • Depth: 243.8 cm (9.6 inches).
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5-2 Installation • Altitude: 1500 meters (5000 feet), Derate power performance 3% for each 300 m above 1500 m (1000 ft above 5000 ft). • Humidity: 5% to 95% non-condensing Ambient operating temperature range and airflow clearances are: • 0 ° to 55° Celsius (32° to 131° Fahrenheit). • 50.8 mm (2 inches) above and below unit for airflow. 4. Bolt the unit to the cabinet using the mounting slots in the drive. Mounting dimensions are shown in Figure 5.2.
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Installation Figure 5.1 5-3 1398-DDM-005 and -005X Mounting Dimensions B B1 B2 B3 A2 C B4 A7 A3 A4 A A8 C1 A9 A1 A10 A5 A11 A6 Minimum unobstructed surrounding space for cooling and exhaust air Above 50.8 mm (2 inches) Below 50.8 mm (2 inches) Sides 12.5 mm (0.5 inches) for cable bend radius Front 76.2 mm (3 inches) Table 5.1: A A1 A2 A3 A4 A5 A6a A7 A8 A9 A10 A11 1398-DDM-005 and -005X Mounting Dimensions Dimension mm inches 198.12 7.80 184.9 7.28 6.35 0.25 13.0 0.51 60.7 2.39 94.49 3.
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5-4 Installation Figure 5.2 1398-DDM-009 and -009X, 1398-DDM-019 and -019X Mounting Dimensions B B1 B2 B3 A2 C B4 A7 A3 A4 A A8 C1 A9 A1 A10 A5 A11 A6 Minimum unobstructed surrounding space for cooling and exhaust air Above 50.8 mm (2 inches) Below 50.8 mm (2 inches) Sides 12.5 mm (0.5 inches) for cable bend radius Front 76.2 mm (3 inches) NOTE: Fan on 1398-DDM-019 only Table 5.
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Installation Interface Connections 5-5 Input/Output and power cables connect to the front panel of a ULTRA 100 Series drive, no internal connections are necessary. Intro ! ATTENTION: Perform the initial power-up with the motor shaft disconnected from a load and the shaft key removed. Improper wiring or undiscovered shipping damage could result in undesired motor motion. Be prepared to remove power if excessive motion occurs.
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5-6 Installation Minimum wire gages for power cables are listed in: ● ● Publication 1398-5.2 – PDF 1997 “Motor Power Contact and Wire Size Recommendations” on page 7-4, “AC Input Power Sizing Requirements” on page 7-8.
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Installation 5-7 Electromagnetic Compatibility General Guidelines Refer to Appendix E, “Electromagnetic Compatibility Guidelines for Machine Design” for an in-depth discussion of electromagnetic compatibility (EMC) and electromagnetic interference (EMI). European Union EMC Directives The ULTRA 100 Series drives are designed and tested to meet the European EMC Directive. Declarations of conformity, which enumerate the standards used, are included in the manual.
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5-8 Installation Table 5.
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Installation MEASUREMENT A A1 A2 B B1 B2 C C1 C2 Voltage/Freq. Figure 5.3 MIF Single Phase AC Line Filter Mounting Diagram Table 5.4: MIF Single Phase AC Line Filter Engineering Specifications SINGLE PHASE SINGLE PHASE 6A 10A P/N 9101-1516 P/N 9101-1517 DIMENSIONAL DATA mm in mm in 170 6.7 214 8.4 152 6.0 192 7.6 9 0.4 11 0.4 92 55 18 3.6 2.2 0.7 145 104 20 5.7 4.1 0.8 5-9 SINGLE PHASE 23A P/N 9101-1518 mm 214 192 11 in 8.4 7.6 0.4 204 164 20 8.0 6.6 0.8 25 1.0 40 1.6 47 1.8 10 0.4 16 0.
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5-10 Installation Table 5.
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Power Wiring Diagram Figure 5.4 Installation 5-11 Publication 1398-5.
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5-12 Installation Publication 1398-5.
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Chapter 6 Interfaces Chapter 6 This chapter provides information about: ● Interface signals available on the ULTRA 100 Series drive • J1 - The Controller interface for commanding and reporting motion • J2 - The Encoder interface for reporting movement by the motor • J5 - The Serial interface for communicating with the drive. ● ● J1 – Controller Commonly encountered interface cabling methods Optional signal extension kits and standard cables.
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6-2 Interfaces Table 6.1: Pin & Signal 1 +5VDC 2 ECOM 3 +5VDC 4 ECOM 5 I/O PWR 6 I/O COM 7 AOUT+ 8 AOUT- 9 BOUT+ 10 BOUT- 11 IOUT+ 12 IOUT- Publication 1398-5.
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Interfaces Table 6.
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6-4 Interfaces Not Assigned (default) Drive Mode Select Integrator Inhibit Reverse Enable Operation Mode Override Preset Select A Follower Enable Forward Enable Fault Reset Preset Select B Preset Select C Start Homing Start Index Define Home Sensor (available only on INPUT 2) Remove COMMAND Offset Refer to the I/O Configuration section of the on-line ULTRA Master Help for information on choosing the input type for each channel. Table 6.
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Interfaces Table 6.3: Preset Select A Preset Select B Preset Select C Start Index Define Home Sensor Remove COMMAND Offset Fault Reset Start Homing 6-5 INPUT1, INPUT2 and INPUT3 Functions (continued) Activea or Inactiveb states select one of the eight presets shown in the following binary table: BINARY CODE C B A Description Preset 0 0 0 0 Preset 0 or Index 0 is selected. Preset 1 0 0 1 Preset 1 or Index 1 is selected. Preset 2 0 1 0 Preset 2 or Index 2 is selected.
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6-6 Interfaces Table 6.5: Parameter ON state Voltage ON state Current OFF state Voltage OFF state Current Digital Input Specifications Description Voltage applied to the input to guarantee an ON state Current flow into the input to guarantee an ON state Voltage applied to the input to guarantee an OFF state External leakage current into the input to guarantee an OFF state Figure 6.2 Minimum 10.8 VDC 3.0 mA -1 VDC Maximum 28 VDC 10.0 mA 2 VDC -0.5 mA 0.
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Interfaces Figure 6.5 6-7 Drive Input Connected to Active Low Output using a Switch/Relay OUTPUT INPUT I/O Pwr (Drive) 5 26 (IQ, for example) 3K 1K I/O COM I/O COM Figure 6.6 6 13 Drive Input Connected to Active Low Output using an Opto-Isolator OUTPUT I/O Pwr INPUT (Drive) 5 26 3K 1K I/O COM I/O COM Figure 6.
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6-8 Interfaces ● ● Dedicated relay outputs Selectable transistor based outputs Both types support 12-24 VDC logic interfaces: Dedicated Relay Outputs BRAKE/DRIVE ENABLED and DRIVE READY. Each output is a normally open relay. The relays are rated for 1 Amp at 30 VDC. Note: The Brake contacts may be used to control 24VDC brakes on Allen-Bradley motors with a 4” frame or smaller. A user provided relay may be driven by these outputs if higher power levels are required. Refer to Figure 6.10 for examples.
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Interfaces 6-9 Selectable Transistor Outputs OUTPUT 1 and OUTPUT 2 are optically isolated and short circuit protected, active high, single ended transistor output channels. Each channel sources a maximum of 50 mA. Figure 6.8 J1 READY and BRAKE/DRIVE ENABLED Circuits Drive + Normally Open Relay - READY and BRAKE/DRIVE ENABLED Circuits Specifications for these outputs are listed in Table 6.6. Table 6.
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6-10 Interfaces Figure 6.10 BRAKE/DRIVE ENABLE Application Examples 1398-DDM-005 and 1398-DDM-005X; 1398-DDM-009 and 1398-DDM-009X; 1398-DDM-019 and 1398-DDM-019X Suggested brake wiring when 24VDC brake current exceeds 500mA or for 90VDC brakes: 1398-DDM-005 and 1398-DDM-005X; 1398-DDM-009 and 1398-DDM-009X; 1398-DDM-019 and 1398-DDM-019X Table 6.7: Current Draw for Brake Motor Coils MOTOR F-4000 24VDC 0.88A 90VDC 0.26A H-3000 H-4000 0.60A 0.69A 0.098A 0.
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Interfaces Table 6.8: Digital Output READY BRAKE Pin Number J1-24 (+) J1-25 (-) J1-49 (+) J1-50 (-) OUTPUT 1 J1-42 OUTPUT 2 J1-43 6-11 Selectable Output Circuits Function/Description Relay closure indicates the drive is operational and does not have a fault. Refer to “READY and BRAKE/DRIVE ENABLED Output Specifications” on page 6-9 Relay closure releases the brake. Delay time is selectable (Refer to ULTRA Master - I/O configuration) and may be used as a drive enabled output.
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6-12 Interfaces Table 6.10: Parameter ON state Voltage Transistor Output Specifications Description Voltage difference between the external I/O power supply and the output when the transistor is ON Current flow when the transistor is ON Voltage difference between the external I/O power supply and the output when the transistor is OFF Leakage current from the output when the transistor is OFF ON state current OFF state Voltage OFF state current Figure 6.11 Minimum 0 VDC Maximum 1.
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Interfaces Figure 6.14 6-13 Drive Output Connected to a Switch/Relay J1 Drive I/O Pwr Pin 6 Pin 13 I/O COM Figure 6.15 Drive Output Connected to Active Low Input using a Switch/Relay INPUT OUTPUT (Drive) I/O Pwr 3.3K I/O Pwr Solid State Relay I/O COM Figure 6.16 I/O COM Drive Output Connected to Active Low Input using an Opto-Isolator OUTPUT INPUT (Drive) I/O Pwr 3.
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6-14 Interfaces Figure 6.17 Drive Output Connected to Active High (Sinking) Input OUTPUT (Drive) INPUT I/O Pwr 1K I/O COM J1-6 or J1-13 I/O COM Figure 6.18 J1 External Current Limit Circuit Drive +15 Volts 10K + 20K I LIMIT 20K Table 6.11: Analog Inputs (I LIMIT) Analog Input Pin Number Current Limit J1-27 (I LIMIT) Table 6.12: .
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Interfaces Figure 6.19 6-15 Analog COMMAND Input Circuit 10K J1 Drive 10K 10K + COMMAND+ 20K .01uF 10K 10K COMMAND- ANALOG COMMAND 10K .01uF Table 6.13: Analog Input COMMAND Analog Command Input Pin Number J1-22 (+) J1-23 (-) Description Analog command signal is a differential type signal to drive the servo controller. If the drive is in Velocity Mode configuration, the differential COMMAND signal is the velocity command.
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6-16 Interfaces A selectable output is available for monitoring by the user: ANALOG 1 (J1-31). Intro ATTENTION: The user must provide an external circuit to ignore the analog output signal for two seconds after power-up. After reset the analog output may be in an indeterminate state for a short period before it stabilizes at the software controlled setting. Failure to observe this precaution could result in severe bodily injury. ! Table 6.
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Interfaces Filter Output R-Phase Current T-Phase Current 6-17 Field Voltage Command Analog COMMAND Input Bus Voltage Motor Encoder Output Signal Figure 6.21 Output Encoder Interface Circuits J1 Drive AOUTAOUT+ AMOUT AM26C31 or AM26LS31 The motor quadrature encoder signals are supplied to an external position controller. The signals are differential, quadrature, and TTL level. The output resolution is selectable and can be divided by 1, 2, 4 or 8.
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6-18 Interfaces Table 6.17: Analog Output AOUT (+) AOUT (-) BOUT (+) BOUT (-) IOUT (+) IOUT (-) Pin Number Description J1-7 (+) J1-8 (-) J1-9 (+) J1-10 (-) J1-11 (+) J1-12 (-) Table 6.18: Parameter Differential Output Voltage Output Current Motor Encoder Output Signal Motor Output Channels A(+) and A(-). Differential TTL levels from line driver. Signal resolution is selectable. Motor Output Channels B(+) and B(-). Differential TTL levels from line driver. Signal resolution is selectable.
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Interfaces 6-19 Note: If a controller connected to the drive requires the Index Output (IOUT) signal to be synchronized to a particular state of the A and B Outputs (AOUT and BOUT) the unbuffered encoder outputs from the motor must be used. (Required for use with A-B 1746, 1771, 4100 and 1354 motion controllers.) Publication 1398-5.
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6-20 Interfaces J2 Breakout Board Assembly – European Union EMC Compliance Two options are available to achieve EMC compliance when a ULTRA 100 Series drive uses the J2 Breakout Board Assembly to transfer an unbuffered encoder signal to a control device. Either method of installation reduces the radiated emissions to an acceptable level. Be aware that either installation option is in addition to the EMC requirements specified elsewhere in this manual.
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Interfaces 6-21 Step and direction signals, such as those created by indexers for step motors CW (Step Up)/CCW (Step Down) signals, typically used with stepper indexers. Note: The use of differential signals is strongly recommended. Singleended signals are susceptible to noise, which may cause intermittent or continuous errors. Note: To improve noise immunity, terminate cable shields at both ends of the cable.
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6-22 Interfaces Table 6.19: Auxiliary Encoder Input AX + and AX-, or Step + and Step-, or CW+ (Step Up+) and CW- (Step Up-) BX (+) and BX(-), or DIR (+) and DIR(-), or CCW+ (Step Down+) and CCW- (Step Down-) IX (+) and IX (-) Pin Number Description J1-14 (+) J1-15 (-) Auxiliary Channels A(+) and A(-). Differential, quadrature, or TTL level encoder input. The signal input and resolution are selectable. J1-16 (+) J1-17 (-) Auxiliary Channels B(+) and B(-).
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Interfaces Figure 6.25 6-23 External Encoder Interface via TTL Differential Line Drivers ENCODER J1 Drive Ch A twisted pair 14 15 AX+ AX- Ch B twisted pair 16 17 BX+ BX- Ch I twisted pair 18 19 IX+ IX- 2 4 +5V Supply Return ECOM twisted pair +5 Volts 3 1 5V @ 250 mA +5V Supply +5VDC For horizontal dashed lines, connect only if J1 sources Encoder power Encoder Case Figure 6.
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6-24 Interfaces Figure 6.27 Complementary Encoder Interface via Standard TTL Logic ENCODER J1 74xx Ch A twisted pair AX+ AX- twisted pair 16 17 BX+ BX- twisted pair 18 19 IX+ IX- 74xx Ch B 74xx Ch I +5V Supply Return Drive 14 15 2 4 ECOM 3 1 +5VDC twisted pair +5 Volts +5V Supply 5V @ 250 mA For horizontal dashed lines, connect only if J1 sources Encoder power Encoder Case Figure 6.
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Interfaces Figure 6.29 6-25 Single-Ended Encoder Interface via Standard TTL Signals (not recommended) ENCODER J1 Drive 74xx TTL Output 14 Ch A twisted pair +5V Supply Return AX+ AX- 4 2 74xx TTL Output ECOM twisted pair Ch B 16 BX+ BX- 18 IX+ IX- 74xx TTL Output Ch I +5 Volts +5V Supply Connect only if J1 sources Encoder power. 3 1 5V @ 250 mA +5VDC Drive Chassis Encoder Case Figure 6.
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6-26 Interfaces Figure 6.31 Single-Ended Encoder Interface via Open Collector Transistor with 24 VDC Pull-up (not recommended) ENCODER J1 24VDC Ch A 14 5.1 V IN751 Drive AX+ AX- twisted pair 4 2 Supply Return ECOM twisted pair 24VDC 16 BX+ BX- 18 IX+ IX- Ch B 5.1 V IN751 24VDC Ch I 5.1 V IN751 Encoder Case Table 6.
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Interfaces Figure 6.32 External Step/Direction Interface via TTL Differential Line Drivers USER ELECTRONICS TTL Differential Line Drivers 6-27 J1 Step Step twisted pair 14 15 Step+ Step- Dir Dir twisted pair 16 17 Dir+ Dir- +5V Supply Return +5 Volts +5V Supply Figure 6.
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6-28 Interfaces Figure 6.34 External CW/CCW (Step Up/Step Down) Interface via TTL Differential Line Drivers (sheet 2 of 2) Figure 6.35 External CW/CCW (Step Up/Step Down) Interface via Single-Ended Line Drivers (not recommended) USER ELECTRONICS J1 CW 14 twisted pair CW+ CW- 4 2 +5V Supply Return + - ECOM twisted pair CCW 16 +5 Volts +5V Supply Drive Connect only if J1 sources +5VDC power to user electronics. CCW+ CCW- 3 1 + - +5VDC 5V @ 250 mA Drive Chassis Publication 1398-5.
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Interfaces J2 – Encoder 6-29 Cables are available in various lengths for connecting between J1 and a suitable controller. Appendix A, “Options and Accessories” lists the cables. “J2 Terminal Strip/Breakout Board” on page 6-30 details the optional signal extension kit.
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6-30 Interfaces Figure 6.37 J2 A, B or C Hall Effect Sensor Circuit Drive 200 +5V 1K MC74HC14F 0.1 uF Table 6.22: Motor Encoder EPWR J2 – Motor Encoder Connector Pin-Outs A+ A– B+ B– I+ I– Pin Number J2-1 J2-3 J2-5 J2-2 J2-4 J2-6 J2-7 (+) J2-8 (–) J2-9 (+) J2-10 (–) J2-11 (+) J2-12 (–) HALL A J2-13 HALL B J2-14 HALL C J2-15 ABS J2-16 TS+ TS– J2-17 J2-18 J2-19 J2-20 ECOM Function/Description Encoder power. Encoder common Motor Encoder Input Channel A+ and Channel A–.
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Interfaces Figure 6.38 6-31 ULTRA 100 Series Motor Encoder Connections MOTOR ENCODER Drive EPWR ECOM EPWR ECOM EPWR ECOM J2-1 J2-2 J2-3 J2-4 J2-5 J2-6- +5V COM AM+ AMBM+ BMIM+ IM- J2-7 J2-8J2-9 J2-10 J2-11 J2-12 A+ AB+ BZ+ Z- HALL A HALL B HALL C ABS J2-13 J2-14 J2-15 J2-16 HALL A1 HALL B1 HALL C1 ABS2 TS+ TS- J2-19 J2-20 THERMOSTAT+ THERMOSTAT- NOTES: 1. For encoders with differential Hall ouputs (A+, A-, B+, B-, C+ and C-) connect only the + outputs to the drive. 2.
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6-32 Interfaces Figure 6.39 RS-232/485 Interface Circuit INT EXT XMT RCV RECEIVE RS-232 XMTXMT+ TRANSMIT TRANSMIT ENABLE RCV+ RCVRS-485 The serial interface of the drive uses the standard NRZ asynchronous serial format, and supports both the RS-232 and the four wire RS-485 communications standards. ● ● ● ● ● Standard baud rates include 1200, 2400, 4800, 9600 and 19200 baud. 9600 is the factory default setting. Even, odd, and no parity generation/checking are supported.
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Interfaces Table 6.24: RCV XMT 6-33 J5 - Serial Port Connector Pin-Outs (continued) J5 - 2 J5 - 3 J5 - 9 RS-232 receiver input (to drive) RS-232 transmitter output (from drive) Reserveda a. Do not connect any device to J5-6, or J5-9, except a TouchPad. Serial Communications Overview ULTRA 100 Series drives communicate via a standard NRZ (nonreturn to zero) asynchronous serial format, which supports either RS232 or four wire RS-485.
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6-34 Interfaces Single Axis RS-232 Set Up A single ULTRA 100 Series drive may be selected using RS-232 communications. After cabling is attached to the unit and the drive address is assigned, configuration of (i.e., communications with) the unit may proceed. Factory default settings for a ULTRA 100 Series drive are: ● ● ● Address 0 9600 Baud 8 Data, No Parity, 1 Stop bit The following steps outline how to select the communications options: 1.
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Interfaces 6-35 D. Select Communications from the menu E. Select PC Set Up from the pull down menu F. Verify the port settings, and if necessary, change them, then choose OK. G. Select Communications from the menu H. Select Read Drive Parameters from the pull down menu I. Choose OK in the Drive Select window. 3. Verify that ULTRA Master reads the drive parameters. If not, refer to “Troubleshooting” on page 11-3.
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6-36 Interfaces Figure 6.41 RS-485/RS-422 Communication Comparison Four Wire RS-485 Differential 4 Wires 2 Signal pairs 1 to 32 transmitters 1 to 32 receivers 1 2 32 RS-422 Differential 4 Wires 2 Signal pairs 1 Transmitter 1 to 10 receivers 1 2 10 1 2 32 RS-485 Standard Differential 2 Wires 1 Signal pair 1 to 32 transmitters 1 to 32 receivers NOTE: Not applicable to ULTRA 100 Series drives Note: Do not connect any device to J5-6 or J5-9 except a TouchPad.
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Interfaces 6-37 5. Verify that ULTRA Master loads the drive parameters. If not, refer to the troubleshooting section. 6. Repeat the preceding two steps for each additional drive. Publication 1398-5.
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6-38 Interfaces Multiple Axes RS-232 Communications Multiple axes systems may be controlled by a computer with an RS232 serial port. An RS-232 serial communication port may be converted to four wire RS-485 communication by attaching an RS232 to four-wire RS-485 converter. The figure below depicts the use of such a device. RS-232 to RS-485 Connection Diagram Return +12 VDC Figure 6.42 PC RS-232 Interface 7* RCV* 3* XMT* 2* * Pin-outs may vary by manufacturer.
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Interfaces Interface Connections 6-39 Shown here are typical components and connections for a ULTRA 100 Series drive, models 1398-DDM-005 and 1398-DDM-005X, 1398-DDM-009 and 1398-DDM-009X, 1398-DDM-019 and 1398-DDM-019X. Figure 6.43 1398-DDM Interface Connection Diagram Intro - - - Publication 1398-5.
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6-40 Interfaces Publication 1398-5.
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Chapter 7 Power Connections Chapter 7 DC bus, single phase AC power and motor connections are provided on the Terminal Block (TB-1). Table 7.
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7-2 Power Connections Motor Power Cabling TB1-6, TB1-7, TB1-8 and TB1-9 are the terminals for connecting the drive to the windings of a motor. Note: Proper phasing of these outputs relative to the motor terminals is critical. Double check the connections after wiring the motor Table 7.3 on page 7-7 lists the drive terminals and typical motor connections. Table 7.4 lists the minimum wire size for making power wiring connections.
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Power Connections Figure 7.1 7-3 Motor Power EMC Shield Connection T Shield Masked area Cable Jacket Power cable shield termination clamp on bottom of 1398-DDM-005, 1398-DDM-009 and 1398-DDM-019 Publication 1398-5.
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7-4 Power Connections LD-Series and Y-Series Motor Cables LD-Series and Y-Series motors have a short “pigtail” cable which connects to the motor but is not shielded. These motor power cables have a 6 inch shield termination wire with a ring lug which should be connected to the closest earth ground. The shield termination wire may be extended to the full length of the motor pigtail if necessary, but it is best to connect the supplied wire directly to ground without lengthening.
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Power Connections ● 7-5 within 20 seconds at 600% overload Power Supply Protection The feedback encoder, auxiliary encoder and optional TouchPad are powered by a single internal power supply. The power supply has a “resettable” fuse that opens at 3 amps and automatically resets itself when the current falls below 3 amps.There are no internal fuses requiring replacement. Emergency Stop Wiring An overlapping contactor may be inserted between the motor and the drive for emergency stop purposes.
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7-6 Power Connections Figure 7.3 Emergency Stop Contactor Wiring R1 R2 R3 Drive R R S S T T GND GND Isolated terminal Unbraided shield Grounded terminal or stud Enclosure wall Publication 1398-5.
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Power Connections AC Power Cabling 7-7 The 1398-DDM-005 and -005X, 1398-DDM-009 and -009X, 1398-DDM-019 and -019X drives require single phase, 100 to 240 VAC rms power with an input frequency of 47 - 63 Hz. “Power” on page G-5 lists the output power characteristics of the drives. The AC input supplies power to the motor. Alternatively, the drive may be powered by an external DC power source. In either case, an external power source must provide input power to the I/O.
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7-8 Power Connections Table 7.4: Drive Model AC Input Power Sizing Requirements Input Current Inrush Current Fuse Size1 5A Wire Size mm (AWG) Transformer Sizea 1398-DDM-005 or 5 A ACrms 75 A peak 1.5 (16) 1 kVA min 100 kVA 1398-DDM-005X max 100 A peak 10 A 2.5 (14) 2 kVA min 100 kVA 1398-DDM-009 or 9 A ACrms max 1398-DDM-009X 100 A peak 20 A 4.0 (12) 4 kVA min 100 kVA 1398-DDM-019 or 18 A ACrms max 1398-DDM-019X 1.
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Power Connections DC Bus 7-9 TB1-1 and TB1-2 are the DC Bus connections for an external shunt. Intro ! ATTENTION: External shunt resistors connect directly to the power bus. For safety reasons, external shunt resistors must be enclosed. Intro ! ATTENTION: DC bus capacitors may retain hazardous voltages after input power has been removed, but will normally discharge in several seconds.
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7-10 Power Connections Publication 1398-5.
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Chapter 8 Application and Configuration Examples Chapter 8 This section explains how to install and verify the ULTRA 100 Series drive for various modes of operation. The procedures verify the installation by: ● ● ● ● Showing how the power and logic wiring is connected. Selecting the Operation Mode setup for the drive. Tuning the drive for a particular motor type and size. Verifying the basic functionality of the drive and motor combination.
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8-2 Application and Configuration Examples • J1-21 (FAULT RESET) and J1-26 (I/O PWR). These connections provide manual control for enabling or disabling the drive and resetting faults. The figure below shows the jumper, including normally open toggle switches. 6. Connect an external 12 to 24 VDC power source for powering I/O to J1-5 (I/O PWR) and J1-6 (I/O COM). 7. Connect the drive to a single phase 100-240 VAC, 50/60 Hz power source. Connection Diagram Figure 8.
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Application and Configuration Examples 8-3 • If the settings are correct, select OK in the Port - Settings dialog box. • If the settings are different, correct the Port - Settings to allow communications with the drive. Factory default communications Port - Settings for the drive are: – Baud Rate: 9600 – Data Bits: 8 – Parity: None – Stop Bits: 1 – Serial Port: COM1 Refer to “RS-232 Communication Test” on page 11-8 for troubleshooting instructions. 6.
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8-4 Application and Configuration Examples Tuning Note: Do not attempt to Tune a drive with the Command mode set for Analog Torque Input. If the drive is set to torque mode, continue with the Operation section below. Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. The drive must be configured in Velocity mode for tuning to be effective. 2.
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Application and Configuration Examples 8-5 Operation The drive is now configured as an Analog Controller in either the velocity or torque mode. ● ● ● The current loop is compensated properly for the selected motor. The servo parameters have been setup with an unloaded motor. The motor speed or current is commanded through the analog input. The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above.
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8-6 Application and Configuration Examples 8Application and Configuration Examples Preset Controller The ULTRA 100 Series drive can be set up as a preset controller in the Velocity or Torque mode by making the connections described below. Three discrete digital inputs provide the programmable speed or torque control. Up to eight different preset speed or torque settings can be selected by using the three digital inputs in various binary combinations, as shown in the table below.
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Application and Configuration Examples 8-7 3. Connect a Power cable from the motor to TB1 (terminals R, S, T and ) on the drive. 4. Connect a jumper wire with a toggle switch between the following pins: • J1-20 (ENABLE) and J1-26 (I/O PWR) • J1-32 (INPUT1) and J1-26 (I/O PWR) • J1-33 (INPUT2) and J1-26 (I/O PWR) • J1-34 (INPUT3) and J1-26 (I/O PWR) • Connect a switch between J1-21 (FAULT RESET) and J1-26 (I/O PWR).
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8-8 Application and Configuration Examples 1. Switch the AC Power to ON and verify: • Status LED is green. Refer to “Status Indicator” on page 10-1 for an explanation of the display codes. 2. Start ULTRA Master on the PC. 3. Choose Cancel from the Drive Select dialog box. 4. Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer’s communication settings 5. Verify the communications port settings of the PC match those of the drive.
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Application and Configuration Examples 8-9 12. Select the Operation Mode parameter for the drive: Velocity Mode Settings Torque Mode Settings Preset Velocities as the Preset Torques as the Operation Mode Operation Mode 13. Choose Close from the Drive Setup window. 14. Choose the Drive Parameters command icon from the Drive window and then select the Preset tab. 15.
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8-10 Application and Configuration Examples 1. Choose the Tuning command icon from the Drive window. The drive must be configured in Velocity mode for tuning to be effective. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5. Close the toggle switch between J1-26 and J1-20 to enable the drive.
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Application and Configuration Examples 8-11 When motion is required: 1. Close the switch between J1-26 and J1-20 to enable the drive. 2. Close any of the switches for INPUT1, INPUT2 or INPUT3 to run the drive at the programmed preset speed or torque. Publication 1398-5.
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8-12 Application and Configuration Examples 8Application and Configuration Examples Position Follower (Master Encoder) The ULTRA 100 Series can be electronically geared to a master incremental encoder generating quadrature encoder signals by making the hardware connections and performing the software setup and tuning described below. The connection diagram depicts the minimum hardware necessary. Interfacing the drive to an external controller requires similar circuitry from the controller to J1.
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Application and Configuration Examples 8-13 Connection Diagram Figure 8.
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8-14 Application and Configuration Examples Factory default communications Port - Settings for the drive are: – Baud Rate: 9600 – Data Bits: 8 – Parity: None – Stop Bits: 1 – Serial Port: COM1 Refer to “RS-232 Communication Test” on page 11-8 for troubleshooting instructions. 6. Select Read Drive Parameters from the Communications menu. 7. Verify the Drive Name and Address are correct for the drive that is being addressed. 8. Choose OK to load the drive parameters.
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Application and Configuration Examples 8-15 19. Select an appropriate digital input from the pull-down lists available as Digital Input Assignments in the I/O Configuration window. For example: • Follower Enable as Input 1 • Not Assigned as Inputs 2 through 3. • Not Assigned as Inputs 1 and 2. 20. Choose Close to exit the I/O Configuration window. 21. Verify the Status indicator is green. Publication 1398-5.
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8-16 Application and Configuration Examples Tuning Note: Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5.
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Application and Configuration Examples 8-17 The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above. When motion is required: 1. Close the switch between J1-26 and J1-20 to enable the drive. 2. Close the switch between J1-26 and J1-32 to enable following. Publication 1398-5.
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8-18 Application and Configuration Examples 8Application and Configuration Examples Position Follower (Step/ Direction) The ULTRA 100 Series drive can be set up as a Position Follower using Step/Direction commands by making the hardware connections and performing the software setup and tuning described below. This configuration allows the ULTRA 100 Series drive to electronically gear or drive a servo motor using step and direction signals that typically control a stepper drive.
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Application and Configuration Examples 8-19 Connection Diagram Figure 8.
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8-20 Application and Configuration Examples • If the settings are different, correct the Port - Settings to allow communications with the drive. Factory default communications Port - Settings for the drive are: – Baud Rate: 9600 – Data Bits: 8 – Parity: None – Stop Bits: 1 – Serial Port: COM1 Refer to “RS-232 Communication Test” on page 11-8 for troubleshooting instructions. 6. Select Read Drive Parameters from the Communications menu. 7.
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Application and Configuration Examples 8-21 19. Select an appropriate digital input from the pull-down lists available as Digital Input Assignments in the I/O Configuration window. For example: • Follower Enable as Input 1 • Not Assigned as Inputs 2 through 3. • Not Assigned as Outputs 1 and 2. 20. Choose Close to exit the I/O Configuration window. Publication 1398-5.
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8-22 Application and Configuration Examples Tuning Note: Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5.
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Application and Configuration Examples 8-23 The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above. When motion is required: 1. Close the switch between J1-26 and J1-20 to enable the drive. 2. Close the toggle switch between J1-26 and J1-32 to enable following. Publication 1398-5.
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8Application and Configuration Examples Position Follower (Step Up/ Down) The ULTRA 100 Series can be set up as a Position Following using Step Up and Step Down signals typically used to control stepper drives. The connection diagram depicts the minimum hardware necessary. Interfacing the drive to a controller requires similar circuitry from the indexer to J1. Instructions are provided to configure the drive with ULTRA Master software.
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Application and Configuration Examples 8-25 Connection Diagram Figure 8.
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8-26 Application and Configuration Examples • If the settings are different, correct the Port - Settings to allow communications with the drive. Factory default communications Port - Settings for the drive are: – Baud Rate: 9600 – Data Bits: 8 – Parity: None – Stop Bits: 1 – Serial Port: COM1 Refer to “RS-232 Communication Test” on page 11-8 for troubleshooting instructions. 6. Select Read Drive Parameters from the Communications menu. 7.
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Application and Configuration Examples 8-27 19. Select an appropriate digital input from the pull-down lists available as Digital Input Assignments in the I/O Configuration window. For example: • Follower Enable as Input 1 • Not Assigned as Inputs 2 through 3. • Not Assigned as Outputs 1 and 2. 20. Choose Close to exit the I/O Configuration window. Publication 1398-5.
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8-28 Application and Configuration Examples Tuning Note: Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5.
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Application and Configuration Examples 8-29 The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above. When motion is required: 1. Close the switch between J1-26 and J1-20 to enable the drive. 2. Close the toggle switch between J1-26 and J1-32 to enable following. Publication 1398-5.
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8-30 Application and Configuration Examples 8Application and Configuration Examples Incremental Indexing Note: This feature is available only on drives capable of indexing: 1398-DDM-005X, 1398-DDM-009X and 1398-DDM-019X. The ULTRA 100 Series drive can be set up as a incremental indexer by making the hardware connections and performing the software setup and tuning described below. A connection diagram depicts the minimum hardware necessary.
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Application and Configuration Examples 8-31 Hardware Set Up Make the connections described below and shown in the Figure 8.7. The appendix “Options and Accessories” on page A-1 lists the interconnect cables available from the factory. 1. Connect an RS-232 cable between the serial port on the PC and the J4 connector on the ULTRA 100 Series. A simple 3 wire cable is depicted in the figure below. 2. Connect a Motor/Feedback cable from the motor to the J2 connector on the ULTRA 100 Series. 3.
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8-32 Application and Configuration Examples Figure 8.7 Incremental Indexing Connection Diagram J4 XMT RCV COM DRIVE 2 RCV J2 Motor Encoder 3 XMT TB1 5 COM Phase R 6 Phase S 7 J1 Phase T 8 26 I/O PWR Close to ENABLE Drive 20 ENABLE Close to RESET Fault 21 FAULT RESET Close to Start INDEX 32 INPUT1 External I/O 12-24 VDC Power Source Motor Gnd 9 TB1 L1 3 L2/N 4 Gnd 5 5 I/O PWR 100-240 VAC 50/60 Hz Single Phase Power Source 6 I/O COM 5.
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Application and Configuration Examples 8-33 9. If the message box appears that a motor must be selected, select OK. The Drive Setup window is displayed with Motor Model selection parameter active. The motor may be selected from the drop down box. If this message box does not appear, the motor displayed in the Motor Model box was previously selected. 10. Select or verify the correct motor model number from the drop down Motor Model list. 11. If a message advises that the drive must be reset, choose Yes.
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8-34 Application and Configuration Examples • Not Assigned as Outputs 1 and 2. 20. Choose Close to exit the I/O Configuration window. Publication 1398-5.
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Application and Configuration Examples 8-35 Tuning Note: Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5.
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8-36 Application and Configuration Examples The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above. When motion is required: 1. Close the switch between J1-26 and J1-20 to enable the drive. 2. Close the toggle switch between J1-26 and J1-32 to start Index 0. Publication 1398-5.
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Application and Configuration Examples 8-37 8Application and Configuration Examples Registration Indexing Note: This feature is available only on drives capable of indexing: 1398-DDM-005X, 1398-DDM-009X and 1398-DDM-019X. The ULTRA 100 Series drive can be set up as a registration indexer by making the hardware connections and performing the software setup and tuning described below. A connection diagram depicts the minimum hardware necessary.
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8-38 Application and Configuration Examples 4. Connect the Index Sensor to the drive as shown in the diagram. 5. Connect a jumper wire with a toggle switch between the following pins: • J1-20 (ENABLE) and J1-26 (I/O PWR) • J1-32 (INPUT1) and J1-26 (I/O PWR) • J1-33 (INPUT2) and J1-26 (I/O PWR) • J1-21 (FAULT RESET) and J1-26 (I/O PWR). These connections provide manual control for enabling or disabling the drive and resetting faults.
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Application and Configuration Examples 8-39 • Status LED is green. Refer to “Status Indicator” on page 10-1 for an explanation of the display codes. 2. Start ULTRA Master on the PC. 3. Choose Cancel from the Drive Select dialog box. 4. Select PC Set Up from the Communications menu in ULTRA Master to display the personal computer’s communication settings. 5. Verify the communications port settings of the PC match those of the drive.
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8-40 Application and Configuration Examples 13. Choose Close to exit the Drive Set Up window. 14. Choose the Drive Parameters command icon from the Drive window and then select the Indexing tab. 15. Enter the following values for Index 0.
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Application and Configuration Examples 8-41 Tuning Note: Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5.
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8-42 Application and Configuration Examples The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above. When motion is required: 1. Close the switch between J1-26 and J1-20 to enable the drive. 2. Close the toggle switch between J1-26 and J1-32 to start Index 0. 3. Close the toggle switch between J1-26 and J1-33 to simulate registration. Publication 1398-5.
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Application and Configuration Examples 8-43 8Application and Configuration Examples Absolute Indexing Note: This feature is available only on drives capable of indexing: 1398-DDM-005X, 1398-DDM-009X and 1398-DDM-019X. The ULTRA 100 Series drive can be set up as a absolute indexer by making the hardware connections and performing the software setup and tuning described below. A connection diagram depicts the minimum hardware necessary.
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8-44 Application and Configuration Examples • J1-33 (INPUT2) and J1-26 (I/O PWR) • J1-21 (FAULT RESET) and J1-26 (I/O PWR). These connections provide manual control for enabling or disabling the drive and resetting faults. The figure below shows the jumper, including normally open toggle switches. 5. Connect an external 12 to 24 VDC power source for powering I/O to J1-5 (I/O PWR) and J1-6 (I/O COM). 6. Connect the drive to a single phase 100-240 VAC, 50/60 Hz power source. Publication 1398-5.
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Application and Configuration Examples 8-45 Connection Diagram Figure 8.
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8-46 Application and Configuration Examples – Baud Rate: 9600 – Data Bits: 8 – Parity: None – Stop Bits: 1 – Serial Port: COM1 Refer to “RS-232 Communication Test” on page 11-8 for troubleshooting instructions. 6. Select Read Drive Parameters from the Communications menu. 7. Verify the Drive Name and Address are correct for the drive that is being addressed. 8. Choose OK to load the drive parameters. Note: A motor must be selected for the parameters to load. 9.
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Application and Configuration Examples 8-47 19. Select an appropriate digital input from the pull-down lists available as Digital Input Assignments in the I/O Configuration window. For example: • Start Index as Input 1. • Define Home as Input 2. • Not Assigned as Input 3. • Not Assigned as Outputs 1 and 2. 20. Choose Close to exit the I/O Configuration window. Publication 1398-5.
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8-48 Application and Configuration Examples Tuning Note: Do not attempt to Auto Tune systems that have gravitational effects. The ULTRA 100 Series will not hold initial position. 1. Choose the Tuning command icon from the Drive window. 2. Select AutoTune from the Tuning mode group. 3. Select the appropriate values for the following Auto Tune commands: • Distance and • Step Current. 4. Select the appropriate entry for the Motor Direction: • BiDirectional, • Forward Only or • Reverse Only. 5.
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Application and Configuration Examples 8-49 The firmware saves the parameters in EEPROM memory. Thus the drive can be power cycled and, after power-up, will use the parameters selected in the steps above. When motion is required: 1. Close the switch between J1-20 and J1-26 to enable the drive. 2. Close the toggle switch between J1-32 and J1-26 to start Index 0. 3. Close the switch between J1-33 and J1-26 to define the Home position. Publication 1398-5.
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8-50 Application and Configuration Examples 8Application and Configuration Examples Modifying User Units The units displayed for any ULTRA 100 Series drive may be modified using a PC with ULTRA Master software. The PC Display Units help menu defines the various parameters displayed by ULTRA Master. Default settings for Units are shown in Figure 8.12. Figure 8.
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Application and Configuration Examples 8-51 6. Choose OK to exit the PC Display Units dialog. The modified units will be displayed where appropriate within the ULTRA Master windows. For example, these changes cause the Indexing tab in the Drive Parameters window to display: ● Distance in Mtr Revs ● Acceleration in Revs/sec2 ● Deceleration in Revs/sec2 The following units were not effected by the changes: ● ● Dwell in msec Velocity in RPM Publication 1398-5.
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8-52 Application and Configuration Examples Publication 1398-5.
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Chapter 9 Tuning Chapter 9 ULTRA 100 Series drives are tuned quickly and easily for a wide variety of applications. Two tuning modes are available through the software: ● ● Tuning Guidelines Auto Tune Manual Tune The following tuning guidelines briefly describe the tuning adjustments. These guidelines provide you with a basic reference point should the application require additional adjustments.
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9-2 Tuning Mechanical Resonance Mechanical resonance between the motor and the load occurs when the motor and load are oscillating with the same frequency but opposite phase: when the motor is moving clockwise the load is moving counter clockwise. The amplitude of the motor and load oscillations is such that the total momentum of the oscillating system is zero.
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Tuning Figure 9.2 9-3 Torque Current Conditioning Structure CURRENT LIMIT TORQUE CURRENT COMMAND OUTPUT AVERAGE LP ENABLE AVERAGE CURRENT CURRENT EXCESSIVE CURRENT TORQUE CURRENT COMMAND INPUT CURRENT LIMIT CURRENT LIMIT PEAK DETECT POSITIVE CURRENT PEAK PEAK DETECT NEGATIVE CURRENT PEAK LOW PASS FILTER Backlash Backlash between the motor and load effectively unloads the motor over a small angle. Within this small angle, the increased gain can result in oscillations.
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9-4 Tuning ● Distance sets the rotation limit of the motor. This is the maximum distance the motor is allowed to move during any one test. Note: Autotuning in the bi-directional mode includes two different tests. ● ● Step Current sets the amount of current given to the motor during the test. If this is set too low, a system may not move enough to gather sufficient data, if it is set too high the test will be too short and very jerky.
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Tuning 9-5 Use the default settings if you are uncertain about what values to enter. The default settings are set to values appropriate to the drive and motor combination selected during drive initialization. 3. Enable the drive. 4. Choose Start from the Tuning window. The drive rotates the motor shaft and then motion will cease. The calculated gains are displayed and the drive is disabled. 5. Disable the drive manually. 6. Choose Normal Drive Operation from the Tuning window. 7. Enable the drive. 8.
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9-6 Tuning Manual Tune Mode Manual tuning may be used to adjust the gain settings and filter frequency of the velocity and position regulator. The following sections briefly explain these settings. An understanding of the function for each type of gain and filtering will allow you to effectively tune the system. Two types of manual tuning are available: ● ● Velocity tuning Position tuning. Before manual tuning is invoked, the Velocity, Distance and Motor Direction parameters must be set.
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Tuning Table 9.1: Parameter P-gain 9-7 Velocity Loop Gains Description Proportional gain of the velocity regulator. P-gain controls the bandwidth of the velocity regulator by adjusting the control response proportional to the error. I-gain The P term of the velocity regulator commands an acceleration current that is proportional to the velocity error. Integral gain of the velocity regulator. Integration in the velocity regulator forces the motor velocity to precisely follow the commanded velocity.
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9-8 Tuning Tuning the Velocity Loop The Auto Tune procedure provides a starting point for velocity loop tuning. Manual tuning is desirable when very precise adjustments are required. The following steps describe how to manually tune the velocity loop. These steps precede the manual position loop tuning procedure, which should follow velocity loop tuning. 1. Disable the drive. 2. Choose Manual Tune (Velocity Step) from the Tuning window. 3.
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Tuning 9-9 Tuning the Position Loop Specify the step period and step position values, and then input a square wave to the position loop. Adjust the gain parameters Kp, Kd, Kff, Ki, and Ki Zone to tune the system. Note: Tune the velocity loop before attempting to tune the position loop. The bandwidth of the velocity loop must be set before position loop tuning is attempted. 1. Disable the drive. 2. Choose Manual Tune (Position Step) from the tuning window. 3.
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9-10 Tuning Figure 9.3 Signal Nomenclature Intro VELOCITY Overshoot Following Error or Steady State Error Undershoot Settle Time Rise Time Transient State Figure 9.4 Underdamped Signal Intro UNDERDAMPED Motor Velocity consistently overshoots the Velocity Command. To correct: Decrease P-gain Decrease I-gain Publication 1398-5.
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Tuning Figure 9.5 9-11 Overdamped Signal Intro OVERDAMPED Motor Velocity consistently undershoots the Velocity Command. To correct: Increase I-gain Increase P-gain Figure 9.6 Critically Damped Signal (Ideal Tuning) Intro CRITICALLY DAMPED Motor Velocity quickly settles to the Velocity Command. Publication 1398-5.
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9-12 Tuning Publication 1398-5.
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Chapter 10 Status Display Chapter 10 A single front panel indicator displays the status of the drive on a continuous basis: ● Status Indicator The Status LED lights whenever the bus is energized. The Status indicator is a three level LED, which indicates the current operational state of the drive. The status level is indicated by the color of the LED.
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10-2 Status Display Table 10.1: Error Code 21 22 23 24 25 26 27 28 29 30 31 - 50 List of Run Time Error Codes (continued) Fault Description Auxiliary Encoder State Error Motor Thermal Protection IPM Thermal Protection Excess Velocity Error Commutation Angle Error Reserved Axis not Homed No Motor Selected Motor Selection not in Table EEPROM Write Error Reserved Power-Up Error Codes A power-up error indicates in almost all cases that the drive should be returned to the factory for service.
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Status Display Table 10.
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10-4 Status Display Publication 1398-5.
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Chapter 11 Maintenance and Troubleshooting Chapter 11 This section provides a description of suggested maintenance activities and an in-depth troubleshooting chart. Maintenance The ULTRA 100 Series drive is designed to function with minimum maintenance. Intro ! ATTENTION: DC bus capacitors may retain hazardous voltages after input power has been removed, but will normally discharge in several seconds.
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11-2 Maintenance and Troubleshooting To transfer the data from the drive to a PC: 1. While on-line with a drive, click on File in the toolbar menu. 2. Select Save As..., the Save As window will appear. 3. Enter the file name and press ENTER or choose OK to save. To transfer the data from a PC to a drive: 1. Close all windows in ULTRA Master. 2. Choose File in the toolbar menu. 3. Choose Open. 4. Select the desired file name or enter the file name to be loaded and press ENTER or choose OK.
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Maintenance and Troubleshooting 11-3 3. When the Drive Select window appears, select Cancel. The Drive Select window closes without connecting to the drive. 4. Choose Upgrade Firmware from the File menu. The Drive Select window will appear. 5. Select the drive to upgrade, and then select OK. The Select Firmware File window will appear. 6. The Select Firmware File window contains a list of firmware files identified by version information.
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11-4 Maintenance and Troubleshooting Error Codes Error codes may be accessed by attaching either a PC with ULTRA Master software or a TouchPad to the serial port (J5): ● ● ULTRA Master displays errors in two windows: Fault History and Display Fault Status, The TouchPad display errors in the DrvStat parameter under the STATUS branch title. Table 11.1: Problem or Symptom Error Code STATUS LED not lit Troubleshooting Guide Possible Cause(s) No AC power Internal power supply malfunction.
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Maintenance and Troubleshooting Table 11.
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11-6 Maintenance and Troubleshooting Table 11.1: Problem or Symptom Motor Overspeed Error Code 18 Troubleshooting Guide (continued) Possible Cause(s) Action/Solution OVERSPEED parameter in the drive set to low for the application Using ULTRA Master (refer to Drive Parameters section) set Overspeed parameter to an acceptable range for the application. Reduce command from position controller or change velocity parameter in the position controller. Check encoder phasing.
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Maintenance and Troubleshooting Table 11.1: Problem or Symptom Error Code Commutation Angle Error 25 RESERVED RESERVED No Motor Selected 26 27 28 Motor Information Missing 29 RESERVED 30-99 11-7 Troubleshooting Guide (continued) Possible Cause(s) Action/Solution Bad encoder Replace encoder or motor/ encoder. Check wiring of motor encoder index signal. No motor was selected when the drive was enabled. The motor number is referencing a motor that is not currently in the drive.
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11-8 Maintenance and Troubleshooting RS-232 Communication Test This test verifies communications between an ULTRA 100 Series drive and a personal computer by connecting the XMT pin to the RCV pin. The jumper bypasses the potentially defective cable and remote unit. Test equipment requirements are: A PC running ULTRA Master ● The Terminal mode available in Microsoft Windows. 1. Close all ULTRA Master windows. ● 2. Select Communication from ULTRA Master and verify your communication settings. 3.
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Maintenance and Troubleshooting 11-9 If you see the character on the screen remove the jumper between pins 2 and 3, close the Windows Terminal and restart ULTRA Master. If the character does not echo back on the screen, do the following: • Disconnect the cable from your PC. • Jumper Pins 2 and 3 on the communication port of the PC. • Type any character on the keyboard. – If the character echoes back, the communication port is OK and the cable or the connectors are defective.
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11-10 Maintenance and Troubleshooting – If the box is checked, the resistance should read approximately 1 Ohm. – If the box is not checked, the resistance should read very high (> 1 MOhm). B. Brake Enable box, then measure the resistance between J1-49 and J1-50. – If the box is checked, the resistance should read approximately 1Ohm. – If the box is not checked, the resistance should be very high (> 1 MOhm). A load is necessary to test the transistor outputs listed below.
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Maintenance and Troubleshooting 11-11 Testing Digital Inputs This test verifies the functionality of the selectable inputs. Note: This test assumes that I/O power is 24 VDC. Test equipment requirements are: ● ● A PC running ULTRA Master A jumper wire. It assumes there are no error codes displayed, and the 24V power supply is connected correctly. 1. Disable the drive by opening the switch connecting J1-26 and J120. 2. Choose the I/O Display command icon from the Drive Window. A. Connect J1-20 to J1-26.
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11-12 Maintenance and Troubleshooting 4. From the Output Diagnostics window select Analog Output 1. 5. Enter 1000 in the D/A level box. 6. Connect a DC voltmeter across analog test points J1-31 and J1-28. The meter should read approximately 1 Vdc. 7. Repeat step using different positive or negative values for the D/A Level. Verify the meter reads the values you enter. If you determine that the output is defective, please refer to “Return Procedure” on page Help-7 to return the unit.
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Maintenance and Troubleshooting 11-13 Testing Encoder Inputs The following test verifies both reception and transmission of the line count from an encoder by the drive. Note: This test assumes that I/O power is 24 VDC. The tests require: ● ● a PC running ULTRA Master, and a motor encoder. Testing Encoder Inputs 1. Disable the drive by opening the connections between the ENABLE input and I/O Power (I/O PWR). 2. Choose the Drive Set Up command icon from ULTRA Master. 3.
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11-14 Maintenance and Troubleshooting Publication 1398-5.
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Appendix A Options and Accessories Appendix A ULTRA 100 Series drives conformance to the European Union Directives is contingent on: 1. Installation of AC line filters between the power source and the drive, and 2. Use of factory supplied cables to connect F-, H-, LD- N-, S-, Wor Y-Series motors to a drive. Diagrams and schematics for all Rockwell Automation cables are shown in Cable Diagrams, Schematics and Examples, beginning on page B-1.
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A-2 Options and Accessories Description TouchPad AC Line Filter for 1398-DDM-005 or -005X (6 Arms continuous, single phase) AC Line Filter for 1398-DDM-009, -009X or -010 (10 Arms continuous, single phase) AC Line Filter for 1398-DDM-019, -019X or -020 (23 Arms continuous, single phase) AC Line Filter for 1398-DDM-030 (30 Arms continuous, single phase) AC Line Filter for 1398-DDM-075 (55 Arms continuous, single phase) AC Line Filter for 1398-DDM-075 (36 Arms continuous, three phase) J1 to 50-pin Terminal
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Options and Accessories Serial Interface Cables Diagrams and schematics for these cables are shown beginning on page B-11. Description J4/J5 to PC [RS-232] (9 pin D-shell connector) J4/J5 to customer supplied connector (no connector) J4/J5 to J4/J5 four wire RS-485 communications J4/J5 D-shell 9-pin Mating Connector (AMP 205204-4) J4/J5 Crimp Pins for Connector (AMP 66506-3) Encoder Feedback Cables A-3 3 m (10 ft) 7.6 m (25 ft) 15 m (50 ft) 3 m (10 ft) 7.
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A-4 Options and Accessories Description (1398-DDM-005, -009 and -019 require Rev D or higher cable) LD-Series and Y-Series Motors to J2 (1398-DDM-005, -009 and -019 require Rev D or higher cable) J2 to customer supplied connector (no connector) (1398-DDM-005, -009 and -019 require Rev C or higher cable) (1398-DDM-005, -009 and -019 require Rev C or higher cable) Motor Power Cables Part Number 9101-1373-100 0.6 m (2 ft) 3 m (10 ft) 7.
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Options and Accessories Description 1398-DDM-150 to 8000 Motors (F-, H- or S-Series) Drive to N-Series Motors Drive to LD-Series and Y-Series Motors 3 m (10 ft) 7.6 m (25 ft) 15 m (50 ft) 23 m (75 ft) 30 m (100 ft) 3 m (10 ft) 7.6 m (25 ft) 15 m (50 ft) 23 m (75 ft) 30 m (100 ft) 0.6 m (2 ft) 3 m (10 ft) 7.
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A-6 Options and Accessories Connector Kits Connector kits provide the ability to construct custom length cables. Kits are available for all ULTRA 100 Series connectors. Each kit consists of the appropriate 3M connector with the corresponding plastic backshell, and instructions.
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Appendix B Cable Diagrams, Schematics and Examples Appendix B Factory supplied cables allow ULTRA 100 Series drives to conform to the European Union Directives when connecting the drive to motors, controllers or computers. The following diagrams provide information on the cables available from the factory. Refer to Appendix A, “Options and Accessories” for ordering information. The information below applies to all factory supplied cables.
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B-2 Cable Diagrams, Schematics and Examples ● ● Publication 1398-5.2 – PDF 1997 Cables are manufactured to inch dimensions. Millimeter dimensions are approximate conversions from inches.
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Cable Diagrams, Schematics and Examples B-3 Interface Cables Figure B.1 J1 to J3 Interface Cable (P/N 9101-1367) Intro ( ( IHHW R R 0$5.(' :,7+ 3$57 $1' 5(9 0$18)$&785(56 3$57 5(9 $1' '$7( &2'( 0 [ 5(75$&7$%/( 0$&+,1(' 7+80%6&5(: )$67(16 ',5(&7/< 72 %2$5' &211(&725 0 [ 5(75$&7$%/( 0$&+,1(' 7+80%6&5(: )$67(16 ',5(&7/< 72 %2$5' &211(&725 Publication 1398-5.
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B-4 Cable Diagrams, Schematics and Examples Figure B.2 Intro 7$% Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.3 B-5 J3 to J3 Interface Cable (P/N 9101-1463) Intro Publication 1398-5.
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B-6 Cable Diagrams, Schematics and Examples BCable Diagrams, Schematics and Examples Figure B.4 J3 to No Connector Interface Cable (P/N 9101-1368) Intro 7$% Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.5 B-7 J1 to 50-pin Terminal Block Kit Diagram (P/N 9101-1391 and 9101-1560) Intro Mounting bracket 0002-7069 (shown) and cable 9101-1369-003 supplied with 9101-1391 kit. Mounting bracket 0002-7069 (shown) and cable 9101-1369-010 supplied with 9101-1560 kit. NOTES: The terminal block and cable provide a one-to-one transfer of the signals from the connector to the respective pin(s) on the terminal block.
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B-8 Cable Diagrams, Schematics and Examples Figure B.6 Intro Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.7 B-9 J2 to 25-pin Terminal Block Kit Diagram (P/N 9101-1392) Intro Mounting bracket 0002-7068 (shown) and cable 9101-1371-003 (next page) supplied with kit. NOTES: The terminal block and cable provide a one-to-one transfer of the signals from the connector to the respective pin(s) on the terminal block. The cabling examples beginning on page B-24 depict the use of this kit to pass a cable through a restricted bulkhead. Publication 1398-5.
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B-10 Cable Diagrams, Schematics and Examples Figure B.8 J2 to 25-pin D-Connector Cable (P/N 9101-1371) Intro 0.38 Publication 1398-5.
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Cable Diagrams, Schematics and Examples B-11 BCable Diagrams, Schematics and Examples Serial Interface Cables Figure B.9 J5 to 9-pin D-Shell Interface Diagram (P/N 9101-1372) Intro RED WHITE/RED GREEN WHITE/GREEN BLACK WHITE/BLACK Publication 1398-5.
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B-12 Cable Diagrams, Schematics and Examples Figure B.10 Intro Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.11 B-13 J5 to No Connector Serial Interface Cable (P/N 9101-1379) Intro Publication 1398-5.
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B-14 Cable Diagrams, Schematics and Examples BCable Diagrams, Schematics and Examples Encoder Feedback Cables Figure B.12 Intro Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.13 B-15 J2 to F- or H-Series Encoder Cable (P/N 9101-1366) Intro Publication 1398-5.
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B-16 Cable Diagrams, Schematics and Examples Figure B.14 J2 to Y-Series Encoder Cable (P/N 9101-1375) Intro 0.38 GRAY 16 AWG WHITE/GRAY 16 AWG BROWN 28 AWG WHITE/BROWN 28 AWG BLACK 28 AWG WHITE/BLACK 28 AWG REDK 28 AWG WHITE/RED 28 AWG GREEN 28 AWG WHITE/GREEN 28 AWG ORANGE 28 AWG WHITE/ORANGE 28 AWG BLUE 28 AWG DRAIN Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.15 B-17 No Connector to Y-Series Encoder Cable (P/N 9101-1373) Intro ( 67$57 2) %(1' 5$',86 02/',1* 0$5.(' :,7+ 3$57 $1' 5(9 0$18)$&785(56 3$57 5(9 $1' '$7( &2'( :,5,1* ',$*5$0 *5$< $:* :+,7( *5$< $:* %52:1 :+,7( %52:1 <(//2: :+,7( <(//2: %/$&. $:* $:* $:* $:* $:* :+,7( %/$&.
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B-18 Cable Diagrams, Schematics and Examples Figure B.16 J2 to No Connector Encoder Cable (P/N 9101-1380) Intro 0.38 28 AWG GRAY (16 AWG) 28 AWG 28 AWG WHITE/GRAY (16 AWG) 28 AWG BLUE (28 AWG) WHITE/BLUE (28 AWG) BLACK (28 AWG) WHITE/BLACK (28 AWG) RED (28 AWG) WHITE/RED (28 AWG) GREEN (28 AWG) WHITE/GREEN (28 AWG) YELLOW (28 AWG) WHITE/YELLOW (28 AWG) ORANGE (28 AWG) WHITE/ORANGE (28 AWG) BROWN (28 AWG) WHITE/BRONW (28 AWG) VIOLET (28 AWG) WHITE/VIOLET (286 AWG) DRAIN Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.17 B-19 Reliance HR2000 Encoder Cable (P/N 9101-1445) Intro 0.38 GRAY 16 AWG WHITE/GRAY 16 AWG BLUE 28 AWG WHITE/BLUE 28 AWG BLACK 28 AWG WHITE/BLACK 28 AWG RED 28 AWG WHITE/RED 28 AWG GREEN 28 AWG WHITE/GREEN 28 AWG YELLOW 28 AWG WHITE/YELLOW 28 AWG ORANGE 28 AWG WHITE/ORANGE 28 AWG VIOLET 28 AWG WHITE/VIOLET 28 AWG DRAIN SHIELD Publication 1398-5.
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B-20 Cable Diagrams, Schematics and Examples Figure B.18 Reliance HR2000 to No Connector Encoder Cable (P/N 9101-1446) Intro 0.
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Cable Diagrams, Schematics and Examples B-21 BCable Diagrams, Schematics and Examples Motor Power Cables Intro ! Figure B.19 ATTENTION: Shielded power cables must be grounded at a minimum of one point for safety. Failure to ground a shielded power cable will result in potentially lethal voltages on the shield and anything connected to it. 2000 or 3000 F- or H-Series Power Cable (P/N 9101-1381) Intro Publication 1398-5.
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B-22 Cable Diagrams, Schematics and Examples Figure B.20 4000 F- or H-Series Power Cable (P/N 9101-1382) Figure B.21 6000 F- or H-Series Power Cable (P/N 9101-1383) Intro Intro Publication 1398-5.
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Cable Diagrams, Schematics and Examples Figure B.22 Y-Series Power Cable (P/N 9101-1385) Figure B.23 1398-DDM-075 to 6000 Motors (F- or H-Series) (P/N 9101-2179) B-23 Intro Intro 72 '5,9( 02'8/( :,5( /(1*7+ '5,9( 02'8/( 02725 (1' /$%(/6 &2/25 &211(&725 3,1 5 5(' $ 6 :+,7( % 7 %/$&. & * *5((1 ' :,5( 6&+(0$7,& 0$18)$&785(56 3$57 $1' 5(9 &2'( '5,9( 02'8/( 02725 5(' $ 5 :+,7( % 6 %/$&. & 7 *5((1 *1' ' Publication 1398-5.
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B-24 Cable Diagrams, Schematics and Examples BCable Diagrams, Schematics and Examples Cabling Examples Figure B.
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Cable Diagrams, Schematics and Examples Figure B.25 B-25 F- or H-Series Motors to ULTRA 100 Series Drive using P2 Terminal Strip Intro Motor Enclosure/Cabinet Screw Terminal Strip 9101-1365-XXX Encoder Connector Motor Power Connector 9101-1392 P2 9101-1391 P1 To Control Interface Screw Terminal Strip Clamp exposed motor cable shield to the chassis ground terminal Motor Power Cable NOTES: This wiring method provides the option to run cables through a restrictive bulkhead or enclosure.
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B-26 Cable Diagrams, Schematics and Examples Figure B.26 Y-Series Motors to ULTRA 100 Series Drive Intro Enclosure/Cabinet Motor Encoder Connectors CPC connectors P2 9101-1375-XXX 9101-1391 P1 To Control Interface Screw Terminal Strip Clamp exposed motor cable shield to the chassis ground terminal Motor Power connectors Pigtail cable to machine chassis ground 9101-1385-XXX NOTES: This wiring method should be used to run cables through a bulkhead or enclosure without removing the connectors.
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Cable Diagrams, Schematics and Examples Figure B.
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B-28 Cable Diagrams, Schematics and Examples Table B.1: 9/260 or 9/290 to Breakout Board (continued) 9/260 or 9/290 8520Breakout Board Connections via J2 ASM-3 1398-DDM-005, -005X, -009, -009X, -019 or -019X 5 CHZ_HI 11 MtrEncdr Input Chnl Index+ 12 CHA_LO 8 MtrEncdr Input Chnl A13 CHB_LO 10 MtrEncdr Input Chnl B14 CHZ_LO 12 MtrEncdr Input Chnl IndexNOTE: A-B 845 encoders are usually wired with the A- signal into the A+ signal on the Allen-Bradley drive Table B.
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Cable Diagrams, Schematics and Examples Table B.4: B-29 9/230 to J1 Connector (continued) 9/230 8520-ASM-4 J1 Connections 1398-DDM-005, -005X, -009, -009X, -019 or -019X 40 CHB_LO 10 Mtr Output Chnl B9 CHZ_LO 12 Mtr Output Chnl IndexNOTE: A-B 845 encoders are usually wired with the A- signal into the A+ signal on the Allen-Bradley drive Publication 1398-5.
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B-30 Cable Diagrams, Schematics and Examples Publication 1398-5.
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Appendix C TouchPad Instructions Appendix C The optional TouchPad is a compact and rugged device for interfacing with ULTRA 100 Series drives. It provides the operator with a convenient device for accessing status information, program variables, and control functions, plus message display capabilities on any ULTRA 100 Series drive. An 8-character dot matrix display and a sealed-membrane type keyboard are housed in a compact case.
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C-2 TouchPad Instructions 4. Verify the Ver##.## displayed is correct at power-up. The version number designates the type of drive and its firmware level. Figure C.2 explains this display. Figure C.
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TouchPad Instructions TouchPad Commands C-3 Commands are entered by pressing a single key or combination of keys. Two modes of operation are available. Parameter mode allows you to move through the TouchPad Command Tree to each parameter. Modify mode allows you to monitor and change each parameter, often while the drive is operational. The Parameter mode displays for the TouchPad Command Tree are depicted on the “Supplemental Instructions” on page C-6.
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C-4 TouchPad Instructions Figure C.
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TouchPad Instructions Figure C.
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C-6 TouchPad Instructions Supplemental Instructions Motor Selection Enter a Motor Identification number to load the correct motor parameters into the drive. Table C.2 on page C-11 and Table C.3 on page C-13 list the motors available in the motor table directory. Selection of a motor defines default operating parameters for the drive and motor combination. Analog Output Scaling Selection of Analog Output Scaling through the TouchPad requires manual input of the scaling parameters.
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TouchPad Instructions C-7 Displays Text A drive name longer than eight characters may require scrolling with the Left, , and Right, , arrow keys. Drive names may be up to 32 characters in length. Flashing characters in the Modify mode display are the characters that are active. ● Change the cursor position and resolution using the and keys. For example: If the Drv Name in the Modify mode displays InFeed with the F flashing, pressing the key causes the first e to flash.
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C-8 TouchPad Instructions ● A filled arrow, , in the most significant digit indicates the active setting from a list of possible settings. Inactive settings are indicated by a unfilled arrow, . For example: If the drive is functioning as Preset Controller in the Velocity mode, pressing the key from DRVPARAM scrolls through the CmdSrc list which includes Presets, AuxEnc, StepDir, StepU/D, and Analog. ● The Mode/Enter, ● List selections that are undefined are indicated by Unknown.
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TouchPad Instructions ● ● ● The TouchPad displays Fault and a description. A Fault message requires additional troubleshooting of the drive. Clear the fault display by depressing the and keys simultaneously. Fault codes are stored in the TouchPad parameter DrvStat and are explained with troubleshooting guidelines in Table 11.1 on page 11-4. The TouchPad alternately displays Error and the error name. Clear an error by pressing the key.
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C-10 TouchPad Instructions Table C.1: Display TouchPad Fault/Error/Warning Displays (continued) Timeout Level Error Description The communications port timed out. UnxpChar Error The communications port received an unexpected character. UpperLim Warning The upper limit of the parameter has been reached. Publication 1398-5.
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TouchPad Instructions C-11 Motor Table Table C.
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C-12 TouchPad Instructions Table C.
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TouchPad Instructions Table C.
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C-14 TouchPad Instructions Table C.3: ID 69 70 71 72 73 792 793 794 795 796 797 798 799 849 850 851 852 853 854 855 1025 1026 1027 1028 1029 1030 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1050 Publication 1398-5.
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TouchPad Instructions Table C.3: ID 1051 1052 1053 1054 Motor H-6100-Q-L H-6200-Q-L H-6300-Q-L H-8350-S-L ID 1547 1548 1549 1550 C-15 TouchPad Motor Table Identification by Motor ID (continued) Motor S-6100-Q-N S-6200-Q-N S-8350-S-N S-8500-S-N ID Motor ID Motor Publication 1398-5.
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C-16 TouchPad Instructions TouchPad Options and Lists Table C.4: Parameter AccelEn SlewEnab I OverRd Parameter SWEnable EncAlign RmvOfst Option Selections for the TouchPad DRVPARM Options Enable/Disable Enable/Disable Enable/Disable STATUS Options Enable/Disable Normal/Align to Rmv Parameter SWEnable TUNING Options Enable/Disable Parameter SWEnable Start CTLPANEL Options Enable/Disable Normal/CtlPanel TouchPad Lists Table C.
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TouchPad Instructions Table C.8: Display Inc Abs Reg C-17 IO Mode Parameter List for TouchPad Parametera Incremental Indexing Absolute Indexing Registration Indexing a. Parameters available only if the drive supports Indexing. Table C.9: Display 00 01 02 03 04 05 06 07 08 Index Pointer Parameter List for TouchPad Parametera Index 0 Index 1 Index 2 Index 3 Index 4 Index 5 Index 6 Index 7 RAM Index a. Parameters available only if the drive supports Indexing. Table C.
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C-18 TouchPad Instructions a. Parameters available only if the drive supports Indexing. Table C.13: Display Inactive Active Reverse Enable for Homing Parametera No reversing if started on Sensor Reverse if started on Sensor a. Parameters available only if the drive supports Indexing. Table C.14: Display Not Asgn DrvMode IntInh FolEnab FwdEnab RevEnab CMD Ovrd PreSelA PreSelB PreSelC StrtInd DefHome Registr -CmdOfs Home FaltRst Table C.
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TouchPad Instructions Table C.15: Display Negative Current Limit Up to Speed Drive Enable Bus Charged Disabling Fault At Home Sequence Complete In Motion In Dwell Axis Homed Table C.
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C-20 TouchPad Instructions Table C.
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TouchPad Instructions Table C.18: Display Input1 Input2 Input3 Table C.19: Display READY BRAKE Outpt1 Outpt2 C-21 Input Flags Parameter List for TouchPad (continued) Parameter Input 1 Input Flag Input 2 Input Flag Input 3 Input Flag Output Flags Parameter List for TouchPad Parameter Ready Output Flag Brake Output Flag Output 1 Flag Output 2 Flag Publication 1398-5.
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C-22 TouchPad Instructions Publication 1398-5.
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Appendix D Creating Custom Motor Files Appendix D Each motor controlled by a ULTRA 100 Series drive requires a unique parameter set. The parameter set provides the drive with information about the motor necessary for proper commutation, precise control and protection. Two types of motor parameter sets can be selected for a ULTRA 100 Series drive using ULTRA Master software: ● ● Standard motors parameters reside in a motor lookup table stored in the drive. Up to 65535 motors may be stored in the drive.
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D-2 Creating Custom Motor Files Motor Parameter Set The motor parameter set configures the ULTRA 100 Series drive to control a specific motor. Motor parameters provide information about the electrical properties, ratings and construction of the motor. Subsequent sections of this appendix explain these properties with meaningful depth. For now it is sufficient to know that accurate and complete definition of the motor’s properties is necessary to achieve good performance. Publication 1398-5.
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Creating Custom Motor Files D-3 Table ID The table ID number tells ULTRA Master whether the motor file represents a standard motor or a custom motor: ● ● Standard motor table IDs occupy the range 0 to 65534. The custom motor table ID is 65535 (also known as “-1”). Standard motor parameter sets are stored in the drive as well as in the motor file. Thus ULTRA Master needs to transmit only the table ID to select the motor model from the drive's personality EEPROM.
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D-4 Creating Custom Motor Files Figure D.
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Creating Custom Motor Files D-5 Encoder Sequencing Separate from the phasing of the commutation and motor power signals, the encoder A quad B signals must sequence properly. The A channel must lead the B channel for CW motion when viewed looking at the motor shaft from the load. Figure D.3 depicts this encoder signal sequencing. If the encoder phasing is not as shown in Figure D.3, the encoder leads must be swapped. Figure D.
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D-6 Creating Custom Motor Files Table ID The table ID value determines whether the motor file represents a standard motor or a custom motor. A table ID in the range of 0 to 65534 identifies a standard motor file, and a table ID of 65535 (also known as table ID “-1”) identifies a custom motor file. Users may define motor parameters for multiple custom motors on a PC, but only one custom motor files may be stored on the drive. (i.e., All custom motor files have the table ID value of “-1”.
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Creating Custom Motor Files D-7 The denominator units of the required torque constant are peak Amps, rather than rms Amps. To convert the torque constant from units of Nm/Amp(rms), use the formula: Intro 1 Newton ⋅ meter Newton ⋅ meter = 0.707 Amp Amp(rms) Many Allen-Bradley motors specify the torque constant in units of Nm/rmsA/phase. In this case, in addition to conversion from rms Amps to peak Amps, the value needs to be multiplied by three because it has been defined as “per phase”.
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D-8 Creating Custom Motor Files Also, a line-to-line value is required, rather than a line-to-neutral. A line-to-line value equals a line-to-neutral value times two. Publication 1398-5.
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Creating Custom Motor Files D-9 Feedback Parameters Linecount The encoder linecount, or size, specifies the number of encoder lines per mechanical revolution of the motor, and is required in units of lines/mechanical revolution. The linecount value can be in the range from 100 to 15000 lines/rev. Note that the linecount value is in units of lines/rev, rather than counts/ rev. The number of lines/rev will be 1/4th of the number of counts/rev.
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D-10 Creating Custom Motor Files Hall Offset The Hall offset specifies the offset of the Hall feedback signals relative to the Allen-Bradley standard. The drive uses the Hall offset to determine the commutation angle at startup. Hall offset is specified as a value in the range from 0 to 359 electrical degrees. The Hall signals, as well as the line-to-line back-EMF voltages, must sequence according to the Allen-Bradley standard (refer to Figure D.2 and the “Motor Phasing” on page D-3).
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Creating Custom Motor Files D-11 The Hall/Hall type of startup commutation should be used unless the motor is a special version of an Allen-Bradley motor. The reasons for this are: ● ● The ABS signal is only available on Allen-Bradley motors. Hall/Hall commutation means that the location of the Index signal is unimportant. If the drive is set up for Hall/Hall startup commutation, the initial commutation angle is determined by the state of the three Hall feedback inputs: 001, 010, 011, 100, 101, or 110.
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D-12 Creating Custom Motor Files Some manufacturers specify the resistance in Ohms/phase. The phaseto-phase resistance requested by ULTRA Master is twice the per phase value. Inductance The inductance value is the measured phase-to-phase inductance in milliHenries of the stator winding. The inductance is used to set the current regulator gains, and is critical to current loop performance. The inductance value can be in the range from 0.0039 to 255.9961mH.
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Creating Custom Motor Files D-13 Rating Parameters Continuous Torque Continuous torque specifies the rated current of the motor in peak Amps. (Note: Continuous torque is peak Amps, rather than rms.) The drive uses the continuous torque current value in its motor thermal protection software. The drive generates a fault if the square of the actual current, after passing through a low pass filter, exceeds the square of the continuous torque current value.
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D-14 Creating Custom Motor Files Occasionally a manufacturer specifies only the maximum instantaneous torque, and does not include the maximum current specification. In such a case, the peak current can be computed using the peak torque and the torque constant. A factor of 1.1 is included to allow for degradation of the torque constant at high temperatures, etc. The formula, assuming the torque constant has already been converted to N-m/A(peak), is given by: Intro IPEAK = 1.
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Creating Custom Motor Files Figure D.6 D-15 Motor Thermal Protection Software Method Intro ITORQUE2 1 1 1+s 1+sτ + Motor Overcurrent Fault IRATED 2 Integral Thermostat The integral thermostat check box should be checked if the motor has a built-in thermostat. If this box is not checked, the thermostat inputs to the drive are ignored. When the integral thermostat check box is selected, a motor overtemperature fault is displayed if the thermostat inputs to the drive are in an open state.
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D-16 Creating Custom Motor Files Example of Custom Motor File Creation The following is an example of a custom motor. A 50:1 gear is included inside this motor. The example illustrates how to configure a custom motor. Manufacturer’s Data The following specifications were taken from the manufacturer’s data sheet: ● ● ● ● ● ● ● ● ● ● ● ● Reduction Ratio = 1:50 Rated Current = 1.4 Amp Maximum Current = 3.8 Amp Maximum Speed = 80 RPM Torque Constant = 270 in-lb/Amp BEMF = 1.
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Creating Custom Motor Files D-17 Intro rev  rev  VMAX =  80  ⋅ ( 50) = 4000  min  min Intro  in ⋅ lb   1 N⋅ m  1  N⋅m K T =  270  ⋅  ⋅   = 0.61  Amp   8.85075 in ⋅ lb   50  Amp The back-EMF constant of the motor, before gearing, is computed as: Intro Volts   1000 RPM  Volts   1 K E =  1.1  ⋅  ⋅ (2) ⋅   = 44   50  RPM   1 KRPM  KRPM Note that the back-EMF was specified as a per phase value, and is doubled to obtain a line-to-line value.
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D-18 Creating Custom Motor Files Jm: Ke: 2.26 kg-cm2 44.0 Volts/kRPM FEEDBACK Linecount: Index Offset: Hall Offset: Startup Commutation: Invert Direction: Publication 1398-5.2 – PDF 1997 1500 lines/rev 0 degrees 120 degrees Hall / Hall Unchecked RATINGS Continuous Torque: Peak Torque: Thermal Time Constant: Integral Thermostat: Maximum Speed: 1.4 Amps 3.
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Creating Custom Motor Files D-19 Troubleshooting Custom Motor Files Problem Motor locks at a certain location. Possible Causes 1. Motor phasing is incorrect. Motor jumps once at startup. 2. Hall Offset is incorrect. Motor runs away. 3. Incorrect startup commutation. Low torque production. 4. Incorrect encoder phasing. 5. Incorrect pole count. High audible noise from motor. 6. Incorrect encoder linecount. 1. Incorrect motor resistance. Velocity loop difficult to stabilize. 2.
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Appendix E Electromagnetic Compatibility Guidelines for Machine Design Appendix E This appendix provides background information about Electromagnetic Interference (EMI) and machine design guidelines for Electromagnetic Compatibility (EMC). Installation requirements for compliance to the European Electromagnetic Compatibility Directive are specified in “European Union Requirements” on page 39. AC Line Filters necessary for European EMC compliance are listed in “AC Line Filters” on page 5-8.
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Electromagnetic Compatibility Guidelines for Machine Design Figure E.1 E-2 EMI Source-Victim Model Intro CONDUCTED EMI EMI SOURCE EMI VICTIM RADIATED EMI EMI VICTIM Immunity to EMI is primarily determined by equipment design, but how you wire and ground the device is also critical to achieving EMI immunity. Therefore, it is important to select equipment that has been designed and tested for industrial environments.
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E-3 Electromagnetic Compatibility Guidelines for Machine Design One method to improve the EMC characteristics of a drive is to use an isolation AC power transformer to feed the amplifier its input power. This minimizes inrush currents on power-up and provides electrical isolation. In addition, it provides common mode filtering, although the effect is limited in frequency by the interwinding capacitance.
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Electromagnetic Compatibility Guidelines for Machine Design E-4 AC Line Filter Selection Selection of the proper filter is only the first step in reducing conducted emissions. Correct filter installation is crucial to achieving both EMI attenuation and to ensure safety. All of the following guidelines should be met for effective filter use. 1. The filter should be mounted to a grounded conductive surface. 2.
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E-5 Electromagnetic Compatibility Guidelines for Machine Design When multiple power cables enter an enclosure, an unfiltered line can contaminate a filtered line external to the enclosure. Therefore, all lines must be filtered to be effective. The situation is similar to a leaky boat. All the holes must be plugged to prevent sinking. Intro ! ATTENTION: Large leakage currents exist in AC line filters. They must be grounded properly before applying power.
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Electromagnetic Compatibility Guidelines for Machine Design E-6 The primary objective of a high frequency ground system is to provide a well defined path for HF currents and to minimize the loop area of the HF current paths. It is also important to separate HF grounds from sensitive circuit grounds. “Single Point Ground Types” shows single point grounds for both series (daisy chain) and parallel (separate) connections. A single point, parallel connected ground system is recommended. Figure E.
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E-7 Electromagnetic Compatibility Guidelines for Machine Design Shielding and Segregation The EMI radiating from the drive enclosure drops off very quickly over distance. Mounting the drive in an enclosure, such as an industrial cabinet, further reduces the radiated emissions. The cabinet should have a high frequency ground and the size of the openings should be minimized.
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Electromagnetic Compatibility Guidelines for Machine Design E-8 1. Motor cables must have a continuous shield and be terminated at both ends. The shield must connect to the ground bus bar or drive chassis at the drive end, and the motor frame at the motor end. Use of a properly shielded motor cable is essential to meet European EMC requirements. 2. Signal cables (encoder, serial, analog) should be routed away from the motor cable and power wiring.
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E-9 Electromagnetic Compatibility Guidelines for Machine Design Publication 1398-5.
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Appendix F DynamicBrakingResistorSelection Appendix F This appendix provides equations to assist in sizing resistors for dynamic braking. A properly sized resistive load may be required to dynamically brake the system by dissipating the energy stored in a motor. The section “Emergency Stop Wiring” on page 7-5 depicts the necessary circuitry. Winding inductance is ignored in this analysis, which allows the load on the motor winding to be considered as purely resistive when dynamic braking occurs.
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F-2 Dynamic Braking Resistor Selection Intro 2 2 ( J L + J M )ω o –2 t ⁄ τ K E K T ω o –2t ⁄ τ P ( t ) = ------------------------------ e = 1.154 ------------------------- e 2τ ( R + 2R L ) (2) For this type of response, 98% of the energy will be dissipated in 4 time constants. Therefore the average power for each dynamic braking event can be calculated as: Intro 2 K E K T ωo 1 2 1 P AVE = --- ( J M + J L )ω o  ----- = 0.
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Dynamic Braking Resistor Selection F-3 Sample Calculations The following example uses an H4075 motor with a 10 times inertia mismatch and dynamic braking resistors sized at four times the motor winding resistance. The average power of the motor is 1116 Watts for the selected paramters, but it is unlikely that a resistor with this Wattage is required. Pulse type currents, such as this example, require sufficient thermal mass to absorb the energy and to dissipate or accomodate the peak Voltage.
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F-4 Dynamic Braking Resistor Selection Intro –t ---τ KE ⋅ ωo ⋅ e i ( t ) := -----------------------------------------0.866 ( R + 2 ⋅ RL ) Intro .e –2 ⋅ t R 1.154 2. R L⋅ K ⋅ K ⋅ ω 2 -----------o τ E T P ( t ) := ------------------------------------------------- ⋅ e P( t ) ( R + 2 ⋅ RL ) 4 1 10 7500 P( t ) 5000 2500 0 0 0.05 0.1 Average Power (Watts): Intro 2 KE ⋅ KT ⋅ ω o · P ave := 0. 144 ------------------------------R + 2 ⋅ RL P ave = 1116 Publication 1398-5.2 – PDF 1997 0.15 0.
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Appendix G Specifications Appendix G Agency Approvals UL 508C File E145959 Low Voltage Directive and Electromagnetic Compatibility Directive Certificate of Conformity from TUV Product Service Environmental Operating Temperature 0oC to 55oC (32oF to 131oF) Storage Temperature -40oC to 70oC (-40oF to 158oF) Humidity 5% to 95% non-condensing Altitude 1500 meters (5000 feet) Derate 3% for each 300 m above 1500 m (1000 ft. above 5000 ft.
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G-2 Specifications Selectable (2) BRAKE READY Digital I/O Power Supply Current Limit (I LIMIT) COMMAND ANALOG1 Auxiliary Encoder Signal Input Digital Outputs 12-24 Volt, Short Circuit Protected, Optically Isolated, Single-ended, Active High, 50 mA maximum Normally Open Relay, 1 A Normally Open Relay, 100 mA User supplied 12 to 24 VDC Analog Inputs 0 to 10 Volt, single-ended, 5 kOhm input Impedance ±10 Volt, Differential, 13 kOhm input Impedance, offset software adjustable Analog Outputs 0 to 10 Volt, 8
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Specifications Data Collection (2) Firmware Operating Modes Command Sources G-3 Software Controls 128 samples @ 5 kHz Sample Rate Factory installed EEPROM Torque, Velocity or Position Analog Auxiliary Encoder Presets Step/Direction CW/CCW Autotuning Indexing: Incremental, Registration, Absolute (Indexing on 1398-DDM-005X, -009X and -019X only) Position and Manual Tuning Velocity Loop Position or User Set-up Diagnostics Velocity Loop ULTRA Master or TouchPad Motor or Auxiliary Encoder Checks Digital
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G-4 Specifications Power-Up Faults Software Controls (cont.
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Specifications G-5 Power AC Input Voltage and Frequency AC Input Current Bus Voltage Output Peak Current Continuous Output Current (peak) Bus Capacitance Energy Absorption (from 325-400 Vdc Bus)a Peak Power Outputb Continuous Power Outputb 1398-DDM-005 & 1398-DDM-005X 100-240 Vacrms nominal Single Phase 1398-DDM-009 & 1398-DDM-009X 100-240 Vacrms nominal Single Phase 1398-DDM-019 & 1398-DDM-019X 100-240 Vacrms nominal Single Phase 47 - 63 Hz 5 Arms 141-339 Vdc 7.5 Amps 2.
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G-6 Specifications T = 4.08 * (Q/A) + 1.1 where: T = Temperature difference between inside air and outside ambient (°F) Q = Heat generated in enclosure (watts) A = Enclosure surface area in ft.2 = (2dw + 2dh + 2wh) / 144 d = Depth in inches h = Height in inches w = Width in inches Publication 1398-5.
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Index HelpIndex A ABS Input G-1 Absolute Indexing 8-43 AC Current input 7-8, G-5 inrush 7-8 Frequency, input G-5 Line Filters 5-7, 5-8 Power TB-1 7-7 Terminals 7-1 Voltage, input G-5 Accessories A-1 Addressing G-1 Agency Approvals G-1 Allen-Bradley 9/Series B-26 Altitude G-1 Analog Controller Configuration Example 8-1 Analog Inputs 3-4 Troubleshooting 11-12 Analog Outputs G-2 Troubleshooting 11-11 Application Examples Absolute Indexing 8-43 Analog Controller 8-1 Incremental Indexing 8-30 Modifying User Un
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Index-2 DC Bus LED 10-1 Terminals 7-1 Default Set Up Parameters Drive/Motor G-5 Digital Inputs ENABLE 3-5 Troubleshooting 11-11 Digital Outputs Troubleshooting 11-9 Digital Signal 3-5 Digital to Analog Converter 3-4 Display User Units, see User Units Drive Addressing Serial Communications 6-33 Specifications G-1 TouchPad Defaults C-1 Installation Interface Connections 5-5 Mechanical Requirements 5-1 Storage 2-8 Drive/Motor Default Set Up Parameters G-5 Dynamic Braking Resistors F-1 E Electromagnetic Compa
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Index-3 Wiring 5-5 I/O Connectors Controller 6-1 Encoder 6-29 Interface Cable Examples 6-21 J1 6-24 J2 6-29, 6-30 J4 and J5 6-31 RS-232 and RS-485 6-31 I/O Power External 6-1 I-gain Defined 9-7 Illegal Hall State 11-5 Incremental Indexing 8-30 Indexing Absolute 8-43 Incremental 8-30 Registration 8-37 Indicators DC Bus 10-1 Inertia Possible Effects 9-2 Initial Inspection 2-1 Input Frequency 7-7 Power 7-8 Troubleshooting 11-12 Inrush Current 7-8 Inspecting the Drive 2-1 Inspection Procedures Checkout Test 2-
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Index-4 Overview 3-7 Phase Connections 7-2 Power Cabling 7-2 Troubleshooting Encoder Error 11-6 Motor Information Missing 11-7 Overspeed 11-6 Overtemperature 11-4 Thermal Protection Fault 11-6 Mounting Requirements 5-1 O Operating Temperature G-1 Options A-1 Output Current Continuous (peak) G-5 Peak G-5 P Part Numbers A-1 AC Line Filters A-2 Cables B-3 Encoder Cables A-3, B-14 Fuses A-1 Interface Cables A-1 Manuals A-2 Mating Connectors A-6 Motor Power Cables A-4, B-21 Serial Interface Cables A-3, B-13 S
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Index-5 Port (J5) 6-31 Serial Interface Cables Schematics and Diagrams B-13 Serial Ports G-1 Serial Protocol G-3 Shipping Damage 2-1 Shock G-1 Signal Extension Kits 6-1 Single Point Ground Example E-6 Software Host Commands Intro-22 Installation 4-1 Instructions Intro-19 Readme File 4-5 Requirements 4-1 Starting and Quitting 4-2 Version Level 4-4 Space Requirements 5-1 Specifications G-1, G-5 ABS Input G-1 AC Input Current G-5 Frequency G-5 AC Voltage G-5 Addressing G-1 Agency Approvals G-1 Altitude G-1 An
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Index-6 Motor Table C-11, C-13 Selections C-7 Modes of Operation C-3 Motor Selection C-6 Motor Table Identification C-11, C13 Revision Level 4-5 Text Selection C-7 Version Display C-2 Warnings C-8 Transformer Sizing 7-8 Troubleshooting 11-1 Analog Outputs 11-11 Auxiliary Encoder Error 11-6 Bus Overvoltage 11-5 Bus Undervoltage 11-5 Current Limit 11-12 Digital Inputs 11-11 Digital Outputs 11-9 Encoder Inputs 11-13 Excess Error 11-6 Excessive Average Current 11-5 Gain Adjustments 9-2 IPM Short 11-4 IPM Ther
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Publication 1398-5.2 – PDF 1997 PN 0013-1042-002 Rev A Copyright 1997 Allen-Bradley Company, Inc.