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

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  • User Manual

    ULTRA 200 Series Digital Servo Drives

    Allen-Bradley

  • Important User Information

    Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

    The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

    Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

    Reproduction of the contents of this copyrighted publication, in whole or in part, without written permission of Allen-Bradley Company, Inc., is prohibited.

    Throughout this manual we use notes to make you aware of safety considerations. For example:

    Attention statements help you to:

    ● identify a hazard

    ● avoid the hazard

    ● recognize the consequences

    Mathcad is a registered trademark of MathSoft, Inc. Microsoft, MS-DOS and Windows are trademarks of Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories.

    !

    Intro

    ATTENTION: This symbol identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.

    Note: This symbol identifies information that is critical for successful application and understanding of the product.

  • Table of Contents

    IntroTable of Contents

    Table of Contents Intro-1

    List of Figures Intro-7

    List of Tables Intro-11

    Preface Intro-15

    About This Manual . . . . . . . . . . . . . . . . . . . . . . . . .Intro-16 Additional Instructions and Manuals . . . . . . . . . . . . . . .Intro-17

    Host Commands and ULTRA Master . . . . . . . . . . . . .Intro-17 TouchPad . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intro-18

    Symbols and Conventions . . . . . . . . . . . . . . . . . . . . .Intro-19 Typographical and Wording Conventions . . . . . . . . . . .Intro-19 Graphical Symbols and Warning Classifications . . . . . . .Intro-20

    Pictorial Index . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intro-21

    Chapter 1 Safety Installing and Using the ULTRA 200 Series . . . . . . . . . . . . . 1-1

    Potential Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

    Chapter 2 Selecting Other System Components ULTRA 200 Series Overview . . . . . . . . . . . . . . . . . . . . . 2-1

    Drive Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

    ULTRA 200 Series Features . . . . . . . . . . . . . . . . . . . . . . 2-2 Stand-alone Design . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 High Performance Microcontroller Technology . . . . . . . . . 2-2 IPM Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Analog and Digital Interfaces . . . . . . . . . . . . . . . . . . . . 2-2 Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Encoder Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Analog I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 AC Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personality Module . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Multiple Protection Circuits . . . . . . . . . . . . . . . . . . . . . 2-4 ULTRA Master Software . . . . . . . . . . . . . . . . . . . . . . 2-4

    Publication 1398-5.0 – October 1998

  • Intro-2 Table of Contents

    Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Autotuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Agency Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

    Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 European Union Requirements . . . . . . . . . . . . . . . . . . . . . 2-7

    Chapter 3 ULTRA Master Installation Hardware and Software Requirements . . . . . . . . . . . . . . . . . 3-1 Installing ULTRA Master . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Starting and Quitting ULTRA Master . . . . . . . . . . . . . . . . . 3-3

    Version Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 The ULTRA Master Start-Up Screen . . . . . . . . . . . . . . . . 3-3 The readme File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Firmware Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

    Chapter 4 Unpacking, Inspecting and Storing Unpacking the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Testing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

    Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Drive Checkout Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

    Storing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

    Chapter 5 Installation Mechanical Installation Requirements . . . . . . . . . . . . . . . . . 5-1 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

    Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . 5-6 Qualified AC Line Filters. . . . . . . . . . . . . . . . . . . . . . . 5-6 Allen-Bradley AC Line Filters . . . . . . . . . . . . . . . . . . . . 5-7

    Chapter 6 Interfaces J1 – Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

    Digital I/O Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Motor Encoder Output Signals . . . . . . . . . . . . . . . . . . 6-17 Auxiliary Encoder Inputs . . . . . . . . . . . . . . . . . . . . . 6-19 Interface Cable Examples. . . . . . . . . . . . . . . . . . . . . 6-21 J1 Terminal Strip/Breakout Board. . . . . . . . . . . . . . . . . 6-26

    J2 – Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

    Publication 1398-5.0 – October 1998

  • Table of Contents Intro-3

    J2 Terminal Strip/Breakout Board . . . . . . . . . . . . . . . . 6-30 J3 – Auxiliary Port . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 J4 and J5 – Serial Port . . . . . . . . . . . . . . . . . . . . . . . . 6-34

    Serial Communications Overview. . . . . . . . . . . . . . . . 6-36 RS-232 Connections. . . . . . . . . . . . . . . . . . . . . . . . 6-38 Four Wire RS-485 Connections. . . . . . . . . . . . . . . . . . 6-40

    A1, A2, and COM – Analog Outputs. . . . . . . . . . . . . . . . 6-44 Interface Connections. . . . . . . . . . . . . . . . . . . . . . . . . 6-45

    Chapter 7 Power Connections TB1 – DC Bus and AC Power. . . . . . . . . . . . . . . . . . . . . 7-1

    Motor Power Cabling. . . . . . . . . . . . . . . . . . . . . . . . 7-3 Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . 7-5 Emergency Stop Wiring. . . . . . . . . . . . . . . . . . . . . . . 7-6 DC Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 AC Power Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

    TB2 – Shunt Regulator. . . . . . . . . . . . . . . . . . . . . . . . 7-11 External Shunt Connection. . . . . . . . . . . . . . . . . . . . 7-14

    Chapter 8 Application and Configuration Examples Analog Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

    Hardware Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

    Preset Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Hardware Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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