ULTRA Series (Catalog Numbers 1398-xxx) Product Data The 1398 ULTRA™ Series is a family of single-axis digital and positioning servo drives designed to offer flexibility and performance for a wide range of applications. The ULTRA 100™ and 200™ digital servo drives offer you versatility and ease of use. Using the Windows™-based Ultra Master software, you can quickly set up, commission, and troubleshoot ULTRA 100 and 200 drives. TheULTRA Plus positioning servo drives combine control and drive functionality to create powerful single-axis motion controllers. Using the graphical Windows-based GML™ Ultra software, you can quickly program, commission, and troubleshoot ULTRA Plus drives. 2ULTRA Series Table of Contents ULTRA100/200Drives................................................5 ULTRA100 Features ...............................................6 ULTRA 100 and DeviceNet ...........................................7 ULTRA100 Specifications ...........................................7 General . ...................................................... 7 Command Sources .............................................. 8 DeviceNet ..................................................... 8 Serial Communication Port ........................................ 8 Control Loops .................................................. 8 Connectors .................................................... 9 Environmental .................................................. 9 InputsandOutputs . ............................................ 10 ULTRA200 Features ..............................................11 ULTRA200 Specifications ..........................................12 General . ..................................................... 12 Command Sources . ............................................ 13 Serial Communication Port ....................................... 13 Control Loops . ................................................ 13 InputsandOutputs . ............................................ 14 Connectors ................................................... 14 Environmental . ................................................ 15 Mating ConnectorKits........................................... 15 Mating Connectors.............................................. 15 ULTRA Series 100/200 Cables ........................................16 ULTRA100 and200 InterconnectDiagrams ............................17 Connector J1 — Controller Connection . . ............................ 18 ConnectorJ2— Encoder Connection............................... 18 Connector J3 — Auxiliary Port Connection (For ULTRA 200 Drives) . . ..... 18 Connectors J4 and J5 — Serial Ports Connections. .................... 19 Cable Specifications ............................................ 19 Cable Installation Guidelines...................................... 19 SystemConfigurationChecklist ......................................20 ULTRA100/200 Drives (choose one ofthefollowing): . ................. 20 ULTRA Series Motors (choose one of the following): . . . ................ 20 Cables:....................................................... 21 Dimensions for 1398-DDM-005, -005X .................................24 Dimensions for 1398-DDM-005-DN, -005X-DN (Ultra 100 with DeviceNet) .....25 Dimensions for 1398-DDM-009, -009X, -019, and -019X . . .................26 Dimensions for 1398-DDM-009-DN, -009X-DN, -019-DN, and -019X-DN (Ultra 100 with DeviceNet) . . . .........................27 Dimensions for 1398-DDM-010, -010X, -020, -020X, -030, and -030X . . . .....28 Dimensions for 1398-DDM-075 and -075X ..............................29 Dimensions for 1398-DDM-150 and -150X ..............................30 ULTRA 100/200 Drives Options and Accessories.........................31 UltraMaster ......................................................31 PC Requirements . ............................................. 31 DeviceNetOption............................................... 31 Publication 1398-2.0 – August 1999 ULTRA Series 3 Host Mode.................................................... 32 UltraMasterWindows........................................... 33 AC Line Filters ...................................................34 AC Line Filter (9101-1516)for 1398-DDM-005 . . . ........................34 AC Line Filter (9101-1517) for 1398-DDM-009, 1398-DDM-010, and 1398-PDM-10 10A 1f . .............35 AC Line Filter (9101-1518) for 1398-DDM-019, 1398-DDM-020, and 1398-PDM-20 23A 1f . .............36 AC Line Filter (9101-1575) for 1398-DDM-150 50A 3f .....................37 AC Line Filter (9101-1387) for 1398-DDM-030 and 1398-PDM-30 36A 1f . . .........................38 AC Line Filter (9101-1388) for Multiple Drives 50A 1f .....................38 AC Line Filter (9101-1389) for 1398-DDM-075 and 1398-PDM-75 36A 3f . . .........................39 AC Line Filter (9101-1390) for Multiple Drives 80A 3f .....................39 AC Line Filter (9101-1575) for 1398-DDM-150 50A . . . ....................40 External Shunt Resistor Kit (9101-1183) for 1398-DDM-010, -020, -030 and 1398-PDM-10, -20, -30 .................40 Passive External Shunt Module (1398-SR9P) for 1398-DDM-075, 1398-DDM-150, and 1398-PDM-075 . .................41 Active External Shunt Module (1398-SR3AF) for 1398-DDM-005, -005-DN, -005X, -005X-DN1398-DDM-009, -009-DN, -009X, -009X-DN, and 1398-DDM-019, -019-DN, -019X, -019X-DN . .........................42 Breakout Board(J1)for ULTRA100/200Drives (9101-1391) ...............42 Breakout Board(J2)for ULTRA100/200Drives (9101-1392) ...............43 TouchPad .......................................................43 TouchPad (1398-HMI-001) ....................................... 44 ULTRAPlusPositioning Drives .......................................45 ULTRA Plus Features . . ............................................46 ULTRAPlusGeneralSpecifications ...................................47 ControlHardware .............................................. 47 Resolutions,Ranges,Accuracy, and Speeds......................... 48 Serial I/O. .................................................... 48 TuningandCompensation ....................................... 48 ULTRA Plus Specifications Specific to 1398-PDM-10, -20, -30, and -75 . . .....49 General ...................................................... 49 ULTRA Plus External Shunt Resistor for 1398-PDM-10, -20, and -30 (9101-1183). . ........................ 49 ULTRA Plus Specifications Specific to 1398-PDM-25, -50, -100, and -150 . . . ........................50 General ...................................................... 50 Power Supply Modules . . ........................................ 50 Operator Terminal.............................................. 50 Block Diagram of the ULTRA Plus Positioning Module ....................51 UltraPlusInterconnectDiagram ......................................52 SystemConfigurationChecklist . .....................................53 ULTRA Plus Drives1............................................ 53 Power Supply Modules . . ........................................ 53 Publication 1398-2.0 – August 1999 4ULTRA Series ULTRASeriesMotors ........................................... 53 Cables ....................................................... 54 Accessories . ................................................. 56 Mating Connectors.............................................. 56 Dimensions for 1398-PDM-10, -20, and -30 .............................57 Dimensions for 1398-PDM-75 . . ......................................58 Dimensions for 1398-PDM-25, -50, -100, and -150 . ......................59 ULTRA Plus Drives Options and Accessories. . ..........................60 GMLUltra forWindows .............................................60 PC Configuration............................................... 60 GML Ultra Windows. ............................................ 61 ULTRA Plus Requirements for Compliance with European Directives .........61 24V Sourcing I/O Conversion Card (9103-0152) and Cables . ............ 62 AC Line Filters. ................................................ 62 Shielded PowerCables. ......................................... 63 ULTRA Plus Optional Cables . . . .....................................63 ULTRA Plus Transformer (0020-5093) and Power Supply (9101-0120) for 1398-PDM-25, -50, -100, and -150 . ..............................64 Power Supply Module Selection Guidelines (1398-PSM-25, -50, -100, and -150) .....................................................64 ULTRAPlusOperator Terminal ......................................65 ULTRA Series Common Accessories. ..................................66 Operator Terminal (1398-HMI-002) . . . .................................66 AC Line Filter (9101-1387) for 1398-DDM-030 and 1398-PDM-30 36A 1f . .....67 AC Line Filter (9101-1388) for Multiple Drives 50A 1f ......................67 AC Line Filter (9101-1389) for 1398-DDM-075 and 1398-PDM-75 36A 3f . .....68 AC Line Filter (9101-1390) for Multiple Drives 80A 3f ......................68 AC Line Filter (9101-1517) for 1398-DDM-009, 1398-DDM-010, and 1398-PDM-10 10A 1f ..............69 AC Line Filter (9101-1518)for 1398-DDM-019, 1398-DDM-020, and 1398-PDM-20 23A 1f . . ......................................70 External Shunt Resistor Kit (9101-1183) for 1398-DDM-010, -020, -030 and 1398-PDM-10, -20, -30 .................70 Passive External Shunt Module (1398-SR9P) for 1398-DDM-075, 1398-DDM-150, and 1398-PDM-075 . ..................71 Publication 1398-2.0 – August 1999 ULTRA Series 5 ULTRA 100/200 Drives ULTRA 100 and 200 drives are feature-rich, high-performance drives that offer the flexibility to handle a wide range of applications. You can set up the ULTRA 100/200 drives as indexing drives, velocity servo drives, stepper drives, or master encoder followers. With the DeviceNet option, you can remotely commission and reprogram ULTRA 100 drives. In addition, you can use the ULTRA 100/200 drives host command protocol to set up multiple drives. Available in seven power ranges, theULT RA100/200 drives can be mated to four high-performance brushless servo motor lines. Ultra Master software, a Windows-based interface, provides you with a familiar programming environment and a powerful commissioning tool for all ULTRA 100/200 drives. Customer-supplied Controller ULTRA 100/200 Drive TouchPad Module (plugs into the serial port on the drive) Windows Compatible Personal Computer (user-supplied) Ultra Master Software Master Encoder F-, H-, Y-, N-Series Motors (user-supplied option) Shunt Resistor/Active Shunt (if required) Note: To learn more about 1398 ULTRA Series 230V brushless servo motors, see publication 1398-2.1. Publication 1398-2.0 - August 1999 6ULTRA Series ULTRA 100 Features ULTRA 100 servo drives deliver flexibility and performance in a very compact size. Each ULTRA 100 drive provides: 115/230V AC, single-phase input Built-in logic power supplies (external 12 to 24V I/O logic power required) The ability to drive sinusoidal AC brushless motors Advanced control algorithms for leading-edge velocity loop bandwidth, fully digital current, velocity, and position loops A 14-bit A/D convertor for velocity command input An internally-shielded filter for electromagnetic compatib ility (EMC) Several analog or digital command interfaces: Indexing—absolute with the Homing feature, incremental, or registration (optional) DeviceNet (optional) ±10 Volt analog interface—position, velocity, or torque control Presets (from one to eight binary inputs)—torque or velocity control Quadrature encoder digital interface—electronic gearing position follower Step/direction digital interface—position control CW/CCW (step up/step down) interface—po sition control Operating mode override—alternate movement interface Four dedicated I/O plus six user-selectable, optically isolated digital inputs and outputs (sourcing/active high): Two dedicated inputs Two dedicated outputs Four user-selectable inputs Two user-selectable outputs One analog input for external current limit One analog output for variable monitoring or torque sharing Unlimited I/O capability over DeviceNet A serial port for RS-232/RS-485 host communication Publication 1398-2.0 - August 1999 7 9 9 6 8 8 7 7 5 6 6 4 ULTRA Series 7 ULTRA 100 and DeviceNet The DeviceNet interface card is an optional card that provides a direct, digital connection between a DeviceNet network and an ULTRA 100 drive. Status J5 The DeviceNet option provides: Two bi-colored LEDs for network and module status J2 Three switches to set node addresses and baud rate Several message protocols 24+ HI J1 SHD LO 24-Explicit messaging ! ? Polled I/O messaging Change-of-state/cyclic messaging ULTRA 100 Specifications The following tables contain ULTRA 100 specifications: General Specification 1398-DDM- 1 1 1 005, 005X , 009, 009X , 0019, 0019X , 2 2 2 005-DN , 009-DN , 0019-DN , 005X-DN 009X-DN 0019X-DN Peak output current 7.5A 15A 30A Continuous output current 2.5A 5A 10A Continuous output power 0.5 kW 1.0 kW 2.0 kW Continuous input current 5A 9A 18A Input voltage 100 to 240V AC RMS nominal (88 to 265 Volts), single phase Input frequency 47-63 Hz 1 The X indicates the indexing version of the drive. 2 The DN denotes the DeviceNet option. Publication 1398-2.0 - August 1999 5 5 3 4 4 3 3 2 Ultra Series 2 2 1 1 1 0 0 0 8ULTRA Series Command Sources Specification Description Analog velocity/torque input ±10 Volts 8 presets, binary selection by digital inputs Presets (unlimited I/O capability over DeviceNet) Step and direction, 1 MHz maximum frequency step up/step down Differential or single-ended line drivers 1 MHz maximum line frequency Master encoder following Differential or single-ended line drivers Digital serial commands Via serial port and ULTRA Series host language DeviceNet commands Via DeviceNet port Absolute (with Homing feature) Indexing Incremental Registration (with high-speed registration) DeviceNet Specification Description Baud rate 125 kps (default), 250 kps, or 500 kps Multiple drive addressing 00-63 (63 default) Power consumption 60 mA (DeviceNet current draw) Serial Communication Port Specification Description Type RS-232, four-wire RS-485 Baud rate 1,200 to 19,200 baud 1 Multiple drive addressing Up to 32 drives 1 You can use the Ultra Master software to setup multiple drives using the ULTRA 100/200 drives host command protocol. Control Loops Specification Description Modes Torque, velocity, and position control Type All loops are digital. Velocity loop bandwidth (maximum) 300 Hz Position loop 1 ms Current loop 125 μs Publication 1398-2.0 - August 1999 ULTRA Series 9 Connectors Specification Description DeviceNet 5-pin open-style connector Serial 9-pin D-shell (for J5) Control and feedback 20-pin (for J2) and 50-pin (for J1) high density Mini D Power Screw terminal block (for TB1) Environmental Specification 1398-DDM- 1 1 1 005, 005X , 009, 009X , 0019, 0019X , 2 2 2 005-DN , 009-DN , 0019-DN , 005X-DN 009X-DN 0019X-DN Storage temperature -40ºC to 70ºC (-40ºF to 158ºF) Operating temperature -5ºC to 55ºC (23ºF to 131ºF) Humidity 5% to 90%, non-condensing Altitude 1500m (5000 ft) Vibration 10 to 2000 Hz at 2g Shock 15g, 11 ms, half sine 3 3 3 Weight 1.68 kg (3.7 lb) 2.03 kg (4.47 lb) 2.0 kg (4.4 lb) 1 The X indicates the indexing version of the drive. 2 The DN denotes the DeviceNet option. 3 The DeviceNet option adds 0.16 kg (0.35lb). Publication 1398-2.0 - August 1999 10 ULTRA Series Inputs and Outputs Specification Description 4 optically isolated, 12 to 24 volt, active high. User-selectable as:  Analog override  Define home  Drive mode select  Integrator inhibit  Fault reset  Follower enable Selectable digital inputs  Forward enable  Mode override 1  Preset select  Registration sensor  Reverse enable  Remove command offset  Starting homing  Start index 2 optically isolated, 12 to 24 volt, active high, short circuit protected. User-selectable as:  At speed  Axis homed  Bus charged  Current limit  Disabling fault  Drive enable Selectable digital outputs  In dwell  In motion  In position  Registered  Sequence complete  Within position window  Within speed window  Zero speed  various fault indications Dedicated digital inputs Enable, Fault Reset (optically isolated, 12-24 Volt, active high) Dedicated relay outputs Ready/Not Faulted, Brake Output 1 external analog current limit, 0 to10 Volt Analog inputs 10-bit resolution Analog outputs 1 user programmable, ±10 Volt 1 MHz maximum line frequency Differential line drivers Encoder output 1 1 1 Scalable by 1, /2, /4, /8 Motor feedback Incremental encoder 1 You must use input 2 as the high-speed input. Publication 1398-2.0 - August 1999 ULTRA Series 11 ULTRA 200 Features ULTRA 200 positioning drives deliver full-featured flexibility and impressive power and performance. Each ULTRA 200 drive provides: 115 to 230V AC single phase input (single phase or three phase for the 75 amp version, three phase only for the 150 amp version) Phase-to-phase and phase-to-ground short circuit protection An internal resistive shunt A built-in auxiliary AC input (to power logic only) Built-in power supplies (including 24V I/O supply)—no external source required (except AC line) The ability to drive sinusoidal AC brushless motors An DC bus available externally for power leveling or for use of shared power supplies Advanced multi-processor design for leading-edge velocity loop bandwidth, fully digital current, velocity, and position loops Large-scale integration with custom ASICs and IPMs for performance and reliability A 16-bit A/D convertor for precise velocity command input Flash memory for simple field upgrades A personality module to store setup parameters and simplify drive replacement Reduced component count for reliability Internally-shielded filters for electromagnetic compatibility (EMC) Four dedicated I/O plus eight user-selectable, optically isolated digital inputs and outputs (sourcing/active high): Two dedicated inputs Two dedicated outputs Four user-selectable inputs Four user-selectable outputs Two analog inputs for external current limit Two analog outputs for variable monitoring or torque sharing Publication 1398-2.0 - August 1999 12 ULTRA Series Two serial connectors to simplify RS-485 multi-dropping and host communications Several analog or digital command interfaces: Indexing (absolute with the Homing feature, incremental, or registration) ±10 Volt analog interface—position, velocity, or torque control Presets (from one to eight binary inputs)—torque or velocity control Quadrature encoder digital interface—electronic gearing position follower Step/Direction digital interface—po sition control CW/CCW (step up/step down) interface—po sition control Operating mode override—alternate movement interface Host command digital interface ULTRA 200 Specifications The following tables contain ULTRA 200 specifications: General 1398-DDM- Specification 1 1 1 030, 030X 075, 075X 150, 150X 1 1 010, 010X 020, 020X (1φ input) 3φ (1φ) (3φ input) Peak output current 10A 20A 30A 75A (50A) 150A Internal continuous output 5A 10A 15A 35A (15A) 65A current Internal continuous output 7.5 kW 1.0 kW 2.0 kW 3.0 kW 15 kW power (3.0 kW) Internal continuous shunt 50W 50W 50W 50W 180W power Internal peak shunt power 4.5 kW 4.5 kW 4.5 kW 10.0 kW 18.0 kW Continuous input current 10A 19A 28A 28A 46A Input voltage 100 to 240V AC RMS nominal (88 to 265 Volts) Input frequency 47-63 Hz 1 The X indicates the indexing version of the drive. Publication 1398-2.0 - August 1999 ULTRA Series 13 Command Sources Specification Description Analog velocity input ±10 Volts, 16-bit resolution Presets 8 presets, binary selection by digital inputs Step and direction, 1 MHz maximum frequency Step up/Step down Differential or single-ended line drivers 1 MHz maximum line frequency Master encoder following Differential or single-ended line drivers Digital serial commands Via serial port and ULTRA Series host language Absolute (with Homing feature) Indexing Incremental Registration (with high-speed registration) Serial Communication Port Specification Description Type RS-232, four-wire RS-485 (for multidrop connections) Baud rate 1,200 to 19,200 baud Multiple drive addressing Up to 32 drives, 10 using front panel rotary dip switch Control Loops Specification Description Modes Torque, velocity, and position control Type All loops are digital. Velocity loop bandwidth 400 Hz (maximum) Position loop 1 ms Current loop 100 μs Publication 1398-2.0 - August 1999 14 ULTRA Series Inputs and Outputs Specification Description  Analog override  Define home  Drive mode select  Fault reset  Follower enable  Forward enable Selectable digital inputs  Integrator inhibit  Preset select  Mode override  Registration sensor  Remove command offset  Reverse enable  Start index  Start homing 4 optically isolated, 12 to 24 volt, active high User-selectable as:  At speed  Axis homed  Bus changed  Current limit  Disabling fault  Drive enabled Selectable digital outputs  In dwell  In motion  In position  Registered  Sequence complete  Within position window  Within speed window  Zero speed  various fault indications Dedicated digital inputs Enable, Fault Reset (optically isolated, 24 Volt, active high) Dedicated relay outputs Ready/Not Faulted, Brake Output 2 external analog current limits, 0 to10 Volt Analog inputs 10-bit resolution 2 user programmable, ±10 Volt Analog outputs 8-bit and 12-bit resolution 1 MHz maximum line frequency Differential line drivers Encoder output 1 1 1 Scalable by 1, /2, /4, /8 Motor feedback Incremental encoder Connectors Specification Description Serial 9-pin D-shell (for J4 and J5) Control and feedback 20-pin (J2), 26-pin (J3) and 50-pin (J1) high density Mini D Power Screw terminal block (TB1) Publication 1398-2.0 - August 1999 ULTRA Series 15 Environmental 1398-DDM- Specification 1 1 1 030, 030X 075, 075X 150, 150X 1 1 010, 010X 020, 020X (1φ input) 3φ (1φ) (3φ input) Storage temperature -40ºC to 70ºC (-40ºF to 158ºF) -5ºC to Operating temperature -5ºC to 55ºC (23ºF to 131ºF) 50ºC (23ºF to 122ºF) Humidity 5% to 95%, non-condensing Altitude 1500m (5000 ft) Vibration 10 to 2000 Hz at 2g Shock 15g, 11 ms, half sine 5.80 kg 6.36 kg 6.48 kg 9.67 kg 14.06 kg Weight (13.78 lb) (14.02 lb) (14.28 lb) (21.32 lb) (30.9 lb) 1 The X indicates the indexing version of the drive. Mating Connector Kits Connector Kit Catalog Number J1 50-pin mini D, 24-30 AWG, solder cup, squeeze latch 9101-1476 J2 20-pin mini D, 24-30 AWG, solder cup, squeeze latch 9101-1477 J3 26-pin mini D, 24-30 AWG, solder cup, squeeze latch 9101-1478 J5 (or J4 for ULTRA 200 drives) 9-pin D shell, solder cup 9101-1479 Mating Connectors Cross-reference of mating connectors with J1, J2, and J3 connectors on your drive. Connectors are crimp style. Option J1 J2 J3 Style Connector AMP 2-175677-7 AMP 2-175677-2 AMP 2-175677-4 1 1 Crimp Backshell AMP 176793-7 AMP 176793-2 AMP 176793-4 Connector 3M 10150-6000EC 3M 10120-6000EC 3M 10126-6000EC 1 2 Crimp Backshell 3M 10350-A200-00 3M 10320-A200-00 3M 10326-A200-00 Connector 3M 10150-3000VE 3M 10120-3000VE 3M 10126-3000VE 3 Solder Backshell 3M 10350-52F0-008 3M 10320-52F0-008 3M 10326-52F0-008 1 For use with MDR Hand Press Tool Kit, 3M part number 3829. Publication 1398-2.0 - August 1999 16 ULTRA Series ULTRA Series 100/200 Use the following table to determine which cables you need for your application. Refer to the ULTRA 100 and 200 Interconnect Diagrams section Cables on page 17 for cable location. Interface Cables Part Number J1 to customer-supplied connector 9101-1370-xxx J1 to a 50-position female D-sub cable (1m/3 ft length) 9101-1369-003 1 J1 to 1756-MO2AE ControlLogix Analog/Encoder 1398-CCAExx J1 to 1756-M02AE flying lead to ULTRA 100/200 molded connector, single axis (10 ft.) 1398-CFLAExx J3 to customer-supplied connector 9101-1368-xxx J3 to J3 (for slaving drives or torque sharing [0.3m, 1 ft]) 9101-1463-002 1 Serial Interface Cables J4 or J5 to PC (RS-232 9-pin D-shell connector) 9101-1372-xxx 2 J4 or J5 to customer-supplied connector 9101-1379-xxx J4 or J5 to J4 or J5 (RS-485 multi-drop communications) (30 cm/1 ft length) 9101-1374-001 Encoder Feedback Cables J2 to F- or H-Series motors 9101-1366-xxx F- or H-Series motor to customer-supplied connector (pig tail) 9101-1365-xxx J2 to Y-Series motor 9101-1375-xxx 3 Y-Series motor to customer-supplied connector (pig tail) 9101-1373-xxx J2 to N-Series motor 9101-1468-xxx N-Series motor to customer-supplied connector (pig tail) 9101-1469-xxx J2 to a 20-position female D-sub cable (1m/3ft length) 9101-1371-003 J2 to customer-supplied connector (pig tail) 9101-1380-xxx Breakout Boards J1 to 50-pin terminal strip (includes 3ft/1m cable and mounting hardware) 9101-1391 4 J2 to 25-pin terminal strip (includes 3ft/1m cable and mounting hardware) 9101-1392 Motor Power Cables Drive to 2000 or 3000 Series motors (F- or H-Series) 9101-1381-xxx Drive to 4000 Series motors (F- or H-Series) 9101-1382-xxx Drive to 6000 Series motors (F- or H-Series) 9101-1383-xxx 5 Drive to 8000 Series motors (F- or H-Series) 9101-1384-xxx Drive to Y-Series motors 9101-1385-xxx 1398-DDM-150, -150 drive to 6300 Series motors (F- or H-Series) 9101-1399-xxx Drive to N-Series motors 9101-1467-xxx 1 Serial interface cables for use with the ULTRA 100 drives cannot exceed 50 ft (15 m). Note: xxx — Last three digits select standard cable length of 10 ft (3.0 m)—010; 25 ft (7.7 m)—025; 50ft (15.0 m)—050; 75 ft (25 m)—075; 100 ft (30.3 m)—100. Publication 1398-2.0 - August 1999 ULTRA Series 17 ULTRA 100 and 200 Interconnect Diagrams Windows compatible TouchPad personal computer OR ULTRA 100 G T S 2 R J5 TB1 1 3 4 J2 5 Encoder Brushless Motor J1 1 4 Note: J1, J2, and J5 are the same as ULTRA 200. Windows compatible TouchPad personal computer ULTRA 200 OR 1 J5 2 Use these numbers to determine which cables you need for your J4 G application. Refer to the table on T page 16 for cable descriptions and S R part numbers. J3 TB1 3 J2 Encoder Brushless Motor 4 J1 5 Publication 1398-2.0 - August 1999 18 ULTRA Series Connector J1 — Controller Connection Pin Description Pin Description Pin Description Pin Description 1 Encoder +5V DC 14 Auxiliary channel A+ 27 Current limit 39 RSVD 2 Encoder com 15 Auxiliary channel A- 28 Analog com 40 RSVD 1 3 Encoder +5V DC 16 Auxiliary channel B+ 29 Negative current limit 41 RSVD 4 Encoder com 17 Auxiliary channel B- 30 Analog output 1 42 Selectable output 1 1 5 Isolated +12 to 24V DC 18 Auxiliary index A+ 31 Analog output 2 43 Selectable output 2 1 6 Isolated +12 to 24V Com 19 Auxiliary index A- 32 Selectable input 1 44 Selectable output 3 Motor output channel 1 7 A+ 20 Drive enable 33 Selectable input 2 45 Selectable output 4 8 Motor output channel A- 21 Fault reset 34 Selectable input 3 46 RSVD Motor output channel 9 B+ 22 Analog cmnd + 35 Selectable Input 4 47 RSVD 10 Motor output channel B- 23 Analog cmnd - 36 RSVD 48 RSVD 11 Motor output index + 24 Drive ready + 37 RSVD 49 Brake enable + 12 Motor output index - 25 Drive ready - 38 RSVD 50 Brake enable - 13 Isolated 12 to 24V com 26 Isolated +12 to 24V DC 1 Reserved on ULTRA 100 drives. Connector J2 — Encoder Connection Pin Description Pin Description Pin Description Pin Description Motor encoder input 1 Encoder pwr 6 Encoder pwr sense - 11 16 Absolute position chnl I+ Motor encoder input Motor encoder input 2 Encoder com 7 12 17 RSVD chnl A+ chnl I- Motor encoder input 3 Encoder pwr 8 13 Hall A 18 RSVD chnl A- Motor encoder input 4 Encoder com 9 14 Hall B 19 Thermal switch + chnl B+ Motor encoder input 5 Encoder pwr sense + 10 15 Hall C 20 Thermal switch - chnl B- Connector J3 — Auxiliary Port Connection (For ULTRA 200 Drives) Duplicates connector J1 pins 1 through 26. Publication 1398-2.0 - August 1999 ULTRA Series 19 Connectors J4 and J5 — Serial Ports Connections Pin Description Pin Description Pin Description Pin Description 1 RCV+ RS-485 4 XMT+ RS-485 6 RSVD 8 XMT- RS-485 2 RCV RS-232 5 COM 7 RCV- RS-485 9 RSVD 3 XMT RS-232 Cable Specifications Specification Description Wire insulation type Polyvinyl chloride 2 28 AWG (0.08 mm ) tinned copper 2 24 AWG (0.25 mm ) for 9101-1372-xxx, -1374-xxx, and -1379-xxx 2 16 AWG (1.5 mm ) for 9101-1381-xxx, -1385-xxx, and -1467-xxx Conductor size 2 14 AWG (2.5 mm ) for 9101-1382-xxx 2 10 AWG (6 mm ) for 9101-1383-xxx 2 8 AWG (10 mm ) for 9101-1384-xxx. 9101-1399-xxx Braid sheet coverage 85% minimum Jacket material Thermoplastic elastomer — oil and chemical resistant Moldings 105ºC (221ºF) black PVC Control cables: Motor power cables: J1: 171 mm (6.75 in.) 9101-1381-xxx: 137 mm (5.4 in.) minimum J2: 130 mm (5.1 in.) 9101-1382-xxx: 147 mm (5.8 in.) minimum J3: 130 mm (5.1 in.) 9101-1383-xxx: 234 mm (9.2 in.) minimum Minimum bend radius 9101-1384-xxx: 227 mm (8.9 in.) minimum 9101-1385-xxx: 107 mm (4.2 in.) minimum 9101-1399-xxx: 227 mm (8.9 in.) minimum 9101-1467-xxx: 91 mm (3.6 in.) minimum Allen-Bradley cables for encoder feedback and motor power connections are tray-rated (stationary) and Flex rating should only be used for one-time flex applications(not flex rated). Cable Installation Guidelines Follow the guidelines below to maintain cable reliability. Always follow the installation instructions of the cable carrier manufacturer. Remove twists, bends, and kinks from the cable before installing it in the cable carrier. It is important to lay out the cabling at least 24 hours before installation to relax any stresses resulting from transit or storage. Publication 1398-2.0 - August 1999 20 ULTRA Series When placing the cable into the cable carrier, the carrier should be laid out flat with the bending direction facing upward. It should then be fitted with the cables in working position. The cables should be laid into the cable carrier and not woven between or around other cables. Allow at least 10% clearance between cables so that they are free to move. Use separators between cables. The cables must be free to move within the carrier. Do not attach the cables to the carrier or to each other. Clamp heavier cables toward the edge of the track and lighter cables in the center of the track. Do not pull cables tight against the inner/outer track curves. System Configuration Checklist Use the following checklist to configure an ULTRA 100/200 system for your application: ULTRA 100/200 Drives (choose one of the following): 1 2 ULTRA 100 Drives ULTRA 200 Drives 1398-DDM-005, -005-DN ! ! 1398-DDM-010, -010X 1398-DDM-005X, -005X-DN ! 1398-DDM-020, -020X 1398-DDM-009, -009-DN ! ! 1398-DDM-030, -030X 1398-DDM-009X, -009X-DN ! 1398-DDM-075, -075X 1398-DDM-019, -019-DN ! ! 1398-DDM-150, -150X 1398-DDM-0019X, -0019X-DN 1 Includes the ULTRA 100 Installation Manual (Publication 1398-5.2). 2 Includes the ULTRA 200 Installation Manual (Publication 1398-5.0). ULTRA Series Motors (choose one of the following): F-Series Motors H-Series Motors Y-Series Motors N-Series Motors ! F-4030-Q-H00AA ! H-2005-K-H00AA ! Y-1002-1-H00AA ! N-2302-1-F00AA ! F-4050-Q-H00AA ! H-3007-N-H00AA ! Y-1002-2-H00AA ! N-2304-1-F00AA 1 ! ! H-3016-N-H00AA ! Y-1003-1-H00AA ! N-3406-2-H00AA F-4075-R-H00AA 1 1 2 ! ! ! Y-1003-2-H00AA ! F-6100-R-H00AA H-4030-M-H00AA N-3412-2-F00AA 1 1 ! ! H-4030-P-H00AA ! Y-2006-1-H00AA ! F-6200-R-H00AA N-3412-2-H00AA Publication 1398-2.0 - August 1999 ULTRA Series 21 F-Series Motors H-Series Motors Y-Series Motors N-Series Motors 1 1 Y-2006-2-H00AA N-4214-2-H00AA ! F-6300-R-H00AA ! H-4050-P-H00AA ! ! 1 Y-2012-1-H00AA N-4220-2-H00AA ! H-4075-R-H00AA ! ! 1 Y-2012-2-H00AA N-5630-2-H00AA ! H-6100-Q-H00AA ! ! 1 Y-3023-2-H00AA N-5637-2-H00AA ! H-6200-Q-H00AA ! ! 1 N-5647-2-H00AA ! H-6300-Q-H00AA ! 1 ! H-8350-S-H00AA 1 ! H-8500-S-H00AA 1 ULTRA 200 drives only. 2 ULTRA 100 drives only Cables: Note: The last three digits select standard cable lengths of: 10 ft (3.0m)—010; 25 ft (7.7m)—025; 50 ft (15.0m)—050; 75 ft (23.0m)—075; 100 ft (31m)—100. TB1 to Motor Power Connections (choose one of the following): Part Number Description 9101-1381-xxx Use for H-2000 and H-3000 motors ! 9101-1382-xxx Use for F-4000 and H-4000 motors ! Use for F-6000 and H-6100, H-6200 motors 9101-1383-xxx ! Use for F-6300 and H-6300 with 1398-DDM-075 9101-1384-xxx Use for H-8000 motors ! ! 9101-1385-xxx Use for Y-Series motors 9101-1399-xxx Use for 1398-DDM-150, -150X with F-6300 and H-6300 motors ! 9101-1467-xxx Use for N-Series motors ! J1 to Controller Connections (choose one of the following): Part Number Description J1 to a 50-position female D-sub cable (1m/3 ft length) ! 9101-1369-003 This cable is included in the 9101-1391 kit. 9101-1370-xxx J1 cable with flying lead opposite (rail mounted) ! J1 to 50-pin terminal strip 9101-1391 ! (includes 1 m/3 ft cable and mounting hardware) J1 to 1756-MO2AE ControlLogix Analog/Encoder Card 1398-CCAExx ! (includes 39-pin connector with no hood) 1398-CFLAExx J1 to 1756-M02AE ControlLogix Analog/Encoder single axis flying lead ! Publication 1398-2.0 - August 1999 22 ULTRA Series J2 to Motor Encoder Connections (choose one of the following): Part Number Description 9101-1365-xxx F- and H-Series motors connector cable with flying leads opposite ! 9101-1366-xxx J2 to motor (F- and H-Series motors) ! J2 to a 20-position female D-sub cable (1m/3 ft length) 9101-1371-003 ! This cable is included in the 9101-1392 kit. 9101-1373-xxx Y-Series motor connector cable with flying leads opposite ! 9101-1375-xxx J2 to motor (Y-Series motors) ! 9101-1380-xxx J2 to customer supplied connector ! J2 to 25-pin terminal strip 9101-1392 ! (includes 1m/3 ft cable and mounting hardware) 9101-1468-xxx J2 to motor (N-Series motor) ! 9101-1469-xxx N-Series motor connector cable with flying leads opposite ! J3 Connections (choose one of the following for ULTRA 200 drives): Part Number Description 9101-1368-xxx J3 to customer-supplied connector ! 9101-1463-002 J3 to J3 (for slaving drives or torque sharing) ! J4 and J5 Connections: Part Number Description 9101-1372-xxx J4 or J5 to PC (RS-232 9-pin D-shell connector) ! 9101-1374-001 J5 to J4 (RS-485 multi-drop communications) (30 cm/1 ft) ! 9101-1379-xxx J4 or J5 to customer-supplied connector (RS-232/RS-485) ! 1398-HMI-001 TouchPad that fits into the J5 position ! Accessories (choose all that apply): Part Number Description 9101-1387 AC line filter (36A, 1φ) for 1398-DDM-030, -030X, -075, -075X ! 9101-1388 AC line filter (50A, 1φ) for 1398-DDM-075, -075X ! 9101-1389 AC line filter (36A, 3φ) for 1398-DDM-075, -075X ! 9101-1390 AC line filter (80A, 3φ) for 1398-DDM-075, -075X ! 9101-1516 AC line filter (6A, 1φ) for 1398-DDM-005, -005X ! Publication 1398-2.0 - August 1999 ULTRA Series 23 Part Number Description 9101-1517 AC line filter (10A, 1φ) for 1398-DDM-009, -009X, -010, -010X ! 9101-1518 AC line filter (23A, 1φ) for 1398-DDM-019, -019X, -020, -020X ! 9101-1575 AC line filter (50A, 3φ) for 1398-DDM-150, -150X ! External shunt resistor for 1398-DDM-010, -10X, -020, -020X, 9101-1183 ! -030 and -030X Master-D-U Ultra Master software for ULTRA 100/100X and ULTRA 200/200X ! 1398-SR3AF Ultra 100 active external shunt module ! Ultra 200 passive shunt module (DDM-010, -020, -030, PDM-010, 1398-SR9P ! -020 and -030) Publication 1398-2.0 - August 1999 24 ULTRA Series Dimensions for 1398-DDM-005, -005X 65.10 (2.56) 38.10 (1.50) 13.30 129.00 (0.52) 6.30 (5.08) 18.60 Clearance hole for (0.25) (0.73) #10 (M5) screws 27.60 (1.09) Status LED 2.40 (0.09) J5 186.70 198.00 (7.35) (7.80) Dimensions mm (in.) J2 TB1 J1 ! ? Optional 5.50 REF TouchPad (0.22) Assembly 2 Notes: 1. Allow 76.2 mm (3.00 in.) clearance 72.60 in front of unit for cables. (2.86) 2. Allow 12.7 mm (0.50 in.) on both sides of the unit. Ground strap 2 Publication 1398-2.0 - August 1999 Ultra Series 9 9 8 8 7 7 6 6 5 5 ULTRA Series 25 Dimensions for 1398-DDM-005-DN, -005X-DN (Ultra 100 with DeviceNet) 87.88 (3.46) 38.10 (1.50) 27.69 18.80 24.64 (1.090 129.03 18.60 (0.74) (0.97) 6.60 (5.08) (0.73) (0.26) 2.29 (0.090) Module Status Network Status Node Address Dimensions (00-63,PGM) MSD mm (in.) 186.44 198.12 LSD (7.34) (7.80) Data Rate 125KB 250KB 500KB Autobaud V+ Can_H Shield Can_L V- ! 5.59 144.27 (0.1875) TouchPad (5.68) Assemby 2 NOTES: 1. Allow 76.2 mm (3.00 in.) clearance in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of unit. 95.50 (3.76) Ground strap 2 Publication 1398-2.0 - August 1999 4 4 3 3 2 2 1 1 0 0 9 9 8 8 7 7 6 6 5 5 26 ULTRA Series Dimensions for 1398-DDM-009, -009X, -019, and -019X 87.88 (3.46) 38.10 (1.50) 27.69 18.80 24.64 (1.090 129.03 18.60 (0.74) (0.97) 6.60 (5.08) (0.73) (0.26) 2.29 (0.090) Module Status Network Status Node Address (00-63,PGM) MSD Dimensions 186.44 mm (in.) 198.12 LSD (7.34) (7.80) Data Rate 125KB 250KB 500KB Autobaud V+ Can_H Shield Can_L V- ! 5.59 144.27 (0.1875) TouchPad (5.68) Assemby 2 NOTES: 1. Allow 76.2 mm (3.00 in.) clearance in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of unit. 120.90 (4.76) Ground strap 2 Fan on 1398-DDM-019, -019x only. Publication 1398-2.0 - August 1999 4 4 3 3 2 2 1 1 0 0 9 9 8 8 7 7 6 6 5 5 ULTRA Series 27 Dimensions for 1398-DDM-009-DN, -009X-DN, -019-DN, and -019X-DN (Ultra 100 with DeviceNet) 87.88 (3.46) 27.69 18.80 38.10 24.64 (1.090 129.03 (0.74) (1.50) (0.97) 6.60 (5.08) (0.26) 2.29 (0.090) Module Status Network Status Node Address (00-63,PGM) MSD Dimensions 186.44 mm (in.) 198.12 LSD (7.34) (7.80) Data Rate 125KB 250KB 500KB Autobaud V+ Can_H Shield Can_L V- ! 5.59 144.27 (0.1875) TouchPad (5.68) Assemby 2 NOTES: 1. Allow 76.2 mm (3.00 in.) clearance in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of unit. 120.90 (4.76) Ground strap 2 Fan on 1398-DDM-019, -019x only. Publication 1398-2.0 - August 1999 4 4 3 3 2 2 1 1 0 0 28 ULTRA Series Dimensions for 1398-DDM-010, -010X, -020, -020X, -030, and -030X 104.1 (4.10) Clearance holes for #10 (M5) mounting screws 226.8 26.6 25.4 (8.93) (1.05) (1.00) 6.4 25.4 (0.25) (1.00) Air Exhaust Ultra Series 1 STATUS A 1 2 A 2 3 COM TB2 TouchPad J5 Insertion Slot WARNING: HIGH VOLTAGE 360.6 349.3 MAY EXIST UP TO FIVE MINUTES J4 Dimensions AFTER REMOVING POWER. DC BUS (14.20) (13.75) mm (in.) R S J3 T DC BUS+ DC BUS – J2 L1 L2/N L1 AUX J1 L2/N AUX TB1 Notes: 1. Allow 76.2 mm (3.00 in.) clearance Air Intake in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of the unit. Publication 1398-2.0 - August 1999 100-240VAC 50/60Hz MOTOR EXTERNAL SHUNT INTERNAL CONTROLLER MOTOR ENCODER AUXILIARY SERIAL 2 SERIAL 1 ULTRA Series 29 Dimensions for 1398-DDM-075 and -075X 151.7 7.0 (5.97) 224.5 (0.27) (8.84) 50.5 25.4 (1.99) (1.00) Air Exhaust Ultra Series STATUS 1 A1 2 A 2 3 COM TB2 J5 Dimensions mm (in.) WARNING: HIGH VOLTAGE MAY EXIST UP TO EIGHT MINUTES AFTER REMOVING POWER. DC BUS J4 360.7 349.3 R (14.20) (13.75) S T J3 DC BUS + DC BUS – L1 L2/N J2 L3 L1 AUX L2/N AUX J1 TB1 25.4 (1.00) Air Intake Air Intake Notes: 1. Allow 76.2 mm (3.00 in.) clearance in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of the unit. Publication 1398-2.0 - August 1999 100-240VAC 50/60Hz MOTOR EXTERNAL SHUNT INTERNAL CONTROLLER MOTOR ENCODER AUXILIARY SERIAL 2 SERIAL 1 30 ULTRA Series Dimensions for 1398-DDM-150 and -150X 203.20 331.5 6.86 (8.00) 224.5 (13.05) (0.27) 139.7 (8.84) 31.70 69.80 (5.50) (1.25) (2.75) Air Exhaust 33.02 Ultra Series (1.30) STATUS 1 36.32 A1 2 A 2 (1.43) 3 COM TB2 J5 26.92 Dimensions (1.06) mm (in.) WARNING: HIGH VOLTAGE MAY EXIST UP TO EIGHT MINUTES AFTER REMOVING POWER. 360.7 DC BUS J4 (14.20) 349.0 R (13.74) S T J3 12.95 DC BUS + (0.51) DC BUS – L1 L2/N J2 L3 L1 AUX 196.09 L2/N AUX J1 (7.72) TB1 31.70 139.70 (1.25) (5.50) Notes: Air Intake Air Intake Air Intake 1. Allow 76.2 mm (3.00 in.) clearance in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of the unit. Publication 1398-2.0 - August 1999 100-240VAC 50/60Hz MOTOR EXTERNAL SHUNT INTERNAL SERIAL 2 CONTROLLER MOTOR ENCODER AUXILIARY SERIAL 1 ULTRA Series 31 ULTRA 100/200 Drives Ultra Master Options and Accessories Ultra Master is a point-and-click interface for customizing the ULTRA 100/200 drives to meet the requirements of your application. Suitable for any PC with Windows, Ultra Master allows you to configure, monitor, and troubleshoot a servo system. The online help and quick start-up windows will simplify your setup while tools, such as the on-screen digital oscilloscope, provide simplified tuning and diagnosis. Ultra Master also provides a full array of on-screen meters and other software tools for rapid debugging and measurement. It also keeps error messages in its own non-volatile message buffer to save time in tracking down a problem. In systems with multiple drives, Ultra Master can simultaneously display status and configuration screens for all drives that are on a four-wire RS-485 link. Ultra Master can also be used offline to configure a drive and save the setup to a disk for later downloadingtoadrive. PC Requirements The minimum PC configuration required for Ultra Master software is: A 386-based IBM compatible PC with 2MB of available hard disk space to load Ultra Master 4 MB minimum of memory Microsoft® Windows version 3.1 or higher A 3.5 in., 1.44 MB floppy disk drive An RS-232 serial port A VGA monitor DeviceNet Option ULTRA 100 with DeviceNet gives you the ability to operate your drive remotely over a network. DeviceNet, an open, low-cost network based on Controller Area Network (CAN) technology, is a device-level network that can connect individual components, such as drives and switches. ULTRA 100 with DeviceNet supports generic object mapping and unconnected message manager (UCMM) for dynamic and multiple explicit message connections. Publication 1398-2.0 - August 1999 32 ULTRA Series Host Mode The ULTRA 100/200 drives host command protocol provides optional drive configuration using the drive serial communications interface. This powerful feature allows your controller to access all of the drive digital controls using sequences of ASCII characters. The protocol includes error checking to ensure the integrity of the transmitted commands. In installations that have multiple axes, up to 32 ULTRA 100/200 drives can be addressed by a host computer. These drives communicate with the host computer using a four-wire RS-485 serial interface. The host command protocol includes specific drive addressing, which allows the host to communicate with all the connected drives concurrently. Host Computer RS485 RS485 RS485 DRIVE DRIVE DRIVE DRIVE Publication 1398-2.0 - August 1999 ULTRA Series 33 Ultra Master Windows Ultra Master has a complete set of easy-to-understand windows available from its pull-down menus. The following is a description of some of these windows: Window Description The Drive window is the main window for performing functions in the Ultra Master. It is a feature-rich and functionally-easy method to visually setup, run, Drive evaluate, and diagnose one or more servo systems. Icon buttons are arranged by function: setup and control, displays, and diagnostics. The Drive Setup window appears automatically when Ultra Master is connected to an uninitialized drive. Usually the only parameter that you need to select is Drive Setup the catalog number of the motor that the drive is connected to. The dialog box allows easy access to drive type, motor model, operation modes, drive name, communications, and encoder setup. The Drive Parameters window accesses common operating parameters for the drive including current limits and fault thresholds. This window, along with the Drive Parameters I/O Configuration window, defines the necessary drive parameters for your application. The Drive Parameters window allows easy selection of command source, drive modes, and limits. The I/O Configuration window assigns functions to digital inputs and outputs I/O Configuration and routes signals to analog outputs. The active and inactive brake delays are also set using this screen. I/O assignments are quickly set up by name. For quick setups, Ultra Master has one-button autotuning. For critical tuning Tuning requirements, a built-in function generator allows manual adjustment of the velocity and position gain loops. The digital oscilloscope provides online monitoring of any drive parameter. Its functions include positive and negative triggering, continuous tracing, A vs. B display, and independent channel scaling and offset. Oscilloscope Note: The digital oscilloscope should be used as a reference only. It is not intended to replace an oscilloscope for true diagnostic situations. The Diagnostics screens provide fast verification of various I/O conditions and allow you to check functions and machine wiring by exercising the digital Diagnostics outputs. A fault history provides complete information on past conditions, and a fault check screen provides instant status on any error conditions. Publication 1398-2.0 - August 1999 34 ULTRA Series AC Line Filters AC line filters are required for EMC compliance. Part Number Description ULTRA 100/200 9101-1516 6A, 1φ 1398-DDM-005 9101-1517 10A, 1φ 1398-DDM-009, -010 9101-1518 23A, 1φ 1398-DDM-019, -020 9101-1575 50A, 3φ 1398-DDM-150 9101-1387 36A, 1φ 1398-DDM-030 1 9101-1388 50A, 1φ For multiple drives on one filter 9101-1389 36A, 3φ 1398-DDM-075 1 9101-1390 70A, 3φ For multiple 1398-DDM-075 drives on one filter 1 For multiple drives using one filter, the combined drive input currents must not exceed filter current rating. AC Line Filter (9101-1516) for 1398-DDM-005 9 (0.4) 152 (6.0) Dimensions mm (in.) 92 55 (3.6) (2.2) LINE LOAD 18 (0.7) 170 25 (6.7) (1.0) 9 (0.4) 152 (6.0) 10 (0.4) Publication 1398-2.0 - August 1999 ULTRA Series 35 AC Line Filter (9101-1517) for 1398-DDM-009, 1398-DDM-010, and 1398-PDM-10 10A 1φ φ φ φ 20 (0.79) LINE LOAD Dimensions 145 104 mm (in.) (5.71) (4.10) 5 11 192 40 (7.56) (0.43) (1.58) 214 (8.43) 11 (0.43) 192 F7 (7.56) 16 (0.63) Publication 1398-2.0 - August 1999 36 ULTRA Series AC Line Filter (9101-1518) for 1398-DDM-019, 1398-DDM-020, and 1398-PDM-20 23A 1φ φ φ φ 11 (0.43) 192 5 (.20) (7.56) Dimensions mm (in.) 204 164 (8.04) (6.46) LINE LOAD 20 (0.79) 214 47 (8.43) (1.85) 11 192 (0.43) (7.56) 19 (0.75) Publication 1398-2.0 - August 1999 ULTRA Series 37 AC Line Filter (9101-1575) for 1398-DDM-150 50A 3φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) (L1) (L1') LINE LOAD 12.00 128.00 (L2') (L2) M6 (0.47) (5.04) (L3) (L3') Scale 2:1 (E) 113.00 (4.45) 120.00 (4.73) 25.00 25.00 (0.98) 25.00 14.00 (0.98) (0.98) 110.00 (0.55) (4.33) 22.00 (0.87) Dimensions 55.00 mm (in.) (2.17) 230.00 147.00 (9.06) (5.79) Publication 1398-2.0 - August 1999 38 ULTRA Series AC Line Filter (9101-1387) for 1398-DDM-030 and 1398-PDM-30 36A 1φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) LOAD LINE 101.00 Dimensions (3.98) mm (in.) 12.00 (0.47) SCALE 2:1 80.00 20.00 (3.15) (0.78) 86.00 (3.39) 104.00 60.00 M6 (4.10) (2.36) M6 x 12 55.00 22.00 (2.17) (0.87) 174.00 120.00 20.00 (6.86) (4.73) (0.79) AC Line Filter (9101-1388) for Multiple Drives 50A 1φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) LINE LOAD 101.00 Dimensions (3.98) mm (in.) 12.00 (0.47) SCALE 2:1 80.00 20.00 (3.15) 86.00 (0.78) (3.39) 104.00 (4.10) M6 60.00 (2.36) M6 x 12 55.00 22.00 (2.17) (0.87) 174.00 120.00 20.00 (6.86) (4.73) (0.79) Publication 1398-2.0 - August 1999 ULTRA Series 39 AC Line Filter (9101-1389) for 1398-DDM-075 and 1398-PDM-75 36A 3φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) LINE LOAD 101.00 Dimensions (3.98) mm (in.) 12.00 (0.47) SCALE 2:1 80.00 20.00 (3.15) 86.00 (0.78) (3.39) 104.00 (4.10) M6 60.00 (2.36) M6 x 12 55.00 22.00 (2.17) (0.87) 174.00 120.00 20.00 (6.86) (4.73) (0.79) AC Line Filter (9101-1390) for Multiple Drives 80A 3φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) (L1) (L1') LINE LOAD (L2') (L2) M8 167.00 12.00 (6.58) (L3) (L3') (0.47) (E) 120.00 152.00 (5.99) (4.73) 40.00 40.00 (1.58) 40.00 (1.58) (1.58) 150.00 (5.91) 29.00 (1.14) Dimensions 85.00 mm (in.) (3.35) 238.00 186.00 (9.38) (7.33) Publication 1398-2.0 - August 1999 40 ULTRA Series AC Line Filter (9101-1575) for 1398-DDM-150 50A 3φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) (L1) (L1') LINE LOAD 12.00 128.00 (L2') (L2) M6 (0.47) (5.04) (L3) (L3') Scale 2:1 (E) 113.00 (4.45) 120.00 (4.73) 25.00 25.00 (0.98) 25.00 14.00 (0.98) (0.98) 110.00 (0.55) (4.33) 22.00 (0.87) Dimensions 55.00 mm (in.) (2.17) 230.00 147.00 (9.06) (5.79) External Shunt Resistor Kit (9101-1183) for 1398-DDM-010, -020, -030 and 1398-PDM-10, -20, -30 77.5 (3.05) 50.8 #10 (M5) (2.00) 12.7 Mounting holes (0.50) 25.4 218.4 (1.00) (8.60) 6.3 (0.25) 120.6 132 101.6 Dimensions (4.75) (5.20) (4.00) mm (in.) Publication 1398-2.0 - August 1999 ULTRA Series 41 Passive External Shunt Module (1398-SR9P) for 1398-DDM-075, 1398-DDM-150, and 1398-PDM-075 Publication 1398-2.0 - August 1999 42 ULTRA Series Active External Shunt Module (1398-SR3AF) for 1398-DDM-005, -005-DN, -005X, -005X-DN 1398-DDM-009, -009-DN, -009X, -009X-DN, and 1398-DDM-019, -019-DN, -019X, -019X-DN 65.10 (2.56) 13.30 38.10 Clearance holes for #10 (1.50) (0.52) 6.30 (M5) screws 18.60 (0.25) (0.73) 186.70 (7.35) Notes: 1. Allow 76.2 mm (3.00 in.) clearance in front of unit for cables. 2. Allow 12.7 mm (0.50 in.) on both sides of the unit. 3. Allow 5.0 cm (2.0 in.) above and below the unit. Breakout Board (J1) for ULTRA 100/200 Drives (9101-1391) 96.98 Dimensions (1.954) mm (in.) 87.12 (3.430) 136.90 69.85 (5.390) (2.750) Publication 1398-2.0 - August 1999 Allen Bradley Ultra Series ULTRA Series 43 Breakout Board (J2) for ULTRA 100/200 Drives (9101-1392) 96.98 Dimensions (1.954) mm (in.) 87.12 (3.430) 81.03 69.85 (3.190) (2.750) TouchPad The TouchPad (part number 1398-HMI-001) is a convenient alternative to using Ultra Master for drive setup and monitoring. The small TouchPad module plugs directly into the front of the drive, and its eight-character dot matrix display and five keys provide access to many of the same functions available in Ultra Master software. The TouchPad is a convenient diagnostic and monitoring tool for use on the factory floor. One TouchPad can support several drives because it is independent of the drive and can be quickly attached and removed once power is removed. You can enter commands by pressing a single key or combinations of keys. Two modes of operation are available: Display mode, which allows you to move through the TouchPad command tree to each parameter. Modify mode, which allows you to monitor and change each parameter. You can modify or view most parameters while the drive is either running or disabled. Refer to the TouchPad Card (publication 1398-5.5) for more information. Publication 1398-2.0 - August 1999 44 ULTRA Series TouchPad (1398-HMI-001) 27.7 (1.09) Dimensions mm (in.) 57.2 (2.25) 50.8 (2.00) Publication 1398-2.0 - August 1999 ULTRA Series 45 ULTRA Plus Positioning The ULTRA Plus drive is an integrated, high-performance positioner and brushless drive all in one module. GML Ultra, the Microsoft Windows user Drives interface for ULTRA Plus drives, provides a familiar graphical programming environment and user interface for any size drive. YES 9 7 8 NO 56 4 1 23 F1 F2 F3 F4 STATUS DISPLAY SYS FAULT COMM KEY 0 MODE CLEAR X1 X2 X3 X4 ENTER Power Supply 1398 ULTRA Module Plus Operator Terminal (optional) (PSM) Positioning Drive only required Module for (PDM) 1398-PDM-25, Windows Compatible 1398-PDM-50, Personal Computer 1398-PDM-100, (user-supplied) 1398-PDM-150 GML Ultra Auxiliary Encoder Software F-, H-, N-Series Motors (user-supplied option) Manuals Software manuals are Shunt Resistor shipped with the GML Ultra software (if required) Hardware manuals are shipped with the ULTRA Plus Drives Publication 1398-2.0 - August 1999 46 ULTRA Series ULTRA Plus Features Features and benefits of the ULTRA Plus Series motors include: Features Benefits  Brushless sinusoidal commutation  Innovative on-the-fly motion profile generator  High performance master/follower operation High performance  Analog and digital I/O with scan functions  Four-function math and logic functions  Hardware-latched high-speed input  Modular packaging  115-240V offline operation 1  No external transformer required (USA) Simple to install  Built-in shunt regulator  Integral 24V DC opto-isolated I/O  Fits in a 30 cm (12 in.) deep NEMA enclosure  Intuitive Microsoft Windows user interface  Automatic velocity and position loop tuning Quick and easy  User-friendly GML Ultra programming language start-up  No potentiometer adjustments  Menu-driven user configuration stored in transferable personality module  Offline editing and compiling of programs  Volatile and nonvolatile variables for speed, distance, time, and loop counters  Multiple application programs stored in 32K transferable memory Built-in flexibility  S-curve, trapezoidal, and complex motion profiles  True feed rate override  Electronic gearing-follower capability  Step and direction inputs  Fault history Comprehensive  Built-in solid state soft start protection and  Motor and drive system thermally protected diagnostics  Phase loss indication (1398-PDM-25, -50, -100, and -150 only)  UL listed  Bright, easy-to-read 4x20 vacuum fluorescent display  Easy user setup for customizing applications Superior  Up to ten ULTRA Plus systems can be addressed from one operator operator terminal terminal  Smart display of user messages and variable entry  Real-time axis status monitoring 1 Isolation transformers may be required for ULTRA Plus drives 1398-PDM-25, -50, -100, and -150. Publication 1398-2.0 - August 1999 ULTRA Series 47 ULTRA Plus General Specifications The following tables contain ULTRA Plus general specifications: Control Hardware Specification Description Microprocessor 80C196KC Clock 20 MHz Hardware watchdog 0.016 seconds Firmware memory 96K with 8K text EPROM Program memory 32K in the personality module Motor feedback Incremental encoder Encoder input frequency 750 kHz Pulse and direction input 800 kHz maximum pulse input frequency One 12-bit DAC output Analog I/O One 8-bit DAC programmable monitor output One 10-bit ADC input 16 general purpose inputs (user-definable) Inputs can be used as:  Enable  FWD limit  Home command  Home switch  Jog FWD  Jog REV  Pause  Return  REV limit  Start 8 general purpose outputs (user-definable) Digital I/O Outputs can be used as:  At home  Error  Home sequence complete  In position  Program running 2 dedicated normally open relays  PDM enabled  PDM ready Publication 1398-2.0 - August 1999 48 ULTRA Series Resolutions, Ranges, Accuracy, and Speeds Specification Description Position: Range 32 bits (±2,147,483,648 encoder counts) Repeatability ±1 encoder count Velocity command: Range 4,294,967,296:1 Resolution 0.000229 RPM (2000-line encoder) Acceleration: Range 4,294,967,296:1 Resolution 0.00381 rev/s/s (2000-line encoder) Type Linear or S-curve Electronic gearing 32767:1 to 1:32767 (+/-) Registration input 2 (35 μs ± 15 μs) Latched input 1.5 μs maximum (Encoder 1 or Encoder 2) Serial I/O Specification Description Serial ports 2 (or 1 with daisy chain) Type RS-232C/RS-422 Baud rate 1,200 to 19,200 Multi-drop Up to 63 addresses Tuning and Compensation Specification Description Position loop: KP Proportional gain KP2 Proportional gain when within PZone PZone KPZ active zone KFF Velocity feed forward gain KI Integral gain IZone KI active zone Velocity loop: PGain Proportional gain IGain Integral gain FGain Acceleration feed forward gain Filter Filters undesirable high frequency Auto-tune application Six levels, adjustable Manual tuning: Command generator Real-time adjustments Publication 1398-2.0 - August 1999 ULTRA Series 49 ULTRA Plus Specifications The following tables contain ULTRA Plus specifications for the 1398-PDM-10, -20, -30, and -75 motors. General 1398-PDM- Specification 10 20 30 75 (3φ φ φ φ) Peak output current/phase 10A 20A 30A 75A Continuous output current/phase 5A 10A 15A 35A Continuous output power 1 kW 2 kW 3 kW 7.0 kW RMS line voltage input 115-240V AC nominal 1 (50/60 Hz, single phase) Internal continuous shunt power 50W (200W with external resistor option) 50W dissipation Internal peak shunt power 4.5 kW (6.0 kW with external resistor option) 10.0 kW Operating temperature 0ºC to 50ºC (32ºF to 122ºF) Storage/shipping temperature -40ºC to 80ºC (-40ºF to 176ºF) Relative humidity 5 to 95% non-condensing Weight 5 kg (11 lb) 10 kg (21 lb) 1 Speed-torque curves represent 230V AC input. Reduced voltage will reduce speed. ULTRA Plus External Shunt Resistor for 1398-PDM-10, -20, and -30 (9101-1183) Specification Description Continuous shunt power dissipation 200W Peak shunt power 6000W Publication 1398-2.0 - August 1999 50 ULTRA Series ULTRA Plus Specifications Specific to 1398-PDM-25, -50, -100, and -150 The following tables contain ULTRA Plus specifications for the 1398-PDM-25, -50, -100, and -150 motors. General 1398-PDM- Specification 25 50 100 150 Peak output current/phase 25A 50A 100A 150A Continuous output current/phase 20A 40A 50A 65A Continuous output power 4 kW 8 kW 10 kW 12 kW Operating temperature 0ºC to 50ºC (32ºF to 122ºF) Storage/shipping temperature -40ºC to 80ºC (-40ºF to 176ºF) Relative humidity 5 to 95% non-condensing Weight 11.0 kg (24.2 lb) Power Supply Modules Specification 1398-PSM-50 1398-PSM-125 RMS line voltage 115-240V AC nominal (three-phase 50/60 Hz VAC) Output bus voltage minimum 325V DC Continuous output current 50A 100A Continuous shunt power dissipation 600W 1200W Peak shunt power 20 kW 40 kW Operating temperature 0ºC to 50ºC (32ºF to 122ºF) Storage shipping temperature -40ºC to 80ºC (-40ºF to 176ºF) Relative humidity 5 to 95% non-condensing Weight 11.9 kg (26.2 lb) Operator Terminal Specification Description Input power 110/240V AC 15% single phase or 24V AC/DC option available Operating temperature 0ºC to 55ºC (-32ºF to 131ºF) Storage/shipping temperature -40ºC to 70ºC (-40ºF to 158ºF) Relative humidity 5 to 95% non-condensing Weight 3 kg (7 lb) Front panel seal Water tight, dust tight Publication 1398-2.0 - August 1999 ULTRA Series 51 Block Diagram of the ULTRA Plus Positioning Module Publication 1398-2.0 - August 1999 FEED RATE S FGAIN PROFILE GENERATOR ICMD MOTION KFF FE VCMD COMMANDS PGEN 12 CGENEN CURRENT BRUSHLESS BIT PROFILE KP PGAIN FILTER LIMIT FEED DAC MOTOR GENERATOR RATE MOTION KI COMMANDS S IGAIN PCMD AVERAGE I AVE VALUE CJOGEN JOG MOTION IZONE S VEL 1 COMMANDS FEED POSN RATE PJOG S FEEDBACK POSITION EXTERNAL PEXT POSITION LATCHED ENCODER 2 OUT POS3 POSITION SELECT POS1 ENCODER 2 AUX. POSITION LPOS FEEDBACK ENCODER 2 IN GPOS VEL 2 POS2 OPTION SLEW ELECTRONIC STEP AND RATE TRACKING GEARING DIRECTION IN LIMIT RATIO GEAR INPUT POSITION 2 52 ULTRA Series Ultra Plus Interconnect Diagram Operator Terminal NC P7-9 NC P7-8 YES 7 8 9 NC P7-7 NO 4 56 Shield P7-6 1 23 Common F1 F2 F3 F4 P7-5 Serial Port #1 STATUS DISPLAY SYS FAULT COMM KEY 0 XMT+ P7-4 MODE CLEAR X1 X2 X3 X4 ENTER XMT- P7-3 RCV- P7-2 RCV+ P7-1 NC P6-9 GML Microsoft Windows NC P6-8 Ultra Personal Computer NC P6-7 Shield P6-6 Common P6-5 Serial Port #2 XMT+ P6-4 XMT- P6-3 RCV- P6-2 RCV+ P6-1 G Shield P5-15 T +5V DC P5-14 S Analog P5-13 R TS+ P5-12 TS- P5-11 I- Brushless Servo Motor P5-10 +5V DC P5-9 NC P5-8 Common P5-7 Common P5-6 I+ P5-5 B- P5-4 B+ P5-3 A- P5-2 A+ P5-1 Shield P4-15 +5V DC Software Configured as: P4-14 Dir- P4-13 a) Master Encoder Input Step- P4-12 b) Indexer (Step and Direction) Input Step+ P4-11 c) Motor Encoder Output PI- P4-10 +5V DC P4-9 Dir+ P4-8 Master Encoder Common +15V DC P4-7 Common P4-6 PI+ 200 P4-5 PB- P4-4 PB+ P4-3 -15V DC PA- P4-2 PA+ +15V DC P4-1 P3 200 +15V DC 8 8 -bit DAC Out (Monitor) 7 12-bit DAC Out +15V DC -15V DC 6 10-bit A/D In 10K 5 Analog Common +15V DC 4 Relay Common 3 4.7K 5K PDM Enable 2 0.22 PDM Ready Normally Normally 1 10K Open Open 1 -15V DC -15 VDC P2 3 Output Loads: Resistance is 330 Ohm minimum. +24V DC W3 Internal 24V Supply 12 Error Output 08 11 In Position Output 07 Typical Output 10 Home Sequence Complete Output 06 9 75 mA maximum per output At Home Output 05 8 Program Running Output 04 500 mA total 7 General Purpose Output Output 03 6 General Purpose Output Output 02 5 +24V DC COM General Purpose Output Output 01 4 General Purpose Input Input 16 3 General Purpose Input Input 15 2 General Purpose Input Input 14 Software Configured as: 1 a) General Purpose Inputs b) Program Select Inputs P1 General Purpose Input Input 13 14 Input 12 Interrupt #2 13 Input 11 Interrupt #1 +24V DC 12 Return Input 10 11 Pause Input 09 10 3.3K Jog Forward Input 08 9 Jog Reverse Input 07 Typical Input 8 Input 06 Home Command 7 Input 05 Home Switch 6 Start Input 04 5 Enable Input 03 4 Reverse Limit Input 02 3 Forward Limit Input 01 2 +24V DC Common W4 1 Internal 24V Supply Input Switches: Resistance is 3000 Ohm maximum. 2 3 Publication 1398-2.0 - August 1999 ULTRA Series 53 System Configuration Checklist Use the following checklist to configure an ULTRA Plus system for your application: 1 ULTRA Plus Drives (choose one of the following): 1398-PDM-10 1398-PDM-25 ! ! 1398-PDM-20 1398-PDM-50 ! ! 1398-PDM-30 1398-PDM-100 ! ! 1398-PDM-75 1398-PDM-150 ! ! 1 Includes the ULTRA Plus Installation Manual (Publication 1398-5.1). Power Supply Modules (choose one of the following if you are using 1398-PDM-25, -50, -100, or -150): 1398-PSM-50 ! 1398-PSM-125 ! Note: You can use up to six ULTRA Plus drives with a single power supply. See page 64 for PSM module selection guidelines. ULTRA Series Motors (choose one of the following): F-Series Motors H-Series Motors N-Series Motors F-4030-Q-H00AA H-2005-K-H00AA N-3406-2-H00AA ! ! ! F-4050-Q-H00AA H-3007-N-H00AA N-3412-2-H00AA ! ! ! F-4075-R-H00AA H-3016-N-H00AA N-4214-2-H00AA ! ! ! F-6100-R-H00AA H-4030-M-H00AA N-4220-2-H00AA ! ! ! F-6200-R-H00AA H-4030-P-H00AA N-5630-2-H00AA ! ! ! F-6300-R-H00AA H-4050-P-H00AA N-5637-2-H00AA ! ! ! H-4075-R-H00AA N-5647-2-H00AA ! ! H-6100-Q-H00AA ! H-6200-Q-H00AA ! H-6300-Q-H00AA ! H-8350-S-H00AA ! H-8500-S-H00AA ! Publication 1398-2.0 - August 1999 54 ULTRA Series Cables Note: The last three digits select standard cable lengths of: 10 ft (3.0m)— 010; 25 ft (7.7m)—025; 50 ft (15.0m)—050; 75 ft (23.0m). TB1 to Motor Power Connections (choose one of the following): Part Number Description ! 9101-0250-xxx Use for 1398-PDM-25, -50, -100, or -150 with H-3000 motors Use for 1398-PDM-25, -50, -100, or -150 with H-4000 and 9101-0251-xxx ! F-4000 motors Use for 1398-PDM-25, -50, -100, or -150 with H-6000 and 9101-0252-xxx ! F-6000 motors ! 9101-0253-xxx Use for 1398-PDM-25, -50, -100, or -150 with H-8000 motors Use for 1398-PDM-10, -20, -30, or -75 with H-2000 and H-3000 ! 9101-1080-xxx motors Use for 1398-PDM-10, -20, -30, or -75 with H-4000 and F-4000 ! 9101-1081-xxx motors 1 ! 9101-1381-xxx Use for H-2000 and H-3000 motors 1 ! 9101-1382-xxx Use for F-4000 and H-4000 motors 1 ! 9101-1383-xxx Use for F-6000 and H-6000 motors ! 9101-1399-xxx Use for 1398-PDM-75, -150 with F-6300 and H-6300 motors 1 ! 9101-1467-xxx Use for N-Series motors Use for 1398-PDM-10, -20, -30, or -75 with H-6000 and F-6000 ! 9101-2179-xxx motors 1 Required for EMC compliance. For more information, see ULTRA Plus Requirements for Compliance with European Directives section on page 61 of this document. P4 Connections (choose one of the following): Part Number Description 9101-1474-xxx P4 to the motor feedback ! 9101-2031-xxx P4 to the auxiliary encoder ! 9101-2127-002 P4 to P4 for master/follower applications ! Publication 1398-2.0 - August 1999 ULTRA Series 55 P5 Connections (choose one of the following): Part Number Description 9101-1474-xxx P5 to the motor feedback ! 9101-2027-xxx P5 to motor encoder ! 9101-2135-025 or P5 to motor encoder (right angle motor connector) ! 9101-2135-050 P6 to Personal Computer Connections: Part Number Description 9101-2024-xxx P6 to personal computer (RS-232) ! 1 P6 communication cables should be no longer than 15.0 m (50 ft) for RS-232) P7 to Operator Terminal Connections: Part Number Description 9101-2025-xxx P7 to operator terminal ! 1 P7 communication cables should be no longer than 15.0 m (50 ft) for RS-232) Publication 1398-2.0 - August 1999 56 ULTRA Series Accessories (choose all that apply): Part Number Description 1 ! 9101-1517 AC line filter (10A, 1φ) for 1398-PDM-10 1 ! 9101-1518 AC line filter (23A, 1φ) for 1398-PDM-20 1 ! 9101-1387 AC line filter (36A, 1φ) for 1398-PDM-30 1 ! 9101-1388 AC line filter (50A, 1φ) for multiple drives on one filter 1 ! 9101-1389 AC line filter (36A, 3φ) for 1398-PDM-75 1 ! 9101-1390 AC line filter (80A, 3φ) for multiple drives on one filter ! 9101-1183 External shunt resistor for 1398-PDM-010, -020, and -030 1 ! 9103-0152 24V sourcing I/O conversion card ! 1398-HMI-002 Operator terminal 2 ! GML-D-U GML Ultra software 1 Required for EMC compliance. For more information, see ULTRA Plus Requirements for Compliance with European Directives section on page 61 of this document. 2 Includes the GML Ultra Getting Started Manual (Publication 1398-5.10), the GML Ultra User Manual (Publication 1398-5.11), and the GML Ultra Reference Manual (1398-5.12). Mating Connectors Cross-reference of mating connectors with P1, P2, and P3 connectors on your drive. Connector Type Poles Manufacturer Catalog Number P1 BL 14 14 Weidmüller 12603.6 P2 BL 12 12 Weidmüller 12601.6 P3 BL 8 8 Weidmüller 12597.6 Publication 1398-2.0 - August 1999 ULTRA Series 57 Dimensions for 1398-PDM-10, -20, and -30 111.8 Clearance holes for M5 (4.40) 226.8 (#10) mounting screws (8.93) 25.4 6.4 (1.0) (0.25) 26.6 25.4 (1.05) (1.0) Air Exhaust 14.20 (360.6) Ultra Plus Series Status 1 P7 Serial 1 2 U10 EEPROM for personality module Auxillary 3 TB2 P6 Serial 2 Computer P5 Encoder 1 Dimensions mm (in.) Motor WARNING: High Voltage May Exist Up To Five Minutes After Removing Power. P4 Encoder 2 349.3 Auxillary (13.75) DC Bus R 5 P3 Status/Analog I/O S T 7 10 DC Bus + P2 Digital Inputs DC Bus - L1 and Outputs 5 L2/N 7 L1 AUX 10 L2 AUX P1 Digital Inputs TB1 5 SW1 7 See Detail A Air Intake Notes: 1. Allow 2.00 inches (50.8 mm) above the unit for air flow. Detail A 2. Allow 2.00 inches (50.8 mm) in front of the Bottom View unit for cable clearance. Publication 1398-2.0 - August 1999 58 ULTRA Series Dimensions for 1398-PDM-75 Clearance holes for M5 151.7 7.0 (5.97) (#10) mounting screws 224.5 (0.27) (8.84) 50.5 25.4 (1.99) (1.00) Air Exhaust 360.7 (14.20) Ultra Plus Series STATUS 1 P7 Serial 1 2 U10 EEPROM for personality module Auxiliary 3 P6 Serial 2 TB2 Computer P5 Encoder 1 Dimensions Motor WARNING: HIGH VOLTAGE MAY EXIST UP TO EIGHT MINUTES mm (in.) AFTER REMOVING POWER. P4 Encoder 2 DC BUS Auxiliary R 349.3 5 (13.75) S P3 Status T Analog I/O 1 DC BUS + 10 DC BUS– P2 Digital Inputs L1 and Outputs 5 L2/N L3 1 L1 AUX 10 L2/N AUX P1 Digital Inputs TB1 5 SW1 1 25.4 (1.00) Air Intake Air Intake Notes: 1. Allow 2.00 inches (50.8 mm) minimum spacing above and below modules for airflow. 2. Allow 0.5 inches (13 mm) minimum spacing between modules for cover removal and around modules for cable clearance and airflow. 3. Allow 11 inches (280 mm) minimum spacing for cable clearance. Publication 1398-2.0 - August 1999 100-240VAC 50/60Hz MOTOR EXTERNAL SHUNT INTERNAL FINAL INSPECTION ULTRA Series 59 Dimensions for 1398-PDM-25, -50, -100, and -150 Clearance holes for M5 114.3 6.3 (#10) mounting screws 252.2 (4.50) (0.25) (9.93) 34.9 246.4 (1.38) 11.5 (9.70) 34.9 (0.45) (1.38) Air Exhaust Ultra Plus Series P7 Serial 1 Auxiliary P6 Serial 2 Computer P5 Encoder 1 Motor P4 Encoder 2 Dimensions Auxiliary mm (in.) 444.5 P3 Status/Analog I/O (17.50) P2 Digital Inputs and Outputs P1 Digital Inputs 410.2 (16.15) 428.7 (16.88) WARNING: Do not apply power with cover removed. Do not remove cover with power applies. Dangerous voltages may exist up to 5 minutes after removing power. See Detail A Air Intake Air Intake Notes: 1. Allow 4.0 inches (102 mm) minimum spacing for airflow above and below modules. 2. Allow 0.5 inches (13 mm) minimum spacing for airflow between modules for cover removal and around modules for cable clearance and airflow. 3. Allow 11.0 inches (280 mm) minimum spacing for cable clearance. Note: Power supply modules have identical dimensions and mounting requirements as PDMs. Detail A Bottom View Publication 1398-2.0 - August 1999 60 ULTRA Series ULTRA Plus Drives Options GML Ultra for Windows and Accessories GML Ultra software offers a departure from traditional programming. It provides a natural, object-oriented environment. Icons—or picture blocks— represent motion functions. You can create a motion program by piecing together icons that represent your application. You place these icons on the screen in the order required by your application and connect them using a “soldering iron.” To break connections and modify them, you can use a “wire cutter.” You can fill in motion and process details later. The result is a well-documented, easy-to-read, and easy-to-troubleshoot program. Once you draw your “flow-chart” diagram of the basic logic of the application, you can enter details about each icon using a “fill-in-the-form” approach. Each icon has a form, which you can call up by pointing and clicking on the icon. The “move axis” icon, for example, has choices for the type of move to perform, plus places to enter position, speed, acceleration, and deceleration. You can enter these details at any time, which minimizes the need to consult a manual or to understand a specialized syntax. Online, content-sensitive help is also available to provide immediate understanding of how each icon can be used. PC Configuration The minimum PC configuration required for GML Ultra software is: A 25 MHz 486-class CPU 4 MByte RAM (8+ Mbyte recommended) Microsoft Windows 3.1 MS-DOS 5.0 (6.0 recommended) An EGA screen (VGA or Super VGA recommended) A Windows compatible mouse and driver A 3.5 high density (1.44 Mbyte) diskette drive Two serial ports (COM1 and COM2) Publication 1398-2.0 - August 1999 ULTRA Series 61 GML Ultra Windows GML Ultra has many features that allow you to quickly program your ULTRA Plus application. The following is a description of some of these features: Feature Description The GML Ultra Dialog Editor window allows you to quickly assemble standard motion icons into a natural, graphical representation of the application. You can quickly assemble and modify your GML diagram to capture the basic logic Dialog editor of the process without the complexity of a traditional programming language. After you complete the basic diagram, you can easily add required information in a “fill-in-the-form” dialog box exposed by double-clicking on each motion icon. The pull-down configuration and setup windows prompt “fill-in-the-form” dialog boxes that allow setup and selection of the control, drive, and I/O Configuration and parameters from preset default values. Because all adjustments are available setup windows through the PC, manual adjustments of the positioning drive module are eliminated. ULTRA Plus provides automatic closed loop gain compensation for velocity and position loops. This unique algorithm provides a refinement to factory default Tuning settings in more demanding applications. Multiple choices are offered for different application types. GML Ultra provides a library of sample application diagrams and templates that Application library you can quickly and easily modify to reduce programming and commissioning time. GML Ultra provides comprehensive, context-sensitive help screens to provide Help screens assistance for on-the-spot programming questions. The Online Manager window allows monitoring and control of real-time tasks and access to GML Ultra diagnostic features like direct commands and watch window. From this window, you can jog an axis, observe selected variables Online manager and I/O, monitor feedback, get status information, and much more. Online trace allows you to control and to observe program flow to identify process and program problems. ULTRA Plus Requirements for Compliance with European Directives To comply with European directives, your ULTRA Plus system must include the following components: A 24V sourcing I/O conversion card An AC line filter Shielded power cables For more information about compliance with European Directives for 1398-PDM-10, -20, -30, and -75, refer to the ULTRA Plus Installation Manual (Publication 1398-5.1). Publication 1398-2.0 - August 1999 62 ULTRA Series 24V Sourcing I/O Conversion Card (9103-0152) and Cables The 24V I/O conversion card converts the 16 internal inputs and 6 internal outputs from an active low state to an active high state. It must be mounted in the same enclosure as the ULTRA Plus. By adding this component, you comply with the European Union Low Voltage Directive (LVD). To connect your ULTRA Plus drive to the I/O conversion card, you can use the following optional cables: Part number 44-0141-003 (3-ft cable) Part number 44-0141-010 (10-ft cable) Note: The conversion card cables are not required for CE compliance. AC Line Filters AC line filters are required for EMC compliance. Part Number Description ULTRA Plus 9101-1517 10A, 1φ 1398-PDM-10 9101-1518 23A, 1φ 1398-PDM-20 9101-1387 36A, 1φ 1398-PDM-30 1 9101-1388 50A, 1φ For multiple drives using one filter 9101-1389 36A, 3φ 1398-PDM-75 1 9101-1390 80A, 3φ For multiple drives using one filter 1 For multiple drives using one filter, the combined drive input currents must not exceed filter current rating. Publication 1398-2.0 - August 1999 ULTRA Series 63 Shielded Power Cables Shielded power cables are required for EMC compliance. 1 Motor Part Number F-4000, H-4000 9101-1382-xxx F-6000, H-6000 9101-1383-xxx H-2000, H-3000 9101-1381-xxx N-Series 9101-1467-xxx 1 The last three digits select standard cable lengths of: 10 ft (3.0m)—010; 25 ft (7.7m)—025; 50 ft (15.0m)—050; 75 ft (23.0m)—075. ULTRA Plus Optional Cables Cable POSITIONING P7 to operator terminal (1) (1) P6 and P7 communication cables should be no longer than 50 ft (15.0 m) for RS-232 MODULE 9101-2025-xxx P7 * Last three digits select Cable standard cable lengths of P6 to personal computer (9-pin) 10 ft (3.0 m) - 010 9101-2024-xxx 25 ft (7.7 m) - 025 P6 50 ft (15.0 m) - 050 Cable 75 ft (23.0 m) - 075 P5 to motor feedback No Termination P5 9101-2031-xxx* Cable P4 to auxiliary encoder No P4 TB1 Termination 9101-2031-xxx* Cable P3 P4 to P4 for master/follower applications P2 9101-2127-002 P1 Publication 1398-2.0 - August 1999 64 ULTRA Series ULTRA Plus Transformer (0020-5093) and Power Supply (9101-0120) for 1398-PDM-25, -50, -100, and -150 ULTRA PLUS TRANSFORMER / POWER SUPPLY Auxiliary power supply to maintain logic voltages when 3-phase power is turned off. 9101-0120 Auxiliary Logic Supply Transformer 0020-5093 P9 Isolation Transformer (4) for Auxiliary Logic Supply Includes four 2m (6 ft) cables Note: Isolation Transformers are not required for operation but may be helpful in reducing electrical noise. Power Supply Module Selection Guidelines (1398-PSM-25, -50, -100, and -150) 1398-PSM power supply modules should be selected based on the PSM rating required by your application. Up to six standard systems can be operated from a single power supply module. To select power supply modules: 1. Select the appropriate standard system(s) for your application. 2. Determine the total PSM rating by adding the PSM rating of each system chosen. 3. Select the power supply module with a PSM model number greater than your application total or select multiple PSMs, as required. 1398-PSM-50 1398-PSM-125 Power Power Supply Supply 50A continuous 100A continuous Shunt power Shunt power Continuous: 0.6 kW Continuous: 1.2 kW Peak: 20 kW Peak: 40 kW For example, if your application uses the following: Quantity Motor Drive PSM Rating 1 H-8350-S-H00AA 1398-PDM-100 45 1 H-6200-Q-H00AA 1398-PDM-100 20 your total PSM rating is 65. The 1398-PSM-125 with a PSM rating of 125 is the power supply module that you need for your application. Publication 1398-2.0 - August 1999 ULTRA Series 65 ULTRA Plus Operator Terminal The 4x20 character vacuum fluorescent display provides you with an output YES 7 8 9 of program-defined application messages. The terminal also allows you to NO 4 56 input numeric and yes/no responses to application message prompts. This 1 23 F1 F2 F3 F4 STATUS DISPLAY SYS FAULT COMM KEY 0 optional terminal is a powerful tool that allows you to customize operator MODE CLEAR X1 X2 X3 X4 ENTER interface terminology to your specific need. Keys Description Select from up to 24 factory-configured functions. You Function keys (F1, F2, F3, and F4) can define function key labels per your specific needs, such as Jog, Run, Stop, Home, Feed Rate, etc. These keys are scanned by the application program. You Unique X-keys (X1, X2, X3, and X4) are prompted for application specific input/output without interrupting program execution. Scrolls through multiple factory-configured screens Status key providing monitoring and troubleshooting information, such as Program status, I/O status, Position, Velocity, etc. Publication 1398-2.0 - August 1999 66 ULTRA Series ULTRA Series Common Operator Terminal (1398-HMI-002) Accessories 6.4 15.7 (0.25) 266.7 (0.62) 254.00 81.3 (10.50) (10.00) 6.4 (3.20) (0.25) COM 1 YES 7 8 9 NO 4 56 139.7 152.4 Dimensions 127.0 1 23 F2 F3 F4 mm (in.) F1 (5.50) (6.00) (5.00) STATUS L1L2/NPE DISPLAY SYS FAULT COMM KEY 0 CLEAR MODE X1 X2 X3 X4 ENTER #10 std x 0.50 long Gasket supplied with unit (nuts supplied with unit) 5.1 (0.20) 254.0 (10.00) 243.8 (9.60) Recommended panel cutout dimensions 129.5 139.7 3.0 (0.12) (5.10) (5.50) maximum radius 5.1 0.203 (0.008) diameter (0.20) Publication 1398-2.0 - August 1999 ULTRA Series 67 AC Line Filter (9101-1387) for 1398-DDM-030 and 1398-PDM-30 36A 1φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) LOAD LINE 101.00 Dimensions (3.98) mm (in.) 12.00 (0.47) SCALE 2:1 80.00 20.00 (3.15) (0.78) 86.00 (3.39) 104.00 60.00 M6 (4.10) (2.36) M6 x 12 55.00 22.00 (2.17) (0.87) 174.00 120.00 20.00 (6.86) (4.73) (0.79) AC Line Filter (9101-1388) for Multiple Drives 50A 1φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) LINE LOAD 101.00 Dimensions (3.98) mm (in.) 12.00 (0.47) SCALE 2:1 80.00 20.00 (3.15) 86.00 (0.78) (3.39) 104.00 (4.10) M6 60.00 (2.36) M6 x 12 55.00 22.00 (2.17) (0.87) 174.00 120.00 20.00 (6.86) (4.73) (0.79) Publication 1398-2.0 - August 1999 68 ULTRA Series AC Line Filter (9101-1389) for 1398-DDM-075 and 1398-PDM-75 36A 3φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) LINE LOAD 101.00 Dimensions (3.98) mm (in.) 12.00 (0.47) SCALE 2:1 80.00 20.00 (3.15) 86.00 (0.78) (3.39) 104.00 (4.10) M6 60.00 (2.36) M6 x 12 55.00 22.00 (2.17) (0.87) 174.00 120.00 20.00 (6.86) (4.73) (0.79) AC Line Filter (9101-1390) for Multiple Drives 80A 3φ φ φ φ R = 3.00 (0.12) = 12.00 (0.47) (L1) (L1') LINE LOAD (L2') (L2) M8 167.00 12.00 (6.58) (L3) (L3') (0.47) (E) 120.00 152.00 (5.99) (4.73) 40.00 40.00 (1.58) 40.00 (1.58) (1.58) 150.00 (5.91) 29.00 (1.14) Dimensions 85.00 mm (in.) (3.35) 238.00 186.00 (9.38) (7.33) Publication 1398-2.0 - August 1999 ULTRA Series 69 AC Line Filter (9101-1517) for 1398-DDM-009, 1398-DDM-010, and 1398-PDM-10 10A 1φ φ φ φ 20 (0.79) LINE LOAD Dimensions 145 104 mm (in.) (5.71) (4.10) 5 11 192 40 (7.56) (0.43) (1.58) 214 (8.43) 11 (0.43) 192 F7 (7.56) 16 (0.63) Publication 1398-2.0 - August 1999 70 ULTRA Series AC Line Filter (9101-1518) for 1398-DDM-019, 1398-DDM-020, and 1398-PDM-20 23A 1φ φ φ φ 11 (0.43) 192 5 (.20) (7.56) Dimensions mm (in.) 204 164 (8.04) (6.46) LINE LOAD 20 (0.79) 214 47 (8.43) (1.85) 11 192 (0.43) (7.56) 19 (0.75) External Shunt Resistor Kit (9101-1183) for 1398-DDM-010, -020, -030 and 1398-PDM-10, -20, -30 77.5 (3.05) 50.8 #10 (M5) (2.00) 12.7 Mounting holes (0.50) 25.4 218.4 (1.00) (8.60) 6.3 (0.25) 120.6 132 101.6 Dimensions (4.75) (5.20) (4.00) mm (in.) Publication 1398-2.0 - August 1999 ULTRA Series 71 Passive External Shunt Module (1398-SR9P) for 1398-DDM-075, 1398-DDM-150, and 1398-PDM-075 Publication 1398-2.0 - August 1999 72 ULTRA Series Publication 1398-2.0 - August 1999 ULTRA Series 73 Publication 1398-2.0 - August 1999 74 ULTRA Series Publication 1398-2.0 - August 1999 F ULTRA Series, ULTRA 100, and ULTRA 200 are registered trademarks of Rockwell Automation. Microsoft is a registered trademark of Microsoft Corporation. Windows is a trademark of Microsoft Corporation. UL and cUL are registered trademarks of Underwriters Laboratories. Reach us now at www.rockwellautomation.com Wherever you need us, Rockwell Automation brings together leading brands in industrial automation including Allen-Bradley controls, Reliance Electric power transmission products, Dodge mechanical power transmission components, and Rockwell Software. Rockwell Automation's unique, flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners, distributors and system integrators around the world. Americas Headquarters, 1201 South Second Street, Milwaukee, WI 53204, USA, Tel: (1) 414 382-2000, Fax: (1) 414 382-4444 European Headquarters SA/NV, avenue Herrmann Debroux, 46, 1160 Brussels, Belgium, Tel: (32) 2 663 06 00, Fax: (32) 2 663 06 40 Asia Pacific Headquarters, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 1398-2.0 – August 1999 Supersedes publication 1398-2.0 - February 1999  1999 Rockwell International. All Rights Reserved. Printed in USA