Allen-Bradley Ultra1500 2092-DA1 User Manual
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Allen-Bradley Ultra1500 2092-DA1 User Manual

Digital servo amplifiers
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Ultra1500™
Digital Servo Amplifiers
(Catalog Numbers
2092-DA1, 2092-DA2, 2092-DA3, 2092-DA4, and
2092-DA5)
User Manual
Table of Contents
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Summary of Contents for Allen-Bradley Ultra1500 2092-DA1

  • Page 1 Ultra1500™ Digital Servo Amplifiers (Catalog Numbers 2092-DA1, 2092-DA2, 2092-DA3, 2092-DA4, and 2092-DA5) User Manual...
  • Page 2 Allen-Bradley and ControlLogix are registered trademarks of Rockwell Automation, Inc. MicroLogix, RSLogix, SoftLogix, Ultra1500, and Ultraware are trademarks of Rockwell Automation, Inc. TYCO is a trademark of Tyco International, Ltd. Bussmann is a registered trademark of Cooper Industries, Inc.

  • Page 3: Table Of Contents

    Allen-Bradley Support ........P-4...
  • Page 4 Grounded Power Configuration ......3-3 Grounding Your Ultra1500 ....... . . 3-5 Grounding Your System to the Subpanel .
  • Page 5 Control Connections........5-2 Configuring the Ultra1500 ......5-3 Configuring the 1756-M02AE .
  • Page 6 Certifications..........A-1 Ultra1500 Power Specifications ......A-2 Ultra1500 Power Specifications.
  • Page 7 Ultra1500 Drives ........
  • Page 8 Mode Displays ......... . D-2 Function Mode.

  • Page 9: Introduction

    The manual is intended for engineers or technicians directly Manual involved in the installation and wiring of the Ultra1500 drive, as well as those responsible for incorporating the Ultra1500 into a control system. If you do not have a basic understanding of the Ultra1500, contact your local Allen-Bradley representative for information on available training courses before using this product.
  • Page 10 Preface this manual. Also specifies the audience for whom this manual is intended. Installing Your Ultra1500 Provides mounting information for the Ultra1500. Provides signal descriptions for the I/O, encoder, Ultra1500 Connector Data and serial interface connectors, and describes terminal connections for the drive power system.

  • Page 11: Related Documentation

    Preface The following documents contain additional information concerning related Related Documentation Allen-Bradley products. To obtain a copy, contact your local Allen-Bradley office, distributor, or download them from www.rockwellautomation.com/literature For: Read This Document: Catalog Number: Basic information on configuring and troubleshooting...

  • Page 12: Allen-Bradley Support

    Preface Allen-Bradley offers support services worldwide, with over 75 Sales/Support Allen-Bradley Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world. Local Product Support Contact your local Allen-Bradley representative for: •...

  • Page 13: Installing Your Ultra1500

    Chapter Installing Your Ultra1500 This chapter provides system installation guidelines and procedures for Chapter Objectives mounting your Ultra1500. This chapter covers the following topics: • Complying with European Union (CE) and TTMRA (C-Tick) Directives • Ultra1500 System Overview • Ultra1500 Servo System Overviews Before Mounting Your System •...

  • Page 14: Complying With Eu And Ttmra Directives

    Trans-Tasman Mutual Recognition Arrangement (TTMRA) Directives are available on-line at www.ab.com/certification/ce/docs. The web site is the authoritative source for verifying compliance and suitability for use of this and other Rockwell Automation/Allen-Bradley products. CE EMC Directive This unit is tested to meet Council Directive 89/336/EEC Electromagnetic...

  • Page 15: Low Voltage Directive

    Use 2090 series motor power and feedback cables and terminate the power cable shields to the drive chassis and motor/machine frame. • Install the Ultra1500 system inside an enclosure (grounded to the enclosure), and run input power wiring in conduit outside of the enclosure.

  • Page 16: Ultra1500 System Overview

    Ultra1500 System Overview typical installation. Ultra1500 System Catalog Numbers Description Component Ultra1500 with 1.4, 2.4, 4.7, 10.7, and 16.4 Amperes continuous output current and 230 Volts input Ultra1500 Drives 2092-DAx power. Ultraware Software 2098-UWCPRG Ultra1500 drives are configured using Ultraware software.
  • Page 17 Installing Your Ultra1500 Figure 1.1 Ultra1500 Servo System Overviews Before Mounting Your System PC-Powered Ultraware Commissioning and Communications Ultra1500 I/O and Commands MicroLogix PLC Encoder Feedback Motor Power Servo Motor PC-Powered Ultraware Commissioning and Communications Ultra1500 I/O and Analog Commands...

  • Page 18: Unpacking Modules

    One connector tool for opening wire clamps on power connectors, and • One Ultra1500 Quick Start manual (publication 2092-QS001x-EN-P) Remove all packing material, wedges, and braces from within and around the components. After unpacking, check the item(s) name plate catalog number against the purchase order.

  • Page 19: System Mounting Requirements

    The ambient temperature of the location in which you will install the Ultra1500 must not exceed 50° C (122° F). • You must install the Ultra1500 vertically on the panel (refer to Figure 1.2 for mounting orientation). • You must install the panel on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors.

  • Page 20: Ventilation Requirements

    If the cabinet is ventilated, use filtered or conditioned air to IMPORTANT prevent the accumulation of dust and dirt on electronic components. The air should be free of oil, corrosives, or electrically conductive contaminates. Refer to Appendix A for Ultra1500 power dissipation specifications. Publication 2092-UM001D-EN-P — July 2005...

  • Page 21: Sizing An Enclosure

    (KVA) of each axis must be known. This can be derived by calculating the Watts for each axis. If you are supplying power to more than one motor and an Ultra1500, simply add the kW ratings together from each calculation to get a system kW total.
  • Page 22 1-10 Installing Your Ultra1500 If you are using the Allen-Bradley system sizing program, IMPORTANT the average speed and average torque data has already been calculated and can be used in the above equation. If you are not sure of the exact speed and torque in your application,...

  • Page 23: Fuse Sizing

    Specifications in Appendix A for fuse recommendations, as well as input current and inrush current specifications. The Ultra1500 utilizes solid state motor short circuit protection rated as shown in the table below. Input Power Type Short Circuit Current Rating with No Fuse...

  • Page 24: Bonding Modules

    1-12 Installing Your Ultra1500 Bonding Modules Unless specified, most paints are not conductive and they act as insulators. To achieve a good bond between modules and the subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance exit path for high-frequency energy.

  • Page 25: Bonding Multiple Subpanels

    This section outlines the practices which minimize the possibility of Planning Your Panel Layout noise-related failures as they apply specifically to Ultra1500 installations. For more information on the concept of electrical noise reduction, refer to System Design for Control of Electrical Noise Reference Manual (publication GMC-RM001x-EN-P).

  • Page 26: Establishing Noise Zones

    Observe the following guidelines when laying out your panel (refer to Figure 1.5 for zone locations). • The clean zone (C) is above and beneath the Ultra1500 and includes CN1, CN2, and CN3 signals, and the DC filter (grey wireways). •...

  • Page 27: Cable Categories For The Ultra1500

    • Mount the AC line filter and bonded cabinet ground bus on the same panel as the Ultra1500, and as close to the Ultra1500 as possible. • Good HF bonding to the panel is critical. For painted panels, refer to Figure 1.3.

  • Page 28: Mounting Your Ultra1500 Drive

    (refer to Establishing Noise Zones for panel layout recommendations). Dimensions for the Ultra1500 are shown in Figure 1.6. 2. Attach the Ultra1500 to the cabinet, first using the lower mounting slots of the drive and then the upper. The recommended mounting hardware is M4 x 10 metric bolts for 2092-DA1 through 2092-DA3 drives, or M5 x 10 metric bolts for 2092-DA4 and 2092-DA5 drives.

  • Page 29: 2092-Da1 And 2092-Da2

    Installing Your Ultra1500 1-17 Figure 1.6 Ultra1500 Mounting Diagrams and Measurements 2092-DA1 and 2092-DA2 153.0 (6.02) 12.0 140.0 55.0 (0.47) (0.20) (5.51) (2.17) 155.0 (6.10) 145.0 (5.70) 50.0 Mounting hole (top) Chassis ground (0.20) (1.97) (0.20) and slot (bottom) terminal...
  • Page 30 1-18 Installing Your Ultra1500 Publication 2092-UM001D-EN-P — July 2005...

  • Page 31: Ultra1500 Connector Data

    Understanding Ultra1500 Motor Encoder Feedback Specifications • Understanding Ultra1500 Power and Ground Connections • Understanding the Ultra1500 Serial Interface The following table provides a brief description of the Ultra1500 front panel Understanding Ultra1500 connectors and describes the connector type. Connectors Designator...

  • Page 32: Ultra1500 Front Panel Connections

    Ultra1500 Connector Data Ultra1500 Front Panel Connections Use the figure below to locate the front panel connections on the Ultra1500 drives. Figure 2.1 Ultra1500 Front Panel Connections 50-pin CN1 I/O Connector 7-Segment LED Display Mode/Set Key Pin 1 Pin 26...

  • Page 33: Fault Outputs

    Ultra1500 Connector Data I/O Connector – CN1 The following table provides the signal descriptions and pin-outs for the CN1 input/output (50-pin) connector. CN1 Pin Description Signal CN1 Pin Description Signal +24V IN Reserved – External 24V Power for Inputs 1–7...

  • Page 34: Motor Feedback Connector - Cn2

    Ultra1500 Connector Data Motor Feedback Connector – CN2 The following table provides the signal descriptions and pin-outs for the CN2 motor feedback (15-pin) connector. CN2 Pin Description Signal CN2 Pin Description Signal Encoder Ground ECOM Reserved – Motor Thermal Switch Reserved –...

  • Page 35: Understanding Ultra1500 I/O Specifications

    Understanding Ultra1500 I/O Specifications Digital I/O Power Supply All Ultra1500 drives require an external 24V power supply for proper operation of the digital inputs. The following table provides a description of the digital I/O power supply. Note: A single 24V power supply can be used to power the digital I/O on multiple drives, provided the cumulative minimum current requirements are met.
  • Page 36 -1 V — supply, to guarantee an OFF state. Firmware Scan Signal delay from the digital input to the — 6 ms — Delay firmware-accessible registers. Figure 2.3 depicts common interface types for Ultra1500 Digital Inputs. Publication 2092-UM001D-EN-P — July 2005...
  • Page 37 Ultra1500 Connector Data Figure 2.3 Digital Input Interface Examples Ultra1500 +24V IN Drive 3.3k Ω 4.7k Ω Power Supply 0.01 µF 330 Ω INPUT1 PS2801 Logic Ground I/O Common Drive Input Connected to Switch/Relay Contact Ultra1500 Drive +24V IN 3.3k Ω...

  • Page 38: Digital Outputs

    Ultra1500 Connector Data Digital Outputs There are three opto-isolated transistor outputs (OUTPUT 1, OUTPUT 2, OUTPUT 3) that can be configured for the following functions using Ultraware software: Up To Speed, Brake, Within Speed Window, Within Near Window, Within Position Window, Velocity Limited, Current Limited, Warning, Absolute Position Valid, and Ready.
  • Page 39 Ultra1500 Connector Data Figure 2.4 Transistor Output Hardware Configuration for OUTPUT 1, OUTPUT 2, OUTPUT 3, and FAULT Signals Ultra1500 Drive Logic Power 330 Ω OUTPUT1+ 0.5A Fuse OUTPUT1- TLP127 Figure 2.5 Transistor Output Hardware Configuration for FAULT1, FAULT2, and FAULT3 Signals...

  • Page 40: Analog Inputs

    Ultra1500 Connector Data Analog Inputs The Ultra1500 has two single-ended analog inputs. One is dedicated as the command input for Analog Velocity mode, and the second is dedicated as the command input for Analog Current mode. The two inputs are identical, and Figure 2.6 shows the configuration of the analog input.

  • Page 41: Analog Outputs

    Ultra1500 Connector Data 2-11 Analog Outputs The Ultra1500 contains two analog outputs that can be configured through Ultraware software to represent internal drive variables. Figure 2.7 shows the configuration of the analog outputs. The following table provides a description of the analog outputs.

  • Page 42: Position Command Inputs

    2-12 Ultra1500 Connector Data Position Command Inputs The Ultra1500, when operating in follower mode, accepts position command signals from a controller. Position command inputs can be A quad B, Step/Direction, or Step Up/ Step Down format as shown in Figure 2.8.
  • Page 43 — 900 kHz input drive) Step/Direction and Step Up/Step Down inputs. Figure 2.3 depicts common interface types for Ultra1500 Position Commands. Figure 2.10 Position Command Interface Examples Controller Ultra1500 Drive 680 Ω...

  • Page 44: Understanding Ultra1500 Motor Encoder Feedback Specifications

    5 Volt Serial Encoders The Ultra1500 supports a serial encoder, known as the SA35. The SA35 device is a multi-turn absolute device with 131,072 counts/revolution, and can track ±32767 revolutions when battery power is present. This encoder is available in selected Allen-Bradley servo motors, such as the TL-Series.

  • Page 45: Hall Inputs

    Hall Inputs The Ultra1500 uses Hall signals to initialize the commutation angle for sinusoidal commutation with incremental encoders. Hall signals must be single-ended and can be either open collector type or TTL type. Figure 2.12 shows the configuration of the Hall inputs (S1, S2, and S3).

  • Page 46: Thermostat Input

    Ultra1500 Connector Data Thermostat Input The Ultra1500 can monitor a thermostat or thermistor signal from a motor and generates a fault if the motor overheats. Figure 2.13 shows the configuration of this drive input. Figure 2.14 on page 2-16 shows a typical connection to a motor with a normally closed thermostat.
  • Page 47 Ultra1500 Connector Data 2-17 Figure 2.15 Sequencing and Phasing of the Hall Signals Figure 2.16 Sequencing and Phasing of the Hall Signals (60° Hall Offset Example) Figure 2.17 shows the proper phasing of TTL A/B encoder signals when positive current is applied.

  • Page 48: Motor Encoder Connection Diagrams

    2-18 Ultra1500 Connector Data Motor Encoder Connection Diagrams Figures 2.18 through 2.22 show typical wiring diagrams for motor feedback cables from various motors. If the thermostat, limit, or Hall signals are not available, no connections are required, but the drive must be configured through software to ignore these signals.
  • Page 49 HALL A+ HALL B+ HALL C+ SHIELD SHIELD NOTES: IF THE MOTOR DOES NOT HAVE A THERMISTOR OR THERMOSTAT, THE THERMOSTAT INPUT OF THE ULTRA1500 FOUND ON PIN 2 OF CN2 SHOULD BE LEFT DISCONNECTED. Publication 2092-UM001D-EN-P — July 2005...
  • Page 50 2-20 Ultra1500 Connector Data Figure 2.20 Anorad Linear Motor to Drive Wiring Diagram ULTRA1500 ANORAD LINEAR MOTOR FEEDBACK CONNECTOR EPWR ECOM HALL A HALL B HALL C THERM+ THERM- SHIELD SHIELD Publication 2092-UM001D-EN-P — July 2005...

  • Page 51: Buffered Motor Encoder Outputs

    SHIELD SHIELD NOTES: IF THE MOTOR DOES NOT HAVE A THERMISTOR OR THERMOSTAT, THE THERMOSTAT INPUT OF THE ULTRA1500 FOUND ON PIN 2 OF CN2 SHOULD BE LEFT DISCONNECTED. Total resistance of the wiring for +5V encoder power and IMPORTANT ground connections between the drive and motor must be less than 2 Ohms.

  • Page 52: Index Pulses

    Z-Pulse Output Index Pulses The Ultra1500 has two separate differential outputs that provide an index pulse for use with controllers. In the case of a rotary motor with a serial encoder, the marker pulse is generated in the drive hardware.

  • Page 53: Volt Encoder Power Supply

    Ultra1500 Connector Data 2-23 5 Volt Encoder Power Supply All Ultra1500 drives supply 5V dc for the operation of the encoder. The following table provides a description of the auxiliary encoder power supply. Parameter Description Minimum Maximum Voltage range of the external power supply for Output Voltage 4.75V...

  • Page 54: Power Connections

    Note: DC Bus Negative is labelled N on the drive cover, but DC- on the removable connector. Input Power Connectors The following power connections are made to an Ultra1500 drive through a six position terminal connector. Main Power – L1, L2, and L3 L1 and L2 are single-phase main AC power input connections for the 2092-DA1, 2092-DA2, and 2092 -DA3 drives.

  • Page 55: Control Power - L1C And L2C

    = 500mS, minimum DELAY Control Power – L1C and L2C L1C and L2C are the single-phase control power inputs for all Ultra1500 drives. These AC inputs power drive logic and I/O circuitry. DC Bus Negative – N N is the negative side of the DC power bus on all 2092 drives.

  • Page 56: Dc Bus And Shunt Power Connectors

    2092-DA2 drives, as these drives do not have internal shunt resistors. Motor Power Connectors The U, V, and W phases of motor power are provided by an Ultra1500 drive through the three-position terminal connector. The motor power cable attaches to this terminal.
  • Page 57 Ultra1500 Connector Data 2-27 Figure 2.26 Ultra1500 Ground Connections Chassis ground terminal Chassis ground terminals (2) Chassis ground terminals (2) 2092-DA1 and 2092-DA2 2092-DA3 2092-DA4 and 2092-DA5 Left-side View Front View Front View Publication 2092-UM001D-EN-P — July 2005...
  • Page 58 2-28 Ultra1500 Connector Data Publication 2092-UM001D-EN-P — July 2005...

  • Page 59: Connecting Your Ultra1500

    Chapter Connecting Your Ultra1500 This chapter provides procedures for wiring your Ultra1500 and making cable Chapter Objectives connections. This chapter includes: • Understanding Basic Wiring Requirements • Determining Your Type of Input Power • Grounding Your Ultra1500 • Power Wiring Requirements •...

  • Page 60: Building Your Own Cables

    Connecting Your Ultra1500 Building Your Own Cables Factory made cables are designed to minimize EMI and are IMPORTANT recommended over hand-built cables to ensure system performance. When building your own cables, follow the guidelines listed below. • Connect the cable shield to the connector shells on both ends of the cable for a complete 360°...

  • Page 61: Determining Your Type Of Input Power

    Connecting Your Ultra1500 Before you wire your Ultra1500 system you must determine the type of input Determining Your Type of power you are connecting to. The Ultra1500 is designed to operate only in Input Power grounded environments. Grounded Power Configuration The grounded power configuration allows you to ground your single-phase or three-phase power at a neutral point.
  • Page 62 Connecting Your Ultra1500 Figure 3.3 Single-Phase Grounded Power Configuration Step-Down Transformer Secondary Transformer Secondary Ultra1500 Single-Phase AC Input Ultra1500 Single-Phase AC Input 2092-DA1, -DA2, and -DA3 2092-DA1, -DA2, and -DA3 L1 and L2 Terminals L1 and L2 Terminals Bonded Cabinet Ground Bus Ground Grid or Power Distribution Ground Figure 3.4...

  • Page 63: Grounding Your Ultra1500

    For CE grounding requirements, refer to Meeting Emission Requirements in Chapter 1. To improve the bond between the Ultra1500 and subpanel, IMPORTANT construct your subpanel out of zinc plated (paint-free) steel.

  • Page 64: Motor Power Cable Shield Termination

    Connecting Your Ultra1500 Figure 3.5 Chassis Ground Configuration (Multiple Ultra1500 Systems on One Panel) BATT 2092-DA1 or -DA2 2092-DA3 2092-DA4 or -DA5 Chassis ground Chassis ground Chassis ground BATT 2092-DA1 or -DA2 Bonded ground bar Chassis ground (optional) Bonded cabinet Note: Refer to Figure 3.6 on page 3-7 for...

  • Page 65: Safety Precautions

    Shielded Power Power Cable Cable Observe the following safety precautions when wiring your Ultra1500 drive. Safety Precautions DC bus capacitors may retain hazardous voltages after ATTENTION input power has been removed. Before working on the drive, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval listed on the drive warning label.

  • Page 66: Power Wiring Requirements

    The National Electrical Code and local electrical codes take IMPORTANT precedence over the values and methods provided. Ultra1500 Main AC Power Wiring Requirements The table below lists the main AC wiring requirements for the Ultra1500 drives. Refer to Figure 3.7 for power terminal positions. Ground Screw(s) Wire Size...
  • Page 67 Connecting Your Ultra1500 Figure 3.7 Ultra1500 Power Terminal Positions Main Input Power Terminals L1 – Main AC Power L2 – Main AC Power L3 – Main AC Power L1C – Control AC Power L2C – Control AC Power N – DC Bus Negative DC Bus and P1 –...

  • Page 68: Connecting Input Power

    3-10 Connecting Your Ultra1500 This procedure assumes you have mounted your Ultra1500 drive and are ready Connecting Input Power to wire your AC input power. To ensure system performance, run wires and cables in the IMPORTANT wireways as established in Chapter 1.
  • Page 69 Ferrules 2mm (0.79 in.) in diameter may be attached to the wires at this point. Ferrules ensure that wires strands are not inadvertently exposed. Note: The Ultra1500 motor power cables listed in Appendix C for use with the TL-Series motors have ferrules, and do not require stripping.

  • Page 70: Connecting Motor Power

    To ensure system performance, run wires and cables in the IMPORTANT wireways as established in Chapter 1. Refer to Figure 3.8 for the power wiring diagram for your Ultra1500. Wiring Motor Power When using TL-Series motors refer to Figure 3.10 for your motor power cable configuration.
  • Page 71 Motor End Terminal End To wire power from the drive to your motor: 1. Route the motor power cable to your Ultra1500 drive. To ensure system performance, run wires and cables in IMPORTANT the wireways as established in Chapter 1.

  • Page 72: Understanding Feedback And I/O Cable Connections

    20-pin connector at drive end. Feedback Connector beginning on page 2-14. CN2 mini-D Connector Kit (20 pin solder cup type) 9101-1477 • Understanding the Ultra1500 Serial PC Cable, premolded cable with connectors both ends 2090-DAPC-D09xx Interface beginning on page 2-23. Serial Connector...

  • Page 73: Commissioning Your Ultra1500

    IMPORTANT applying power to the system. 2. Apply main and control input power to the Ultra1500, and observe the Operator Interface on the front of the drive. The drive should enter a normal startup, as outlined below and shown in Figure 4.1.

  • Page 74: Detecting Your Ultra1500 Drive

    Go to Detecting Your Ultra1500 Drive. This procedure assumes you have successfully applied power to your drive. Detecting Your Ultra1500 Follow the steps below to ensure your Ultra1500 drive is communicating with Drive your Ultraware software. To detect your Ultra1500 drive: 1.

  • Page 75: Configuring Your Ultra1500 Drive

    4. Look for the Ultra1500 icon (1.5k) under the On-Line Drives tree. The Ultra1500 icon indicates that your drive is detected. 5. 5.Click on the [+] next to the Ultra1500 icon to expand the branch menu (as indicated in the window above).
  • Page 76 Commissioning Your Ultra1500 2. Invoke the Setup Wizard by highlighting the Drive branch, and then select the Setup Wizard from the Commands menu: 3. The initial step for the Ultraware Setup Wizard is to recommend resetting the drive parameters to factory settings.
  • Page 77 Commissioning Your Ultra1500 4. Ultraware prompts for the type of Controller and the Operation Mode of the drive. The Controller selection helps Ultraware determine many of the drive settings. The Operation Mode setting dictates additional parameters that must be selected on subsequent screens.
  • Page 78 Commissioning Your Ultra1500 7. After the motor is selected, the Setup Wizard allows an autotune procedure to execute. Autotune sets the tuning gains to values appropriate for the motor and load. Note: In the case of Analog Current operation mode, this tuning step is not necessary, since the external controller is responsible for the velocity and position loops.

  • Page 79: Testing Your Motor

    Note: Refer to the Help file provided with Ultraware for more information on using the velocity control panel. To test your motor: 1. Double-click the Ultra1500 icon. The Drive Properties window opens. Note: Actual values depend on your application. 2. Select Velocity Control Panel (as indicated in the window above). The velocity control panel window opens.
  • Page 80 Commissioning Your Ultra1500 4. Activate the hardware ENABLE input to the drive. Note: The hardware ENABLE (Drive Enable in Ultraware) must be assigned to one of the general-purpose digital inputs. 5. Press the Jog Forward or Jog Reverse button. 6. Observe the motor. The motor should be moving at the speed (velocity) you entered in step 3.

  • Page 81: Ultra1500 Application Examples

    Chapter Ultra1500 Application Examples This chapter provides instructions on using the Ultra1500 with various types Chapter Objectives of equipment as part of a digital servo system. This chapter includes these sections: • ControlLogix 1756-M02AE System • MicroLogix Follower • Absolute Positioning •...

  • Page 82: Controllogix 1756-M02Ae System

    Analog Velocity or Analog Current mode. The Ultra1500 drive can be connected to a TL-Series motor with a battery-backed, multi-turn serial absolute encoder, and the absolute position can be provided to the ControlLogix system via the buffered encoder feedback connections.

  • Page 83: Configuring The Ultra1500

    2. Select Ready as the value of Output 2. Figure 5.2 Ultra1500 Digital Outputs Window Configuring the 1756-M02AE This procedure assumes that you have finished wiring and configuring your Ultra1500 drive. For greater detail on the RSLogix5000 software as it applies to Publication 2092-UM001D-EN-P — July 2005...
  • Page 84 Ultra1500 Application Examples ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication. Refer to this For: Publication Number Document Detailed information on configuring and ControlLogix Motion troubleshooting your ControlLogix motion Module Setup and 1756-UM006x-EN-P module Configuration Manual...
  • Page 85 Ultra1500 Application Examples 6. Check the box Make this controller the Coordinated System Time master. 7. Select OK. 8. Right-click on I/O Configuration in the explorer window and select New Module. The Select Module Type window opens. 9. Select 1756-M02AE or 1784-PM02AE as appropriate for your actual hardware configuration.

  • Page 86: Testing And Tuning Your Axis

    19. Drag-and-drop axis from Ungrouped Axis folder to your new Motion Group folder. 20. Download your program to the Logix processor. Testing and Tuning Your Axis This procedure assumes that you have configured your Ultra1500 and the analog motion module. Before proceeding with testing and tuning your axes, ATTENTION verify that the drive is not faulted.
  • Page 87 Ultra1500 Application Examples Note: For detailed testing and tuning information, refer to the appropriate Logix motion module setup and configuration manual for specific instructions and troubleshooting. To test and tune your axis: 1. Remove the load from your axis. 2. Right-click on the axis in your Motion Group folder in the explorer window and select Axis Properties.
  • Page 88 Ultra1500 Application Examples 6. Select the Hookup tab. 7. Select 2.0 as the number of revolutions for the test (or another number more appropriate for your application). 8. Select the Test Feedback button to verify feedback connections. The Online Command – Encoder Test window opens. When the test completes, the Command Status changes from Executing to Command Complete.
  • Page 89 Ultra1500 Application Examples 10. The Online Command – Apply Test window opens. When the test completes, the Command Status changes from Executing to Command Complete. 11. Select OK. 12. Select the Tune tab. 13. Enter values for Travel Limit and Speed. In this example the Travel Limit is 5 revs and the Speed is set to 5 revs/s.
  • Page 90 5-10 Ultra1500 Application Examples 14. Select the Start Tuning button to auto-tune your axis. The Online Command – Tune Servo window opens. When the test completes, the Command Status changes from Executing to Command Complete. 15. Select OK. The Tune Bandwidth window opens.

  • Page 91: Micrologix Follower

    MicroLogix controller with the Ultra1500. The 2.2kΩ resistor is necessary in order to limit the current through the opto-isolator input of the Ultra1500, since the Ultra1500 AX and BX inputs are designed for 5V interfaces, and the MicroLogix outputs have 24V levels.

  • Page 92: Configuring The Micrologix Controller

    Configuring the MicroLogix Controller This procedure assumes that you have finished wiring and configuring your Ultra1500 drive. For greater detail on the RSLogix500 software and MicroLogix 1200 and MicroLogix 1500 controllers, refer to the table below for the appropriate publication.
  • Page 93 Ultra1500 Application Examples 5-13 PTO configuration parameters can be accessed directly using the Function Files window found in the Controller folder of the project tree: Select the PTO tab of the function files window to access all PTO-related configuration parameters:...

  • Page 94: Testing Your Axis

    DECEL pulses and the type of profile: s-curve or trapezoid. 7. The DECEL phase completes. 8. The PTO instruction is DONE. Testing Your Axis This procedure assumes that you have configured your Ultra1500 and the MicroLogix controller, and have previously tested your drive-motor interface. Publication 2092-UM001D-EN-P — July 2005...
  • Page 95 Ultra1500 Application Examples 5-15 Refer to Testing Your Motor on page 4-7 to verify that the drive and motor are operating normally. Before proceeding with testing your axis, verify that ATTENTION the drive is not faulted. To test your axis, a very simple program can be written using the RSLogix500...

  • Page 96: Absolute Positioning

    5-16 Ultra1500 Application Examples The Ultra1500 can be used with the TL-Series motors, which have serial Absolute Positioning encoders with battery-backed, multi-turn absolute position capability. The absolute position of the motor is read from the encoder by the drive, and the drive in turn provides the absolute position to the external controller.

  • Page 97: Encoder Battery Life

    Instead of using the battery compartment of the Ultra1500, an external 3.6V battery can be connected to pins 25 and 49 of the CN1 connector of the Ultra1500 drive. This method allows a potentially larger capacity battery to be used, for example if extra long battery life is desired.

  • Page 98: Battery Voltage Loss Detection

    Battery Voltage Loss Detection The encoder in the TL-Series motors monitors the battery voltage at all times, and supplies the Ultra1500 drive with battery status that is in turn relayed to the user through the status display of the drive.
  • Page 99 (A simple power cycle will not clear the battery error, even if the battery is replaced or reconnected.) The Ultra1500 provides a method for an external position controller to monitor the state of the absolute position feedback, in order to determine if a loss of absolute position has occurred.

  • Page 100: Extracting Absolute Position From The Drive

    (If the PLC digital output is active high, it must be converted with an external circuit to active low to properly drive the Ultra1500 input.) This digital input must be assigned to have Position Strobe...
  • Page 101 Therefore, the following algorithm can be used by a controller to extract the absolute position from the drive: 1. Ensure that the Ultra1500 drive is disabled, and the motor is stationary. Any movement of the motor during the absolute transfer process will not be accounted for by the controller, since the motor encoder inputs are ignored by the drive during the transfer.

  • Page 102: Using The Internal Dynamic Brake

    10. The position counter should now be tracking the absolute position of the drive. The Ultra1500 incorporates a dynamic brake relay that can short together the Using the Internal Dynamic motor windings under certain conditions. The circumstances in which the Brake dynamic brake relay is employed are selectable by the user.
  • Page 103 The diodes in the integrated power module (IPM) in conjunction with the three diodes shown in the figure, effectively short the motor windings to each other and also to the positive terminal of the DC bus. Figure 5.7 Ultra1500 Dynamic Braking Relay Circuitry Integrated Diode Power...

  • Page 104: Circuit Protection

    Ultra1500 Application Examples Circuit Protection The Ultra1500 will not allow the drive to be enabled if the motor characteristics are such that the dynamic braking circuitry could be damaged in the event of a stop. (Even if the Fault and Disable Braking parameter of the drive is set to Free Stop, a loss of control power will also activate the dynamic braking circuitry.)

  • Page 105: Stopping Profiles

    Stopping Profiles Figure 5.8 depicts calculated stopping profiles for TL-Series motors when used with the Ultra1500. If the load: motor inertia ratio is greater than 10:1, the stopping time will be longer and additional heating will occur in the drive.
  • Page 106 5-26 Ultra1500 Application Examples Figure 5.8 Dynamic Braking Times from Maximum Velocity 10:1 10:1 10:1 10:1 10:1 10:1 10:1 10:1 Publication 2092-UM001D-EN-P — July 2005...

  • Page 107: Tuning Descriptions

    This section provides explanations of the Ultra1500 tuning parameters Tuning Descriptions available for adjustment. Current Regulator Settings Although the current regulator of the Ultra1500 is automatically tuned using the electrical parameters of the motor, there are three settings available to the user: •...
  • Page 108 5-28 Ultra1500 Application Examples Figure 5.9 Resonance Effects at 200rpm Figure 5.10 shows the effect of the Resonant Frequency Suppression filter. The Resonant Frequency Suppression parameter is set to 458 Hz, the Low Pass Filter is set to 10000 Hz. The current and velocity waveforms appear very smooth as compared to the original waveforms.
  • Page 109 Ultra1500 Application Examples 5-29 10000 Hz. The current and velocity waveforms appear very smooth as compared to the original waveforms. Figure 5.11 458 Hz Low Pass Filter Setting Publication 2092-UM001D-EN-P — July 2005...

  • Page 110: Velocity Regulator Settings

    5-30 Ultra1500 Application Examples Velocity Regulator Settings The velocity regulator includes the following parameters available for adjustment by the user: • P Gain • Integrator Time • Integrator Mode • Integrator Threshold • D Gain • Low Pass Filter Bandwidth P Gain The P Gain parameter sets the proportional response of the velocity regulator.

  • Page 111: Integrator Time

    Ultra1500 Application Examples 5-31 Figure 5.12 Velocity Regulator Step Response with Varying P Gain. P Gain = 500 Velocity Command P = 20 P = 40 P = 200 P = 500 P Gain = 20 Time (msec) Integrator Time The Integrator Time parameter sets the integral response of the velocity regulator.

  • Page 112: Integrator Mode

    5-32 Ultra1500 Application Examples Figure 5.13 Velocity Regulator Step Response with Varying Integrator Time Integrator Time = 1 Velocity Command I = 0 I = 100 I = 10 Integrator Time = 0 Integrator Time = 100 I = 1...

  • Page 113: D Gain

    Ultra1500 Application Examples 5-33 Integrator Mode Setting Description Always On The velocity regulator integral term is always used. This parameter value is specified as a percentage of the motor continuous current rating. The velocity regulator integral term is updated normally when the current command is less than the Integrator Threshold setting.

  • Page 114: Low Pass Filter Bandwidth

    5-34 Ultra1500 Application Examples Figure 5.14 Velocity Regulator Step Response with Varying D Gain D Gain = 0 D Gain = 200 Velocity Command D = 0 D = 75 D = 200 Time (msec) Low Pass Filter Bandwidth The Low Pass Filter Bandwidth parameter sets the bandwidth frequency of the low pass filter that is applied to the velocity command input for the velocity regulator.

  • Page 115: Kff

    Ultra1500 Application Examples 5-35 The Kp parameter sets the proportional response of the position regulator. It can be in the range 0–700. The regulator uses this gain to generate a velocity command proportional to the position error. Larger gains result in larger velocity commands, faster response, and increased stiffness in the system for a given position error.
  • Page 116 5-36 Ultra1500 Application Examples the Kff term is increased, it affects the response more. When Kff = 50, the system response is good, with the quickest rise time and no overshoot. When Kff = 100 the response is faster, but has some overshoot (that could be reduced by increasing the Integrator Time setting of the velocity loop).

  • Page 117: Kff Low Pass Filter Bandwidth

    Ultra1500 Application Examples 5-37 Figure 5.17 Position Regulator Response During Move with Varied Kff 20000 Kff = 0 15000 10000 Kff = 0 Kff = 50 Kff = 100 5000 Kff = 100 -5000 Time (msec) Kff Low Pass Filter Bandwidth...
  • Page 118 5-38 Ultra1500 Application Examples Figure 5.18 shows the effect of varying the offset value on the position error during a typical motion profile. In the first figure, the drive was operated with the position regulator default gain settings, (Kp = 20, Kff = 0), and the threshold was set to 2000 counts.

  • Page 119: Control Block Diagrams

    Output Offset = 400 -2000 -3000 -4000 Time (msec) This section includes graphical representation and descriptions of the Control Block Diagrams regulators, control modes, and settings of the Ultra1500. Details are provided in the following areas: • Position Regulator • Velocity Regulator •...

  • Page 120: Position Regulator

    5-40 Ultra1500 Application Examples Position Regulator Figure 5.20 shows the block diagram of the position regulator in the Ultra1500 Figure 5.20 Position Regulator Block Diagram gear Sampled Master Position Velocity Command Command To Velocity gear Regulator +Offset Sampled Follower -Offset...

  • Page 121: Velocity Regulator

    Ultra1500 Application Examples 5-41 Velocity Regulator Figure 5.21 shows the block diagram of the velocity regulator in the Ultra1500: Figure 5.21 Velocity Regulator Block Diagram Sample d Cu rrent Ve locity Command Comman d Curre nt Curren t Curren t...

  • Page 122: Analog Velocity Mode

    5-42 Ultra1500 Application Examples The velocity command limit is set to the minimum of the following: • Zero if the velocity command is in the direction of an active overtravel limit, • Manual Velocity Limit (if activated), • Analog Velocity Limit (if activated), and •...

  • Page 123: Preset Velocity Mode

    Ultra1500 Application Examples 5-43 Preset Velocity Mode Figure 5.23 shows the block diagram of the preset velocity mode for the Ultra1500: Figure 5.23 Preset Velocity Mode Block Diagram Vel Preset 1 Vel Preset 2 V elocity Vel Preset 3 Comma nd...

  • Page 124: Analog Current Mode

    5-44 Ultra1500 Application Examples Analog Current Mode Figure 5.25 shows the block diagram for the analog current mode of the Ultra1500: Figure 5.25 Analog Current Mode Block Diagram Curren t Comma nd to Curren t Analog Cu rrent Reg ulator...

  • Page 125: Dual Current Command Mode

    Main Drive Window : Current Limits; Main Drive Window : Stopping Functions : Maximum Stopping Current Block/Switch definitions shown in Figure 5.26 refer to the Ultraware parameter names where applicable. In this operating mode, an external controller performs all commutation functions, and the Ultra1500 drive functions as a simple three-phase current regulator. •...
  • Page 126 5-46 Ultra1500 Application Examples Publication 2092-UM001D-EN-P — July 2005...

  • Page 127: Maintaining And Troubleshooting Your Ultra1500

    Maintaining and Troubleshooting Your Ultra1500 This chapter provides a description of maintenance and troubleshooting Chapter Objectives activities for the Ultra1500. This chapter includes these sections: • Safety Precautions • Maintaining Your Ultra1500 Drive • Status Indicators and the Operator Interface •...

  • Page 128: Maintaining Your Ultra1500 Drive

    Maintaining and Troubleshooting Your Ultra1500 The Ultra1500 is designed to function with a minimum of maintenance. Maintaining Your Ultra1500 Drive To maintain your Ultra1500 drive: • Clean the drive periodically, using an OSHA approved nozzle that provides compressed air under low pressure, less than 20 kPa (30 psi), to blow the exterior surface and the vents clean.

  • Page 129: Status Indicators And The Operator Interface

    Status Indicators and the and settings. The major features of the Ultra1500 Operator Interface are Operator Interface identified in Figure 6.1 and briefly described below. Refer to Ultra1500 Operator Interface on page D-1 for detailed information about using the operator interface.

  • Page 130: General Troubleshooting

    If problems persist after attempting to troubleshoot the system, please contact your Allen-Bradley representative for further assistance. To determine if your Ultra1500 drive has an error, refer to the table immediately below. If the Main Power and Control Power LEDs are ON...

  • Page 131: Fault Codes

    Maintaining and Troubleshooting Your Ultra1500 Fault Codes The following list of assigned error codes is designed to help you resolve problems. Warning Messages Warnings are drive abnormalities that allow motor control to continue. Warnings are displayed on the drive's Status display using the last three segments of the display to display an abbreviated title.
  • Page 132 Maintaining and Troubleshooting Your Ultra1500 Error Display Description Possible Cause(s) Action/Solution Code Text Verify continuity of motor power cable and Motor cables shorted connector. Disconnect motor power cables from the motor. If Motor winding shorted internally the motor is difficult to turn by hand, it may need to be replaced.
  • Page 133 Maintaining and Troubleshooting Your Ultra1500 Error Display Description Possible Cause(s) Action/Solution Code Text • Verify cooling fan operation (2092-DA4 and 2092-DA5 only). • Check tuning. • Reduce acceleration rate. E036 Excessive heat exists in the drive • Reduce duty cycle (ON/OFF) of commanded Drive Overtemperature motion.
  • Page 134 Maintaining and Troubleshooting Your Ultra1500 Error Display Description Possible Cause(s) Action/Solution Code Text E100 The drive operating mode and motor Change the operating mode and/or the motor Drive Set Up selection are incompatible. selection, and reset the drive. E101 Motor cable open Verify power connection between motor and drive.

  • Page 135: Specifications And Dimensions

    • Ultra1500 Power Specifications • Ultra1500 General Specifications • Dimensions The Ultra1500 is certified for the following when the product or package is Certifications marked. • UL listed to U.S. and Canadian safety standards (UL 508 C File E145959) •...

  • Page 136: Ultra1500 Power Specifications

    Specifications and Dimensions The following sections provide power specifications for the Ultra1500. Ultra1500 Power Specifications Ultra1500 Power Specifications The tables below lists general power specifications and requirements for the Ultra1500 drives (2092-DAx). Main Input Power Drives 2092-DA1 2092-DA2 2092-DA3 2092-DA4 2092-DA5 200–240 Vrms, 1φ...

  • Page 137: Dc Bus And Shunt Circuitry

    Specifications and Dimensions DC Bus and Shunt Circuitry Drives 2092-DA1 2092-DA2 2092-DA3 2092-DA4 2092-DA5 Voltage 400 VDC – 660 µF 990 µF Capacitance Discharge Time (to < 50V) 3 minutes, maximum Overvoltage Detect 410V Undervoltage Detect 230V Shunt Circuitry Shunt Turn-on Voltage –...

  • Page 138: Fuse And Contactor Specifications

    Power Dissipation Specifications Use the following table to size an enclosure and calculate required ventilation for the Ultra1500. Typical heat losses run approximately one-half maximum power losses. The maximum power losses are shown below. Maximum Loss...

  • Page 139: Ultra1500 General Specifications

    Specifications and Dimensions The following sections provide physical, environmental, control, I/O, Ultra1500 General communication, feedback, connector, and AC line filter specifications for the Specifications Ultra1500 drives. Physical and Environmental Specifications Drives 2092-DA1 2092-DA2 2092-DA3 2092-DA4 2092-DA5 Operating Temperature 0° C to 50° C (32° F to 122° F)

  • Page 140: Current Loop

    Specifications and Dimensions Current Loop 50 µS Update Period -3dB Bandwidth 2 kHz, typical 350 Hz, typical Bandwidth Type PI, Flux Vector Control, Space Vector Modulation Notch Filter, Low Pass Filter, Automatically tuned using motor Features parameters Velocity Loop 200 µS Update Period -3dB Bandwidth 550 Hz achievable through tuning...

  • Page 141: Digital Outputs

    Specifications and Dimensions Digital Outputs Quantity 3 general purpose, opto-isolated Type Differential (both collector and emitter available for connection) Output Current 20 mA, maximum Output Voltage 21.6–26.4 Volts 50 µs Propagation Delay Firmware Scan delay 2 ms Absolute Position Valid, Brake, Current Limited, Ready, Up to Assignable Functions Speed, Velocity Limited, Warning, Within Near Window, Within Position Window, Within Speed Window...

  • Page 142: Command Inputs

    Specifications and Dimensions Command Inputs Analog Velocity, Analog Current, Preset Velocity, Follower, Dual Operating Modes Current Command Analog Velocity Input -10 to +10 Volt, single-ended, 16-bit A/D conversion Analog Current Input -10 to +10 Volt, single-ended, 12-bit A/D conversion Follower Input 5 Volts, opto-isolated Follower Types Step/Direction, Step Up, Step Down, Master Encoder...

  • Page 143: Ac Line Filter Specifications

    Specifications and Dimensions AC Line Filter Specifications The following AC line filters are compatible with the Ultra1500 drives. Specifications AC Line Filter Power Weight Operating Catalog Number Voltage Phase Current Humidity Vibration Loss kg (lb.) Temperature 6A @ 50° C 2090-UXLF-106 3.5W...

  • Page 144: Dimensions

    A-10 Specifications and Dimensions The figures below provide basic outline dimensions for the Ultra1500 drives. Dimensions Refer to Chapter 1 beginning on page 1-1 for additional drive dimensions, mounting hole locations, drive clearance requirements, and other information. Figure A.1 Ultra1500 Basic Outline Dimensions (2092-DA1 and 2092-DA2) 140.0...

  • Page 145: Interconnect And Cable Diagrams

    Appendix Interconnect and Cable Diagrams This appendix contains the following interconnect diagrams and cable Chapter Objectives assembly drawings that show you how to connect your Ultra1500 to the other parts of a motion control system: • Power Connections • CN1 I/O Control Connections •...

  • Page 146: Power Connections

    Interconnect and Cable Diagrams Figure B.1 shows the recommended power wiring for a typical Ultra1500 drive Power Connections and motor system. Figure B.1 Ultra1500 Simplifier Power Wiring Diagram ADDITIONAL DRIVES FUSED ULTRA1500 DISCONNECT OR CIRCUIT FUSE 1:1 ISOLATION BREAKER BLOCK...

  • Page 147: Cn1 I/O Control Connections

    Interconnect and Cable Diagrams Figure B.2 shows typical input/output connections to the CN1 control CN1 I/O Control connector of the Ultra1500. Connections Figure B.2 Ultra1500 CN1 I/O Control Interface Diagram Publication 2092-UM001D-EN-P — July 2005...

  • Page 148: Controllogix 1756-M02Ae System Connections

    Interconnect and Cable Diagrams Figure B.3 shows the recommended connections for a typical 1756-M02AE ControlLogix 1756-M02AE system using an Allen-Bradley ControlLogix PLC control system. System Connections Figure B.3 Ultra1500 to 1756-M02AE System Interface Diagram 1756-M02AE ULTRA1500 +OUT ICMD+ -OUT ICMD-...

  • Page 149: Softlogix 1784-Pm02Ae System Connections

    Interconnect and Cable Diagrams Figure B.4 shows the recommended connections for a typical 1784-PM02AE SoftLogix 1784-PM02AE system using an Allen-Bradley SoftLogix5800 control system. System Connections Figure B.4 Ultra1500 to 1784-PM02AE System Interface Diagram 1784-PM02AE ULTRA1500 +OUT ICMD+ -OUT ICMD- +CHA...

  • Page 150: Generic Controller Connections

    Interconnect and Cable Diagrams Figure B.5 shows the recommended connections for a typical system using a Generic Controller generic motion controller. Connections Figure B.5 Ultra1500 to Generic Controller System Interface Diagram PARTY ULTRA1500 CONTROLLER CMD+ VCMD+ CMD- VCMD- ENABLE+ INPUT1...

  • Page 151: Micrologix 1200/1500 Connections

    MicroLogix 1200/1500 MicroLogix 1200 or 1500 programmable logic controller with the Ultra1500. Connections In this example, the Ultra1500 is operating in Follower mode and the PLC provides Step and Direction commands to the drive. Figure B.6 Ultra1500 to MicroLogix 1200/1500 System Interface Diagram...

  • Page 152: Tl-Series Motor Connections

    Interconnect and Cable Diagrams Figure B.7 shows the recommended feedback wiring for the TL-Series motors TL-Series Motor to the Ultra1500. Connections Figure B.7 Ultra1500 and TL-Series Motor Feedback Wiring Diagram ULTRA1500 MOTOR FEEDBACK CONNECTOR EPWR EPWR ECOM ECOM BAT+ BAT+...

  • Page 153: Generic Rotary Motor Connections

    HALL A+ HALL B+ HALL C+ SHIELD SHIELD NOTES: IF THE MOTOR DOES NOT HAVE A THERMISTOR OR THERMOSTAT, THE THERMOSTAT INPUT OF THE ULTRA1500 FOUND ON PIN 2 OF CN2 SHOULD BE LEFT DISCONNECTED. Publication 2092-UM001D-EN-P — July 2005...

  • Page 154: Anorad Linear Motor Connections

    B-10 Interconnect and Cable Diagrams Figure B.9 shows the recommended feedback wiring for an Anorad linear Anorad Linear Motor motor. Connections Figure B.9 Ultra1500 and Anorad Linear Motor Feedback Wiring Diagram ULTRA1500 ANORAD LINEAR MOTOR FEEDBACK CONNECTOR EPWR ECOM HALL A...

  • Page 155: Generic Linear Motor Connections

    HALL A+ HALL B+ HALL C+ SHIELD SHIELD NOTES: IF THE MOTOR DOES NOT HAVE A THERMISTOR OR THERMOSTAT, THE THERMOSTAT INPUT OF THE ULTRA1500 FOUND ON PIN 2 OF CN2 SHOULD BE LEFT DISCONNECTED. Publication 2092-UM001D-EN-P — July 2005...

  • Page 156: Host Communications Connections

    Interconnect and Cable Diagrams Figure B.11 shows the connections between a personal computer and the Host Communications Ultra1500 drive. These connections are necessary when Ultraware is used for Connections configuration or monitoring the drive, or if a PC-based software program is used to communicate with the drive directly using serial commands Figure B.11...

  • Page 157: Tl-Series Motor Power Cable Assembly (2090-Danpt-16Sxx

    Interconnect and Cable Diagrams B-13 Figure B.12 shows the wiring diagram for the motor power cable assembly TL-Series Motor Power sold by Allen-Bradley (catalog number 2090-DANPT-16Sxx) to interface the Cable Assembly Ultra1500 drive to the TL-Series motor family. (2090-DANPT-16Sxx) Figure B.12...

  • Page 158: Cn1 Control Cable Assembly (2090-Daio-D50Xx

    B-14 Interconnect and Cable Diagrams Figure B.13 shows the wiring diagram for the CN1 control cable assembly sold CN1 Control Cable by Allen-Bradley (catalog number 2090-DAIO-D50xx) to interface the Assembly Ultra1500 drive to a motion controller. (2090-DAIO-D50xx) Figure B.13 CN1 Control Cable Diagram...

  • Page 159: Cn2 Feedback Cable Assembly For Tl-Series Motors

    Figure B.14 shows the wiring diagram for the motor feedback cable assembly CN2 Feedback Cable sold by Allen-Bradley (catalog number 2090-DANFCT-Sxx) to interface the Assembly for TL-Series Ultra1500 drive to the TL-Series motor family. This cable assembly includes Motors (2090-DANFCT-Sxx) connections for serial encoders as well as incremental encoders. Figure B.14 TL-Series Motor Feedback Cable Diagram.

  • Page 160: Cn3 Pc Communications Assembly (2090-Dapc-D09Xx

    Figure B.15 shows the wiring diagram for the CN3 PC communications cable CN3 PC Communications assembly sold by Allen-Bradley (catalog number 2090-DAPC-D09xx) to Assembly interface the Ultra1500 drive to a host computer. (2090-DAPC-D09xx) Figure B.15 Ultra1500 CN3 PC Communications Cable Diagram...

  • Page 161: Catalog Numbers And Accessories

    Appendix Catalog Numbers and Accessories This appendix lists the Ultra1500 drives and accessory items in tables by Chapter Objectives catalog number providing detailed descriptions of each component. This appendix describes catalog numbers for: • Ultra1500 Drives • Ultraware Software •...

  • Page 162: Ultraware Software

    Catalog Numbers and Accessories Use the following table to identify Ultra1500 drives based on Continuous Ultra1500 Drives Output Current, or Intermittent Output Current. Continuous Output Current Intermittent Output Current Catalog Number 1.4A (0–peak) 3.4A (0–peak) 2092-DA1 2.4A (0–peak) 7.2A (0–peak) 2092-DA2 4.7A (0–peak)

  • Page 163: Cables

    Use the following tables to identify motor power, feedback, interface, and Cables brake cables for your Ultra1500 drive. Length of cable xx is in meters. Power, feedback and brake cables for connection to TL-Series motors are available in standard lengths up to 30 m ( ft).

  • Page 164: Battery

    Catalog Numbers and Accessories Use the following table to identify the battery for your Ultra1500 drive. Battery Description Catalog Number 3.6 Volt, ½-size AA, Lithium Battery 2090-DA-BAT Publication 2092-UM001D-EN-P — July 2005...

  • Page 165: Ultra1500 Operator Interface

    The Operator Interface provides immediate access to Ultra1500 drive status Using the Operator displays and monitoring, parameter settings, or functional commands. The Interface major features of the Ultra1500 Operator Interface are identified in Figure D.1 and described below. Figure D.1 Ultra1500 Operator Interface...

  • Page 166: Publication 2092-Um001D-En-P — July

    Ultra1500 Operator Interface The following briefly explains the MODE/SET, ENTER, and directional keys and their use. Name Function Example Saves the current value of the setting in To save any change: • Press and hold SET until the display blinks.
  • Page 167 Ultra1500 Operator Interface 2. Select the function to perform from the list below using either the UP or DOWN key: Select from: 00 the Jog function, 01 the Run Auto Tuning function, through 12 the Reset to Factory Settings function.
  • Page 168 Ultra1500 Operator Interface If you are Complete the following step(s) to: performing this function: -JoG- Perform a Jog (00) function: 1. Press MODE to select the JoG-On display Note: MODE toggles between JoG-On and JoG-OFF. 2. Press the UP key to jog in the forward direction, or the DOWN key to jog in the reverse direction.

  • Page 169: Monitor Mode

    Ultra1500 Operator Interface Monitor Mode The Monitor mode displays numerical data about drive and motor functions. To access the monitor data: 1. Enter the Monitor mode by pressing the MODE key. The display indicates the selected Function by displaying (where nn is a variable number from the tables below).
  • Page 170 Ultra1500 Operator Interface Variable Name Unit Numbers Up to eight alarms stored in numerical order (most recent =1, to oldest =8) with error code number: Most significant digit is alarm number (1–8), Error History Least significant six digits are the error code number referenced in the Error Displays beginning on page 6-5.

  • Page 171: Status Mode

    Ultra1500 Operator Interface Variable Name Unit Numbers Servo Alarm: No errors Digital Outputs 3 - 1: Input and Output Status 3 and 1 active E-Stop: Not active Digital Inputs 7 - 1: 6, 5, 3, and 1 active Up to eight alarms stored in numerical order (most recent =1, to oldest =8) with error code number: Most significant digit is alarm number (1–8),...

  • Page 172: Set Parameter Mode

    Ultra1500 Operator Interface Figure D.2 shows these categories and briefly defines the information provided by each category. Refer to Maintaining and Troubleshooting Your Ultra1500 beginning on page 6-1 for a complete listing and description of Warning Messages, Error Displays, and Overtravel Conditions.

  • Page 173: Parameter Groupings

    Ultra1500 Operator Interface 3. Press the ENTER key to display the current value of the parameter. 4. Modify the current value of the parameter with the directional keys, and save the modified value in memory by pressing the SET key.
  • Page 174 D-10 Ultra1500 Operator Interface Pr-0.01 Motor and Encoder Selection Applicable Operating Mode Data Size: 4 digits Digit 0: Auto Motor Identification Range: Value Description Disable automatic motor identification Enable automatic motor identification Default: Encoder Backup Battery (Single- or Multi-turn Absolute...
  • Page 175 Ultra1500 Operator Interface D-11 Digit 1: Overtravel Stop Method Range: Value Description Stop by change of mode to Normal Current. Set stopping current with Overtravel Current limit parameter (Pr-4.05). Dynamic Brake Default: Digit 2: Command Polarity (Direction of Motor Rotation)
  • Page 176 D-12 Ultra1500 Operator Interface Slowest Slower Slow Medium-Slow Medium Medium-Fast Fast Faster Fastest Default: Units: – Pr-0.04 Inertia Ratio Range: 0 to 6000 Default: Units: (Load Inertia / Motor Inertia) * 100 Ultraware Link: Inertia Ratio Pr-0.05 Input Signal Assignment - Group 1...
  • Page 177 Ultra1500 Operator Interface D-13 Input Signal ON Data Size: 4 digits Digits: Digit Description Default Fault Reset Current Limit – Negative Current Limit – Positive Operation Mode Override Applicable Operating Mode Pr-0.07 Input Signal Assignment - Group 3 Range for all digits:...
  • Page 178 D-14 Ultra1500 Operator Interface Pr-0.09 Input Signal Assignment - Group 5 Data Size: 4 digits Digits: Digit Description Default Position Strobe Reserved Reserved Reserved Applicable Operating Mode Pr-0.10 Output Signal Assignment – Group 1 Range for all digits: 0 to 3...

  • Page 179: Group 1 Parameters

    Ultra1500 Operator Interface D-15 Pr-0.12 Output Signal Assignment – Group 3 Range for all digits: 0 to 3 Value Description Output Signal OFF Output signal assigned to 1 to 3 hardware outputs 1 through 3 Data Size: 4 digits Digits:...
  • Page 180 D-16 Ultra1500 Operator Interface Pr-1.02 Main Velocity Regulator Gains: Integrator Time Range: 0 to 60000 Default: Applicable Operating Mode: Follower, Analog Velocity, Preset Velocity Ultraware Link: Main Velocity Regulator Gains: Integrator Time Pr-1.03 Main Position Regulator Gains: Kp Range: 0 to 700...
  • Page 181 Ultra1500 Operator Interface D-17 Units: Applicable Operating Mode: Main Current Regulator Gains: Resonant Frequency Ultraware Link: Suppression Pr-1.08 Position Regulator Kff Gain: Kff Range: 0 to 100 Default: Units: Applicable Operating Mode: Follower Ultraware Link: Position Regulator Kff Gain: Kff Pr-1.09 Main Position Regulator Gains: Kff Low Pass Filter...
  • Page 182 D-18 Ultra1500 Operator Interface Pr-1.11 Main Velocity Regulator Gains: Integrator Hold Threshold Range: 0 to 3000 Default: Then the Units are measured Units: If Pr-1.10 equals: % of rated continuous current rpm for rotary motors mm/sec for linear motors Counts...

  • Page 183: Group 2 Parameters

    Ultra1500 Operator Interface D-19 Group 2 Parameters Group 2 Parameters provide speed control settings. Pr-2.00 Analog Velocity Command Scale Range: 100 to 20000 Default: 5000 Units: rpm/V*10 for rotary motors mm/sec/V*10 for linear motors Applicable Operating Mode: Analog Velocity Pr-2.01 Jog Velocity Command...
  • Page 184 D-20 Ultra1500 Operator Interface Pr-2.05 Preset Velocity 1 Range: -5000 to 5000 Default: Units: rpm for rotary motors mm/sec for linear motors Applicable Operating Mode: Preset Velocity Ultraware Link: Preset Velocity 1 Pr-2.06 Preset Velocity 2 Range: -5000 to 5000...
  • Page 185 Ultra1500 Operator Interface D-21 mm/sec for linear motors Applicable Operating Mode Preset Velocity Ultraware Link: Preset Velocity 5 Pr-2.10 Preset Velocity 6 Range: -5000 to5000 Default: Units: rpm for rotary motors mm/sec for linear motors Applicable Operating Mode Preset Velocity...

  • Page 186: Group 3 Parameters

    D-22 Ultra1500 Operator Interface Group 3 Parameters Group 3 Parameters provide position control settings. Pr-3.00 Follower Configuration Data Size: 4 digits Digit 0: Command Type Range: Value Description CW + CCW, Positive logic CW + CCW, Negative logic Pulse Line + Sign, Positive Logic...

  • Page 187: Group 4 Parameters

    Ultra1500 Operator Interface D-23 Pr-3.01 Gear Ratio Follower Lines Gear Ratio Follower Lines Range: 1 to 65535 Default: Units: Counts/4 = Lines Applicable Operating Mode: Follower Ultraware Link: Gear Ratio Follower Lines Pr-3.02 Gear Ratio, Master Counts Range: 1 to 65535...
  • Page 188 D-24 Ultra1500 Operator Interface Units: % of rated continuous current/V*10 Applicable Operating Mode: Analog Current, Dual Current Ultraware Link: Current Scale Pr-4.01 Current Limits: Positive Internal Range: 0 to 500 Default: Units: % of motor rated continuous current Applicable Operating Mode:...

  • Page 189: Group 5 Parameters

    Ultra1500 Operator Interface D-25 Pr-4.06 Initial Current Bias Ultraware Link: Initial Current Bias Description: Prevents the downturn of vertical load during initial operation Range: -100 to100 Default: Units: % of motor rated continuous current Applicable Operating Mode: Group 5 Parameters Group 5 Parameters provide supplementary drive system and I/O settings Pr-5.00 Position Functions: In Position Size...
  • Page 190 D-26 Ultra1500 Operator Interface mm/sec for linear motors Applicable Operating Mode: Follower, Analog Velocity, Preset Velocity Ultraware Link: Speed Functions: Speed Window Pr-5.03 Speed Functions: Up to Speed If the motor’s speed is higher than this speed and a digital...
  • Page 191 Ultra1500 Operator Interface D-27 Disable Delay is the time from when Drive Disable command Description: is received to when the command is actually executed. Range: 0 to 1000 Units: 10 msec Applicable Operating Mode: Ultraware Link: Stopping Functions: Disable Delay Pr-5.07 Brake Active Delay...
  • Page 192 D-28 Ultra1500 Operator Interface Units: msec Applicable Operating Mode: Ultraware Link: AC Line Loss Fault Delay Pr-5.11 Reserved This parameter is Reserved. Pr-5.12 Analog Output 1: Signal The drive signal assigned to channel 1 from the Channel Description: Setup dialog box in the Oscilloscope window.

  • Page 193: Group 6 Parameters

    Ultra1500 Operator Interface D-29 See Monitor Variable Numbers (except 0x0F) beginning on Units: page D-6. Applicable Operating Mode: Ultraware Link: Analog Output 2: Scale Group 6 Parameters Group 6 parameters provide supplementary gain settings and fault reports. Pr-6.00 Analog Velocity Command Offset Description: The offset to the Analog Velocity Command input.

  • Page 194: Publication 2092-Um001D-En-P — July

    D-30 Ultra1500 Operator Interface Default: Applicable Operating Mode: Follower, Analog Velocity, Preset Velocity Ultraware Link: Main Velocity Regulator Gains: D Pr-6.05 Reserved This parameter is Reserved. Pr-6.06 Fault Detail Setup: Sample Period The time, in 0.2 msec increments, between signal samples.
  • Page 195 Ultra1500 Operator Interface D-31 Pr-6.10 Fault Detail Setup: Channel D Description: Selects the drive signal to assign to Channel D. See Monitor Variable Numbers (except 0x0F) beginning on Range: page D-6. Default: 0x10 Ultraware Link: Fault Detail Setup: Channel D Pr-6.11 Alternate Gain: VReg P Gain...
  • Page 196 D-32 Ultra1500 Operator Interface Pr-6.15 Alternate Gain: VReg Low Pass Bandwidth This command allows you to set an Alternate Velocity Description: Regulator Low Pass Bandwidth for use in tuning. Range: 0 to 10000 Default: 1000 Units: Applicable Operating Mode: Follower, Analog Velocity, Preset Velocity...
  • Page 197 2-11 analog output 1-15 zoning categories analog outputs catalog numbers specifications AC line filters application examples accessories to Ultra1500 drive applications battery 5-16 absolute positioning connector kits ControlLogix 1756-M02AE interface cables 5-22 dynamic brake motor brake cables...
  • Page 198 SoftLogix 1784-PM02AE commissioning TL motor connecting Ultra1500 I/O maintenance 5-22 Ultra1500 power wiring dynamic brake connector 5-16 battery 2-25 control power – L1C, L2C elevation requirements dc bus negative – DC- see dc bus negative – N...
  • Page 199 2-14 +5V serial single-phase 2-14 A, B, and I inputs single-phase amplifiers on 3-phase 2-18 connections power 2-16 encoder phasing installing your Ultra1500 2-15 Hall inputs 5-32 integrator mode 2-16 thermostat input 5-31 integrator time motor feedback interface cables 3-14...
  • Page 200 Ultra1500 digital drives quick start panel manual 1-15 cable categories Ultraware CD installation 1-13 layout instructions PC communications cable...
  • Page 201 5-30 velocity regulator system design for control of electrical typical installation noise reference manual system mounting requirements elevation 1-11 Ultra1500 fuse sizing accessories minimum clearances application examples sizing an enclosure commissioning transformer sizing component overview ventilation...
  • Page 202 5-41 grounded power configuration Ultra1500 commissioning grounding via operator interface 3-14 I/O connections Ultra1500 control mode 3-10 3-11 input power 5-44 analog current 3-phase delta 5-42 analog velocity 3-phase WYE...
  • Page 204 For more information refer to our web site: www.ab.com/motion For Allen-Bradley Technical Support information refer to: www.ab.com/support or Tel: (1) 440.646.5800 Publication 2092-UM001D-EN-P — July 2005 0013-2065-004-01 Supersedes publication 2092-UM001C-EN-P — October 2004 Copyright © 2005 Rockwell Automation. All rights reserved. Printed in USA.

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