Allen-Bradley Ultra1500 2092-DA1 User manual

Simple Motion Control Connected
Components Building Block
Quick Start

Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines
for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell
Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Rockwell Automation, Allen-Bradley, MicroLogix, PanelView, RSLogix 500, Ultra1500, and TechConnect are either trademarks or registered trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage,
or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence
SHOCK HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.
BURN HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.

3Publication CC-QS008B-EN-P - December 2009 3
Where to Start
Follow the path below to complete your Simple Motion Control application.
Chapter 1 Ultra1500 Drive Integration
Chapter 2 System Validation and Application Tips
Connected Components
Building Blocks, publication
CC-QS001
Chapter 3 Control Program Integration

4Publication CC-QS008B-EN-P - December 2009
Where to Start
Notes:

Publication CC-QS008B-EN-P - December 2009 5
Preface
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Ultra1500 Drive Integration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connect to the Ultra1500 Drive via Ultraware . . . . . . . . . . . . . . . . . . 12
Reset the Drive to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Configure the Drive Operation Mode Parameter . . . . . . . . . . . . . . . . 15
Configure the Drive Follower Parameters . . . . . . . . . . . . . . . . . . . . . . 15
Configure the Drive Encoder Output Parameters. . . . . . . . . . . . . . . . 16
Configure the Drive Digital Input Parameters. . . . . . . . . . . . . . . . . . . 17
Configure the Drive Digital Output Parameters . . . . . . . . . . . . . . . . . 17
Save the Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Configure Your Application-specific Drive Parameters . . . . . . . . . . . 18
Chapter 2
SystemValidationandApplication
Tips
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multiple Drive Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Configure Controller-to-Drive Communication . . . . . . . . . . . . . . . . . 20
Configure PVc Terminal-to-Controller Communication . . . . . . . . . . 23
Understanding the Network Overview Screen Functionality . . . . . . . 24
Test the Simple Motion Control Functionality . . . . . . . . . . . . . . . . . . 26
Navigate the Program Mode Screen . . . . . . . . . . . . . . . . . . . . . . . 26
Navigate the Operator Mode Screen . . . . . . . . . . . . . . . . . . . . . . . 28
Test the Operator Mode Functionality . . . . . . . . . . . . . . . . . . . . . 29
Test the Program Mode Functionality . . . . . . . . . . . . . . . . . . . . . 31
Chapter 3
Control Program Integration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Review the Ladder Logic Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Review the Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Review the Program Mode Commands . . . . . . . . . . . . . . . . . . . . . . . . 39
Customize the Axis User Program Ladder Logic . . . . . . . . . . . . . . . . 41
Customize the Machine Control Ladder Logic . . . . . . . . . . . . . . . . . . 42
Alter the Ultra1500 Drive Follower Gear Ratio. . . . . . . . . . . . . . . . . . 44
Table of Contents

6Publication CC-QS008B-EN-P - December 2009
Table of Contents
Notes:

Publication CC-QS008B-EN-P - December 2009 7
Preface
Introduction
This quick start is designed to provide a way to implement a connected
component for simple motion control.
To assist in the design and installation of your system, application files and
other information are provided on the Connected Component Building
Blocks Overview CD, publication CC-QR001. The CD provides bills of
materials (BOM), CAD drawings for panel layout and wiring, control
programs, Human Machine Interface (HMI) screens, and more. With these
tools and the built-in best-practices design, the system designer is free to focus
on the design of their machine control and not on design overhead tasks.
The beginning of each chapter contains the following information. Read these
sections carefully before beginning work in each chapter:
•Before You Begin - This section lists the steps that must be completed
and decisions that must be made before starting that chapter. The
chapters in this quick start do not have to be completed in the order in
which they appear, but this section defines the minimum amount of
preparation required before completing the current chapter.
•What You Need - This section lists the tools that are required to
complete the steps in the current chapter. This includes, but is not
limited to, hardware and software.
•Follow These Steps - This illustrates the steps in the current chapter
and identifies which steps are required to complete the examples.
IMPORTANT The Simple Motion Control Connected Component Building
Block uses predefined configurations in the Ultra1500 drive
(such as gear ratio and output ratio) and the MicroLogix 1400
controller (such as pulse train output, high speed counters, and
input filters) to create a functional connected component
solution. Altering or failing to correctly configure the settings
and parameters explained in Chapter 1…Chapter 3 or failure to
use the pre-configured RSLogix 500 files provided with the
Simple Motion Control Building Block may result in unexpected
behavior and potentially unexpected motion. If you want to
alter the Simple Motion Control Connected Component
configurations or application code, consult the user manuals for
each related product to understand the ramifications of your
desired changes.
IMPORTANT Use this Quick Start in conjunction with the Connected
Components Building Blocks Quick Start, publication CC-QS001.
Refer to Additional Resources on page 9 for a listing of other
related documents.

8Publication CC-QS008B-EN-P - December 2009
Preface
Conventions Used in This
Manual
This manual uses the following conventions.
Convention Meaning Example
Check or uncheck To activate or deactivate a checkbox. Check Disable Keying.
Click Click the left mouse button once while the cursor is positioned
on object or selection. Click Browse.
Double-click Click the left mouse button twice in quick succession while the
cursor is positioned on object or selection. Double-click the application icon.
Expand Click the + to the left of a given item /folder to show its
contents. Expand 1768 Bus under I/O Configuration.
Right-click Click the right mouse button once while the cursor is positioned
on object or selection. Right-click the 1768 Bus icon.
Select Using the mouse to highlight a specific option. Select the New Module folder.
Enter What you type. Enter your choice.
Press Pressing a specific key on the keyboard. Press Enter.
>Use this symbol to indicate the sub-menu name. Choose File>Menu>Options.

Publication CC-QS008B-EN-P - December 2009 9
Preface
Additional Resources
Resource Description
Connected Components Building Blocks Quick Start,
publication CC-QS001 Provides information on how to select products and gain access to panel and wiring
information.
Connected Component Building Blocks Overview
CD, publication CC-QR001 Provides files for the Connected Component Building Blocks.
MicroLogix 1400 Programmable Controllers User
Manual, publication 1766-UM001 Provides information on using the MicroLogix 1400 programmable controller.
MicroLogix 1400 Programmable Controllers
Installation Instructions, publication 1766-IN001 Provides information on using the MicroLogix 1400 programmable controller.
MicroLogix 1400 Programmable Controllers
Instruction Set Reference Manual, publication
1766-RM001
Provides information on using the MicroLogix 1400 programmable controller
RSLogix 500 instruction set.
PanelView Component Operator Terminals User
Manual, publication 2711C-UM001 Provides information on using the PanelView Component HMI terminals.
Ultra1500 Digital Servo Amplifiers User Manual,
publication 2092-UM001 Provides information on installing the Ultra1500 drive, including wiring and
configuration options.
Ultraware Software User Manual, publication
2098-UM001 Provides information on using the Ultraware software including creating, opening
and saving Ultraware files as well as changing drive parameters.
http://www.ab.com Provides access to the Allen-Bradley website.
http://www.rockwellautomation.com/
knowledgebase Provides access to self-service support.
http://www.rockwellautomation.com/components/
connected Provides access to the Connected Components website.

10 Publication CC-QS008B-EN-P - December 2009
Preface
Notes:

Publication CC-QS008B-EN-P - December 2009 11
Chapter 1
Ultra1500 Drive Integration
Introduction
In this chapter, you configure the Ultra1500 drive parameters as necessary for the MicroLogix 1400
controller to communicate with the drive. (Configuration is done by using your personal computer connected
to the drive.)
The Ultra1500 drive communicates with the MicroLogix 1400 controller by using discrete I/O connections,
including Pulse Train Output step/direction signals. Each of your Ultra1500 drives must be configured by
using Ultraware software to send/receive the required discrete I/O to/from the MicroLogix 1400 controller.
This chapter provides step-by-step instructions for configuring each of your Ultra1500 drives, whether you
are using the 1-axis, 2-axis, or 3-axis Simple Motion Control Building Block solution.
In addition, this chapter specifies the minimum number of parameters that need to be changed from the
factory default settings in order to establish communication with the MicroLogix 1400 controller. For your
machine application, there may be other drive parameters that need to be adjusted as well. You will need to
consult the drive documentation for information on all other drive parameters.
Before You Begin
•Review the Connected Components Building Blocks Quick Start, publication CC-QS001.
•Install Ultraware software.
•Apply power to your drive.
What You Need
•Personal computer with serial connection
•Ultra1500 drives
•Ultra1500 serial interface cable
•Ultraware software
•MicroLogix 1400 controller
•Connected Components Building Blocks Overview CD, publication CC-QR001

12 Publication CC-QS008B-EN-P - December 2009
Chapter 1 Ultra1500 Drive Integration
Follow These Steps
Follow these steps to configure each of your Ultra1500 drives.
Connect to the Ultra1500 Drive via Ultraware
Ultra1500 drives are configured by using Ultraware (catalog number 2098-UWCPRG) software. Ultraware
software is a Windows-based application that allows drive configuration to be done offline and saved to disk.
By using the Ultraware software, your personal computer can be connected to the Ultra1500 drives with the
Ultra1500 serial interface cable (catalog number 2090-DAPC-D09xx).
Start
Connect to the Ultra1500
Drive via Ultraware, page
12
Reset the Drive to Factory
Settings, page 14
Configure the Drive
Operation Mode
Parameter, page 15
Configure the Drive
Follower Parameters,
page 15
Configure the Drive
Encoder Output
Parameters, page 16
Configure the Drive
Digital Input Parameters,
page 17
Configure the Drive
Digital Output
Parameters, page 17
Save the Drive
Parameters, page 18
Configure Your
Application-specific Drive
Parameters, page 18

Publication CC-QS008B-EN-P - December 2009 13
Ultra1500 Drive Integration Chapter 1
To configure the Operation mode parameter, perform the following steps.
1. Connect your personal computer’s serial connection to the
Ultra1500 drive’s CN3 connection by using the Ultra1500 serial
interface cable.
Consult the Ultra1500 drive user manual for further information.
2. Go online with the Ultra1500 drive by using the
Ultraware software.
Consult the Ultra1500 drive user manual for
further information.
After your Ultra1500 drive is online and you are able to browse its parameters, continue to the next section.
TIP Your Ultra1500 drive must be listed in the On-Line Drives section, as shown above. If it is not listed in the
On-Line Drives section, then your Ultra1500 drive is still offline.

14 Publication CC-QS008B-EN-P - December 2009
Chapter 1 Ultra1500 Drive Integration
Reset the Drive to Factory Settings
To be sure that the Ultra1500 drive is at a known starting point, you must reset the drive to its factory
settings.
To reset the Ultra1500 drive to factory settings, perform the following steps.
1. Right-click your Ultra1500 drive and
choose Commands>Reset To Factory
Settings.
2. At the confirmation dialog
box, click Yes.
3. Wait until the Ultraware application returns to the Workspace view and the Ultra1500 drive is ready.
If the Ultraware set-up wizard executes after going online with the drive, cancel it and return to the
Workspace view shown above. This will allow you to enter each required Ultra1500 drive parameter for
this building block application one by one as described in the sections below.
If you would like to use the setup wizard to configure most Ultra1500 drive parameters, feel free to do so,
but be sure to return to the Workspace view after you have completed the wizard so that you can
configure each required parameter for this building block application.
After the Ultra1500 drive is done resetting to its factory settings, continue to the next section.

Publication CC-QS008B-EN-P - December 2009 15
Ultra1500 Drive Integration Chapter 1
Configure the Drive Operation Mode Parameter
Ultra1500 drives can be configured to run in a variety of operational modes. This Building Block requires the
Ultra1500 drives to be configured in Follower mode. In Follower mode, a position command is provided by
external step and direction inputs.
To configure the Ultra1500 drive Operation mode parameter, perform the following steps.
1. Double-click your
Ultra1500 drive.
2. Change the
Operation Modes
(Main/Override)
parameter to
Follower/None.
Configure the Drive Follower Parameters
In addition to configuring the Ultra1500 drives for Follower mode, parameters must also be configured for
the correct Command Type, Controller Output Type and Gear Ratio, otherwise the Pulse Train Output step/
direction signal generated by the MicroLogix 1400 controller may not be interpreted correctly.
To configure the Ultra1500 drive Follower mode parameters, perform the following steps.
1. Expand your Ultra1500 Drive and then Mode Configuration.
2. Double-click Follower.
3. Change the Command
Type to Step/Direction.
4. Change the Controller Output Type to Line Drive.
5. Change the Gear Ratio to 1:109.
6. Press Enter.
Be sure to press Enter after typing the parameter values. Typing the information without pressing Enter
will not actually alter the drive parameter, leaving it unchanged.

16 Publication CC-QS008B-EN-P - December 2009
Chapter 1 Ultra1500 Drive Integration
Configure the Drive Encoder Output Parameters
The Ultra1500 drive Encoder Output parameters must be configured appropriately because the MicroLogix
1400 controller uses the Ultra1500 drive Buffered Encoder Motor Outputs to determine the drive relative
position feedback and to derive the drive relative speed feedback.
To configure the Ultra1500 drive Encoder Output parameters, perform the following steps.
1. Double-click Encoders.
2. Change the Encoder
Output Forward
Direction to A Leads B.
3. Change the Output Ratio to 45:4096.
4. Press Enter.
Be sure to press Enter after typing in the parameter values. Typing the information without pressing enter
will not actually alter the drive parameter, leaving it unchanged.
IMPORTANT The Ultra1500 drive Follower Gear Ratio parameter specifies the Master Counts to Follower Counts
relationship. In your case, this means the number of PTO Counts to Encoder Counts. The MicroLogix 1400
controller application code is based on a 1:109 gear ratio and must be set accordingly, otherwise the
Ultra1500 drive may misinterpret the PTO counts output from the MicroLogix 1400 controller, resulting in
unexpected motion.
TIP Not all PTO Count to Encoder Count relationships can be represented in Ultraware, due to the limitation of
the Gear Ratio parameter, and thus some very small error can be expected with each PTO based move. If
your application requires a higher degree of precision, consult Chapter 3 for further information on how to
choose a more granular Gear Ratio and how to adapt the MicroLogix 1400 controller code and Ultraware
configuration to use it.
IMPORTANT The Ultra1500 drive Follower Encoder Output parameters specify the Output Counts to Motor Counts
relationship. In your case, this means the number of Buffered Encoder Motor Output counts to Encoder
Counts. The MicroLogix 1400 controller application code is based on a 45:4096 output ratio and must be set
accordingly, otherwise the MicroLogix 1400 controller may misinterpret the drive relative position feedback
and drive relative speed feedback.

Publication CC-QS008B-EN-P - December 2009 17
Ultra1500 Drive Integration Chapter 1
Configure the Drive Digital Input Parameters
The Ultra1500 drive Digital Input parameters must be configured appropriately because the MicroLogix 1400
controller uses them to enable the Ultra1500 drive and clear its drive faults.
To configure the Ultra1500 drive Digital Input parameters, perform the following steps.
1. Double-click Digital Inputs.
2. Change the
Input 1 value
to Drive
Enable.
3. Change the
Input 2 value
to Fault
Reset.
Configure the Drive Digital Output Parameters
The Ultra1500 drive Digital Output parameters must be configured appropriately because the MicroLogix
1400 controller uses them to determine if the Ultra1500 drive is ready.
To configure the Ultra1500 drive Digital Output parameters, perform the following steps.
1. Double-click
Digital
Outputs.
2. Change the
Output 1
value to
Ready.
IMPORTANT The Ultra1500 drive Follower Digital Input parameters specify which Ultra1500 drive functionality is
mapped to which digital input. The MicroLogix 1400 controller application code uses digital input 1 to
enable the Ultra1500 drive and digital input 2 to clear the Ultra1500 drive’s faults. If either digital input is
configured incorrectly, you will not be able to employ this functionality.

18 Publication CC-QS008B-EN-P - December 2009
Chapter 1 Ultra1500 Drive Integration
Save the Drive Parameters
The Ultra1500 drive parameters that you have just adjusted must now be saved to the Ultra1500 drive.
To save the Ultra1500 drive parameter configuration, click Save Parameters, shown below, located on the
right side of the screen.
Configure Your Application-specific Drive Parameters
The remaining Ultra1500 drive parameters may or may not need further configuring based on your particular
application requirements. Consult the Ultra1500 drive and Ultraware software documentation for further
information regarding other drive parameters, such as tuning parameters, that you may have to configure for
your application.
Additional Resources
Refer to page 9 for a listing of product and information resources.
IMPORTANT The Ultra1500 drive Follower Digital Output parameters specify which Ultra1500 drive functionality is
mapped to which digital output. The MicroLogix 1400 controller application code uses digital output 1 to
determine if the Ultra1500 drive is ready. If this digital output is configured incorrectly, the MicroLogix 1400
controller will always consider the Ultra1500 drive to be not ready and will not allow enable, move, jog,
and user program functions to be executed on the Ultra1500 drive.
IMPORTANT If the Ultra1500 drive parameters are not saved to the drive, the parameter adjustments you just made will
be lost upon power cycling the drive.
IMPORTANT Repeat the steps in this chapter for each Ultra1500 drive in your application that will use the Simple
Motion Control Building Block.

19Publication CC-QS008B-EN-P - December 2009 19
Chapter 2
System Validation and Application Tips
Introduction
In this chapter, you validate that communication is occurring as intended between the MicroLogix 1400
controller and the Ultra1500 drives, as well as between the MicroLogix 1400 controller and the PanelView
terminal.
The operation of the sample screens for Simple Motion Control Program mode and Operator mode is
described as well.
Before You Begin
•Verify that you have completed all of the steps in Chapter 1 of this document.
•Verify that all the devices are connected per the Simple Motion Control CAD wiring diagram.
•Verify that the MicroLogix 1400 controller, Ultra1500 drive, and PanelView Component terminal
have power applied to them.
•Review the Connected Components Building Blocks Quick Start, publication CC-QS001, verifying
that you have completed all of the steps in Chapter 3 of that quick start.
What You Need
•Personal computer with Internet Explorer or Firefox web browser.
•PanelView Component terminal.
•Ultra1500 drives.
•MicroLogix 1400 controller.
•Previously loaded software.
•Standalone Ethernet switch so that you can connect your personal computer to both the MicroLogix
1400 controller and PanelView terminal over an isolated Ethernet network.
•Connected Component Building Blocks Overview CD, publication CC-QR001.

20 Publication CC-QS008B-EN-P - December 2009
Chapter 2 System Validation and Application Tips
Follow These Steps
Follow these steps to verify that communication is occurring between your devices.
Multiple Drive Considerations
The Simple Motion Control Building Block supports 1-axis, 2-axis, and 3-axis configurations. When
completing Chapter 3 of the Connected Components Building Blocks Quick Start, publication CC-QS001,
be sure to use the correct RSLogix Control and PanelView Component HMI Programs for your particular
application. Additionally, Chapter 1 of this document should be completed for each of your Ultra1500 drives.
Configure Controller-to-Drive Communication
Once you have the correct RSLogix control program downloaded to the MicroLogix 1400 controller, you are
ready to validate the controller-to-drive communication. Perform the following steps to complete this
validation for each Ultra1500 drive.
IMPORTANT The RSLogix Control and PanelView Component HMI Programs must be the same version (1-axis, 2-axis, or
3-axis) for the Simple Motion Control Building Block to function correctly.
Start
Configure Controller-to-Drive
Communication, page 20
Configure PVc Terminal-to-
Controller Communication,
page 23
Test the Simple Motion Control
Functionality, page 26