Rockwell Automation Allen-Bradley Ultra5000 User manual

Ultra5000 Intelligent
Positioning Drives
(Catalog Numbers
2098-IPD-005, -005-DN
2098-IPD-010, -010-DN
2098-IPD-020, -020-DN
2098-IPD-030, -030-DN, -HV030, -HV030-DN
2098-IPD-HV050, -HV050-DN
2098-IPD-075, -075-DN,
2098-IPD-HV100, -HV100-DN
2098-IPD-150, -150-DN, -HV150, -HV150-DN
2098-IPD-HV220, -HV220-DN
Installation Manual

Important User Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary
steps have been taken to assure that each application and use
meets all performance and safety requirements, including any
applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples
shown in this guide are intended solely for purposes of example.
Since there are many variables and requirements associated with
any particular installation, Allen-Bradley®does not assume
responsibility or liability (to include intellectual property liability)
for actual use based upon the examples shown in this
publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into
consideration when applying products such as those described
in this publication.
Reproduction of the contents of this copyrighted publication, in
whole or part, without written permission of Rockwell
Automation, is prohibited.
Throughout this manual we use notes to make you aware of
safety considerations:
Attention statements help you to:
•identify a hazard
•avoid a hazard
•recognize the consequences
Allen-Bradley is a registered trademark of Rockwell Automation.
ControlLogix, RSLogix 5000, Ultra5000, and Ultraware are trademarks of Rockwell Automation.
CSA is a registered trademark of Canadian Standards Association.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
UL and C-UL are registered trademarks of Underwriters Laboratories, Inc.
ATTENTION
!
Identifies information about practices or
circumstances that can 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.

iPublication 2098-IN001E-EN-P — April 2002
Table of Contents
Preface Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . P-4
Product Receiving and Storage Responsibility . . . . . . . . . . . P-4
Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-5
Comments Regarding this Manual . . . . . . . . . . . . . . . . . P-5
Chapter 1
Installing Your Ultra5000 Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Complying with European Union Directives . . . . . . . . . 1-1
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Low Voltage Directive. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Before Mounting Your System . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Store Your Ultra5000 Before Installation . . . . . . 1-3
How to Unpack the System. . . . . . . . . . . . . . . . . . . . . . 1-4
Minimum Mounting Requirements. . . . . . . . . . . . . . . . . 1-5
Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . 1-6
Sizing an Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Transformer Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Calculating Transformer Size Based on Speed/Torque
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fuse Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Bonding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . 1-11
Mounting Your Ultra5000 Drive . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2
Ultra5000 Connector
Information
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Understanding Ultra5000 Controller Functions. . . . . . . . . . . 2-2
Ultra5000 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 2-2
Understanding Ultra5000 Connectors . . . . . . . . . . . . . . . . . 2-3
230V Ultra5000 Front Panel Connections . . . . . . . . . . . . 2-4
500W, 1 kW, and 2 kW Ultra5000
(2098-IPD-005, -010, and -020). . . . . . . . . . . . . . . . . 2-4
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . . 2-6
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . . 2-7
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3 kW Ultra5000
(2098-IPD-030) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Publication 2098-IN001E-EN-P — April 2002
ii Table of Contents
7.5 kW, and 15 kW Ultra5000
(2098-IPD-075, and -150) . . . . . . . . . . . . . . . . . . . . 2-10
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . 2-11
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . 2-11
Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
230V Ultra5000 with DeviceNet Front Panel Connections . . .
2-13
500W, 1 kW, and 2 kW Ultra5000 with DeviceNet
(2098-IPD-005-DN, -010-DN, and -020-DN). . . . . . . 2-13
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . 2-14
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . 2-14
DeviceNet Connector. . . . . . . . . . . . . . . . . . . . . . . 2-14
3 kW, 7.5 kW, and 15 kW Ultra5000
(2098-IPD-005-DN, -010-DN, and -020-DN). . . . . . . 2-15
460V Ultra5000 Front Panel Connections . . . . . . . . . . . 2-16
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Motor Encoder Connector . . . . . . . . . . . . . . . . . . . 2-17
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . 2-17
Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Understanding Ultra5000 I/O Specifications. . . . . . . . . . . . 2-19
Digital I/O Power Supply . . . . . . . . . . . . . . . . . . . . . . 2-19
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Understanding Motor Encoder Feedback Specifications . . . 2-25
AM, BM, and IM Inputs . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Hall Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Thermostat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
+ Limit and - Limit Inputs . . . . . . . . . . . . . . . . . . . . . . 2-28
Encoder Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Motor Encoder Connection Diagram . . . . . . . . . . . . . . 2-31
Unbuffered Motor Encoder Outputs . . . . . . . . . . . . . . 2-31
Buffered Motor Encoder Outputs . . . . . . . . . . . . . . . . 2-31
Understanding Auxiliary Encoder Feedback Specifications . 2-32
Auxiliary Encoder Interface . . . . . . . . . . . . . . . . . . . . . 2-32
Understanding the Serial Interface. . . . . . . . . . . . . . . . . . . 2-34
Default Serial Interface Settings . . . . . . . . . . . . . . . . . . 2-34

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Table of Contents iii
Chapter 3
Connecting Your Ultra5000 Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Powering the Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Accessing the Internal Digital I/O Power Supply . . . . . . 3-2
Understanding Basic Wiring Requirements . . . . . . . . . . . . . 3-4
Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . 3-4
Routing High and Low Voltage Cables. . . . . . . . . . . . . . 3-5
Grounding Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Grounding Your System to the Subpanel . . . . . . . . . . . . 3-6
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . 3-7
Motor Power Cable Shield Termination . . . . . . . . . . . . . 3-7
Wiring Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting Interface Cables . . . . . . . . . . . . . . . . . . . . . 3-9
Wiring I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting to a DeviceNet Network . . . . . . . . . . . . . . 3-10
Connecting Your DeviceNet Cable . . . . . . . . . . . . . . . 3-11
Assigning Your Ultra5000 DeviceNet Address . . . . . . . 3-12
Wiring Power Connections . . . . . . . . . . . . . . . . . . . . 3-14
Chapter 4
Commissioning Your Ultra5000 Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Understanding Communication Switch Settings . . . . . . . . . . 4-2
Applying Power To Your System . . . . . . . . . . . . . . . . . . . . 4-3
Configuring Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Chapter 5
Maintaining Your Ultra5000 Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintaining the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning the Drive . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Inspecting the Cables . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Troubleshooting for DeviceNet Drives . . . . . . . . . . . . . . . . 5-6
DeviceNet Module Status LED. . . . . . . . . . . . . . . . . . . . 5-6
DeviceNet Network Status LED . . . . . . . . . . . . . . . . . . . 5-7
Node Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Device Failure - LED Status Check. . . . . . . . . . . . . . . . . 5-8
Scanner Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Power Supply Problems . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cable Installation and Design Problems. . . . . . . . . . . . 5-10
Adjusting the Physical Network Configuration . . . . . . . 5-10

Publication 2098-IN001E-EN-P — April 2002
iv Table of Contents
Appendix A
Specifications and
Dimensions
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Ultra5000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General Power Specifications . . . . . . . . . . . . . . . . . . . . A-1
2098-IPD-005-xx, -010-xx, and -020-xx . . . . . . . . . . . A-1
2098-IPD-030-xx, -075-xx, and -150-xx . . . . . . . . . . . A-2
2098-IPD-HV030-xx, -HV050-xx, -HV100-xx, -HV150-xx,
and -HV220-xx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Physical and Environmental. . . . . . . . . . . . . . . . . . . . . . A-4
Power Dissipation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
User Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Motor Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Auxiliary Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Appendix B
Interconnect Diagrams Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ultra5000 and Motor Cable Diagrams . . . . . . . . . . . . . . . . . B-1
Ultra5000 Drive and Motor Cable Combinations . . . . . . . B-1
Ultra5000 to Motor Interconnect Diagrams . . . . . . . . . . . B-3
Ultra5000 Power Wiring Diagrams . . . . . . . . . . . . . . . . . . B-15
Using an Emergency Stop Contactor . . . . . . . . . . . . . . . . . B-20
Grounding for Ultra5000 CE Requirements . . . . . . . . . . . . B-22
Ultra5000 Shunt Module Information. . . . . . . . . . . . . . . . . B-23
300 Watt Active Shunt Module. . . . . . . . . . . . . . . . . . . B-23
200 Watt Passive Shunt Module . . . . . . . . . . . . . . . . . . B-23
900 Watt Passive Shunt Module . . . . . . . . . . . . . . . . . . B-24
2090 Passive Shunt Module . . . . . . . . . . . . . . . . . . . . . B-24

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Table of Contents v
Appendix C
Catalog Numbers and
Accessories
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Ultra5000 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Ultraware Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
External Shunt Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
300 Watt Active Shunt Ferrites. . . . . . . . . . . . . . . . . . . . C-5
2090 Series Passive Shunts . . . . . . . . . . . . . . . . . . . . . . C-5
Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Motor Feedback Cables . . . . . . . . . . . . . . . . . . . . . . . . C-7
MP-Series Motor Brake Cable . . . . . . . . . . . . . . . . . . . . C-8
Ultra5000 Interface Cables. . . . . . . . . . . . . . . . . . . . . . . C-8
Break Out Boards, Cables, and Kits . . . . . . . . . . . . . . . . . . C-8
Mating Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Appendix D
Wiring Three Phase Power to a
Single Phase Ultra5000
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Applicable Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Mandatory Neutral Connection of Isolation Transformer . . . D-2
Adding a Safety Ground to the Isolation Transformer. . . D-3
Three Phase Line Filtering Requirements for EMC . . . . . . . . D-3
Voiding of CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Publication 2098-IN001E-EN-P — April 2002
vi Table of Contents

1Publication 2098-IN001E-EN-P — April 2002
Preface
Introduction
Read this preface to familiarize yourself with the rest of the manual.
This preface contains the following topics:
•Who Should Use this Manual
•Purpose of this Manual
•Contents of this Manual
•Related Documentation
•Conventions Used in this Manual
•Product Receiving and Storage Responsibility
•Allen-Bradley Support
Who Should Use this
Manual
Use this manual for designing, installing, programming, and
troubleshooting the Ultra5000™Intelligent Positioning Drive (IPD). If
you do not have a basic understanding of the Ultra5000, contact your
local Allen-Bradley representative for information on available training
courses before using this product.
Purpose of this Manual
This manual describes the function and installation of the Ultra5000
products and standard Rockwell Automation/Allen-Bradley motors
recommended for use with the Ultra5000. The manual is intended for
engineers or technicians directly involved in the installation,
operation, and field maintenance of the Ultra5000.

Publication 2098-IN001E-EN-P — April 2002
P-2 Preface
Contents of this Manual
Refer to the following listing for the descriptive contents of this
installation manual.
Chapter Title Contents
Preface Describes the purpose, background, and
scope of this manual. Also specifies the
audience for whom this manual is intended.
1 Installing Your Ultra5000 Provides mounting information for the
Ultra5000.
2 Ultra5000 Connector
Information Provides connection and wiring information for the Ultra5000.
3 Connecting Your Ultra5000 Provides steps to follow when applying
power to the Ultra5000 for the first time.
4 Commissioning Your
Ultra5000 Powering-up and configuring the Ultra5000 drive.
5 Maintaining Your Ultra5000 Provides diagnostic aids that help isolate
problems with a drive.
Appendix A Specifications and
Dimensions Provides physical, electrical, environmental, and functional specifications for the
Ultra5000.
Appendix B Interconnect Diagrams Provides interconnect diagrams for the
Ultra5000.
Appendix C Catalog Numbers and
Accessories Provides catalog numbers and descriptions of the Ultra5000 and related products.
Appendix D Wiring Three Phase Power
to a Single Phase Ultra5000 Discusses star (Y) connection of single phase Ultra5000 drives to a three phase
power source.

Publication 2098-IN001E-EN-P — April 2002
Preface P-3
Related Documentation
The following documents contain additional information concerning
related Allen-Bradley products. To obtain a copy, contact your local
Rockwell Automation office or distributor, or access the documents
on-line at
www.theautomationbookstore.com or
www.ab.com/manuals/gmc .
A copy of the DeviceNet Specification, Volumes I and II, Release 2.0
may be ordered from the web site http://www.odva.org of the Open
Device Vendor Association.
For: Read This Document: Catalog Number:
Active shunt installation instructions for:
•2098-IPD-005, -005-DN
•2098-IPD-010, -010-DN
•2098-IPD-020, -020-DN
300 Watt Active Shunt Regulator Installation
Instructions 2090-IN001
Passive shunt installation instructions for:
•2098-IPD-075, -075-DN
•2098-IPD-150, -150-DN
900 Watt Passive Shunt Module Installation
Instructions 2090-IN002
Passive shunt installation instructions for:
•2098-IPD-030, -030-DN 200 Watt Passive Shunt Module Installation Instructions 2090-IN003
Passive shunt installation instructions for:
•2098-IPD-HV030, -HV030-DN
•2098-IPD-HV050, -HV050-DN
•2098-IPD-HV100, -HV100-DN
•2098-IPD-HV150, -HV150-DN
•2098-IPD-HV220, -HV220-DN
2090 Series Passive Shunts Installation
Instructions 2090-IN004
Ultraware™installation instructions Ultraware CD Installation Instructions 2098-IN002
Information on how to add a DeviceNet™
Expansion Kit to a Ultra5000 drive Ultra5000 DeviceNet Expansion Kit Installation Instructions 2098-IN004
Information on programming the Ultra5000 using
the Motion Library Ultra5000 Motion Library C Programming Manual 2098-PM001
Information on communicating with the
Ultra5000 using DeviceNet Ultra5000 DeviceNet Reference Manual 2098-RM002
Information on configuring your Ultra5000 using
Ultraware Ultraware User Manual 2098-UM001
How to minimize and control system-level noise System Design for Control of Electrical Noise GMC-RM001
Information on attaching Ultra5000 drives to a
DeviceNet network DeviceNet Cable System Planning and Installation Manual DNET-UM072

Publication 2098-IN001E-EN-P — April 2002
P-4 Preface
Conventions Used in this
Manual
The following conventions are used throughout this manual.
•Bulleted lists such as this one provide information, not procedural
steps.
•Numbered lists provide sequential steps or hierarchical
information.
•Words that you type or select appear in bold.
•When we refer you to another location, the section or chapter
name appears in italics.
Product Receiving and
Storage Responsibility
You, the customer, are responsible for thoroughly inspecting the
equipment before accepting the shipment from the freight company.
Check the item(s) you receive against your purchase order. If any
items are obviously damaged, it is your responsibility to refuse
delivery until the freight agent has noted the damage on the freight
bill. Should you discover any concealed damage during unpacking,
you are responsible for notifying the freight agent. Leave the shipping
container intact and request that the freight agent make a visual
inspection of the equipment.
Store the product in its shipping container prior to installation. If you
are not going to use the equipment for a period of time, store using
the following guidelines.
•Use a clean, dry location
•Maintain an ambient temperature range of -40 to 70° C
(-40 to 158° F)
•Maintain a relative humidity range of 5% to 95%, non-condensing
•Store it where it cannot be exposed to a corrosive atmosphere
•Store it in a non-construction area

Publication 2098-IN001E-EN-P — April 2002
Preface P-5
Allen-Bradley Support
Allen-Bradley offers support services worldwide, with over 75 Sales/
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:
•Sales and order support
•Product technical training
•Warranty support
•Support service agreements
Technical Product Assistance
If you need to contact Allen-Bradley for technical assistance, please
review the information in the chapter Maintaining Your Ultra5000 first, then
call your local Allen-Bradley representative. For the quickest possible
response, please have the catalog numbers of your products available
when you call.
Comments Regarding this Manual
To offer comments regarding the contents of this manual, go to
www.ab.com/manuals/gmc and download the Motion Control
Problem Report form. Mail or fax your comments to the address/fax
number given on the form.

Publication 2098-IN001E-EN-P — April 2002
P-6 Preface

1Publication 2098-IN001E-EN-P — April 2002
Chapter 1
Installing Your Ultra5000
Chapter Objectives
This chapter provides system installation guidelines and procedures
for mounting your Ultra5000. This chapter covers the following topics:
•Complying with European Union Directives
•Before Mounting Your System
•Bonding Your System
•Mounting Your Ultra5000 Drive
Complying with European Union Directives
If this product is installed within the European Union or EEC regions
and has the CE mark, the following regulations apply.
Note: Declarations of Conformity (DOCs) to EU Directives are
available on-line at www.ab.com/certification for Motion
Control products. The web site is the authoritative source for
verifying compliance and suitability for use of this and other
Rockwell Automation/Allen-Bradley products.
The web site also provides links to other certification agencies
(UL, CSA, etc.).
ATTENTION
!
The following information is a guideline for proper
installation. The National Electrical Code and any
other governing regional or local codes overrule this
information. The Allen-Bradley Company cannot
assume responsibility for the compliance or the
noncompliance with any code, national, local or
otherwise, for the proper installation of this system
or associated equipment. If you ignore codes during
installation, the hazard of personal injury and/or
equipment damage exists.

Publication 2098-IN001E-EN-P — April 2002
1-2 Installing Your Ultra5000
EMC Directive
This unit is tested to meet Council Directive 89/336/EEC
Electromagnetic Compatibility (EMC) using a technical construction
file and the following standards, in whole or in part:
•EN 50081-2 EMC - Emission Standard, Part 2 - Industrial
Environment
•EN 50082-2 EMC - Immunity Standard, Part 2 - Industrial
Environment
•EN 61800-3 - Adjustable Speed Electrical Power Drive Systems,
Part 3 - EMC Product Standard including specific test methods
The product described in this manual is intended for use in an
industrial environment.
To meet CE requirements, the following additions are required:
•Install a power line filter between the AC power source and the
drive input, as close to the drive as possible. (Refer to AC Line
Filters on page C-3.)
•Terminate the motor power cable shield to the chassis clamp
provided.
•To meet CE requirements, the following additions may also be
required:
–Run single-phase input wiring in conduit that is grounded to
the enclosure.
–Terminate the shields of the motor power cables and the
motor feedback cables to the enclosure at the point of entry.
Low Voltage Directive
These units are tested to meet Council Directive 73/23/EEC Low
Voltage Directive. The EN 60204-1 Safety of Machinery-Electrical
Equipment of Machines, Part 1-Specification for General Requirements
standard applies in whole or in part. Additionally, the standard
EN 50178 Electronic Equipment for use in Power Installations applies
in whole or in part.
Refer to Appendix B for interconnect information.

Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-3
Before Mounting Your
System
Before you mount your Ultra5000 system make sure you understand
the following:
•How to Store Your Ultra5000 Before Installation
•How to Unpack the System
•Minimum Mounting Requirements
How to Store Your Ultra5000 Before Installation
The Ultra5000 should remain in the shipping container prior to
installation. If the equipment is not to be used for a period of time,
store it as follows:
•Use a clean, dry location
•Maintain an ambient temperature range of -40 to 70° C
(-40 to 158° F)
•Maintain a relative humidity range of 5% to 95%, non-condensing
•Store it where it cannot be exposed to a corrosive atmosphere
•Store it in a non-construction area

Publication 2098-IN001E-EN-P — April 2002
1-4 Installing Your Ultra5000
How to Unpack the System
Each Ultra5000 ships with the following:
•One Ultra5000 drive
•One installation manual, publication 2098-IN001
•Two I/O connector plugs (28 pin CN1A and 14 pin CN1B)
•One screwdriver
•One clear plastic terminal strip cover
Ultra5000 drives with DeviceNet (2098-IPD-xxx-DN and -HVxxx-DN
only) ship with the following additional items:
•One reference manual, publication 2098-RM002, for Ultra5000
drives with DeviceNet
•One DeviceNet connector plug for Ultra5000 drives with DeviceNet
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.
IMPORTANT
Do not discard the clear plastic terminal strip cover.
Installing the plastic strip on the power terminal strip
provides a physical barrier and protection.

Publication 2098-IN001E-EN-P — April 2002
Installing Your Ultra5000 1-5
Minimum Mounting Requirements
There are several things that you need to take into account when
preparing to mount the Ultra5000:
•The Ultra5000 is classified as IEC controlgear, and must be housed
in an enclosure that meets IEC60529 requirements for electrical
enclosure of controlgear.
•The ambient temperature of the location in which you will install
the Ultra5000 must not exceed 55° C (131° F).
•You must install the enclosure on a flat, rigid, vertical surface that
will not be subjected to shock, vibration, moisture, oil mist, dust, or
corrosive vapors.
•You need to maintain minimum clearances (refer to Figure 1.1)
within the enclosure for proper airflow, easy module access, and
proper cable bend radius.
Refer to Appendix A for mounting dimensions, power dissipation, and
environmental specifications for the Ultra5000.

Publication 2098-IN001E-EN-P — April 2002
1-6 Installing Your Ultra5000
Ventilation Requirements
This section provides information to assist you in sizing your cabinet
and locating your Ultra5000 drive(s) inside the cabinet.
Figure 1.1
Minimum Clearance Requirements
Refer to Power Dissipation on page A-5 for Ultra5000 power
dissipation specifications.
50.8 mm (2.0 in.) clearance
for airflow and installation
50.8 mm (2.0 in.) clearance
for airflow and installation
Allow 12.7 mm (0.5 in.)
side clearance Allow 12.7 mm (0.5 in.) side clearance
Motor cable entry area for ground
clamp
Minimum cabinet depth = 243.8 mm (9.6 in.)
Minimum front clearance = 76.2 mm (3.0 in.)
IMPORTANT
If the cabinet is ventilated, use filtered or
conditioned air to prevent the accumulation of dust
and dirt on electronic components. The air should be
free of oil, corrosives, or electrically conductive
contaminates.