Rockwell Automation Allen-Bradley Ultra5000 User manual

Ultra5000 Intelligent
Positioning Drives
Catalog Numbers
(2098-IPD-005, -010, and -020)
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.
Ultraware is a trademark of Rockwell Automation.
UL and cUL are registered trademarks of Underwriters Laboratories.
Windows is a trademark of Microsoft Corporation.
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-IN001B-EN-P — July 2000
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-2
Conventions Used in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Product Receiving and Storage Responsibility. . . . . . . . . . . . . . . . . . . . . . . P-3
Allen-Bradley Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Technical Product Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Chapter 1
Installing Your Ultra5000 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Complying with European Union Directives. . . . . . . . . . . . . . . . . . . . . . . . . 1-1
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Before Mounting Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Storing Your Ultra5000 Before Installation . . . . . . . . . . . . . . . . . . . . . . 1-2
Unpacking Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Ventilation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Transformer Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Bonding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Mounting Your Ultra5000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Chapter 2
Connecting Your Ultra5000 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Understanding Ultra5000 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Ultra5000 Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Motor Encoder Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Serial Port Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Understanding Ultra5000 I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Understanding Encoder Feedback Specifications . . . . . . . . . . . . . . . . . . . . . 2-9
Encoder Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Auxiliary Encoder Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Understanding Serial Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Understanding Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Routing High and Low Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Grounding Your Ultra5000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Grounding Your System to the Subpanel . . . . . . . . . . . . . . . . . . . . . . . 2-14
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
EMC Motor Ground Termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Publication 2098-IN001B-EN-P — July 2000
ii Table of Contents
Wiring Your Ultra5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Connecting Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Wiring I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Wiring Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Chapter 3
Commissioning Your Ultra5000 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Understanding Communication Switch Settings . . . . . . . . . . . . . . . . . . . . . . 3-2
Applying Power To Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Configuring Your Ultra5000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Chapter 4
Maintaining Your Ultra5000 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintaining the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Appendix A
Specifications and Dimensions Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Ultra5000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Physical and Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Power Dissipation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
User Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Motor Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Auxiliary Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Appendix B
Options and Accessories Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ultra5000 Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ultra5000 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
External Shunt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Mating Connector Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Break Out Board, Cables, and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Motor Feedback Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Publication 2098-IN001B-EN-P — July 2000
Table of Contents iii
Appendix C
Application Information Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Mechanical Resonance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Using an Emergency Stop Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Grounding for Ultra5000 CE Requirements . . . . . . . . . . . . . . . . . . . . . . . . C-4
Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Persistent EMI Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Publication 2098-IN001B-EN-P — July 2000
iv Table of Contents

1Publication 2098-IN001B-EN-P — July 2000
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
•The 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, or 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-IN001B-EN-P — July 2000
P-2 Preface
Contents of this Manual
Refer to the following listing for the descriptive contents of this installation
manual.
Related Documentation
The following documents contain additional information concerning related
Allen-Bradley products. To obtain a copy, contact your local Allen-Bradley
office or distributor.
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
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 Connecting Your Ultra5000 Provides connection and wiring information
for the Ultra5000.
3 Commissioning Your
Ultra5000
Outline steps when applying power to
equipment for the first time.
4 Maintaining Your Ultra5000 Diagnostic aids that help isolate problems
to a system module.
Appendix A Specifications and
Dimensions
Provides physical, electrical, environmental,
and functional specifications for the
Ultra5000.
Appendix B Options and Accessories Provides identification numbers and
descriptions of the Ultra5000 and related
products.
Appendix C Application Information Provides information for specific
applications.
For information about Read This Document Product Number
Configure and operate
Ultra5000 drives
Ultraware

User Manual 2098-UM001A-EN-P
Ultra5000 Programming
Instructions
Ultraware

Programming
Manual
2098-PM001A-EN-P
Ultraware Installation
Instructions
Ultraware CD Installation
Instructions
2098-UM002A-EN-P

Publication 2098-IN001B-EN-P — July 2000
Preface P-3
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
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 theMaintaining Your Ultra5000chapter 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.

Publication 2098-IN001B-EN-P — July 2000
P-4 Preface

1Publication 2098-IN001B-EN-P — July 2000
Chapter
1
Installing Your Ultra5000
Chapter Objectives
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.
EMC Directive
This unit is tested to meet Council Directive 89/336 Electromagnetic
Compatibility (EMC) using a technical construction file and the following
standards, in whole or in part:
•EN 5008x-2 EMC - Emission Standard, Part 2 - Industrial Environment
•EN 5008x-2 EMC - Immunity Standard, Part 2 - Industrial Environment
The product described in this manual is intended for use in an industrial
environment.
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, hazard of personal injury and/or
equipment damage exists.

Publication 2098-IN001B-EN-P — July 2000
1-2 Installing Your Ultra5000
To meet CE requirements, the following additions are required:
•You must run single-phase input wiring in a conduit that is grounded to the
enclosure.
•You must install a power line filter (Allen-Bradley catalog number
2090-UXLF-106, 2090-UXLF-110, 2090-UXLF-123 or equivalent based on
system current) between the single-phase input line and the system module
input.
•You must 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.
Refer to Appendix C for interconnect information.
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
•the minimum mounting requirements
Storing 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-IN001B-EN-P — July 2000
Installing Your Ultra5000 1-3
Unpacking Modules
Each Ultra5000 ships with the following:
•One Ultra5000 drive
•One screwdriver
•One instruction manual (publication 2098-IN001B-EN-P)
•Two I/O connector plugs (14 and 28 pin)
Remove all packing material, wedges, and braces from within and around the
components. After unpacking, check the item(s) nameplate catalog number
against the purchase order.
System Mounting Requirements
There are several things that you need to take into account when preparing to
mount the Ultra5000:
•The Ultra5000 must be enclosed in a grounded conductive enclosure
offering protection as defined in standard EN 60529 (IEC 529) to IP55
such that they are not accessible to an operator or unskilled person. A
NEMA 4X enclosure exceeds these requirements providing protection to
IP66.
•The ambient temperature of the location in which you will install the
Ultra5000 must not exceed 55° C (131° F).
•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.
•You need to maintain minimum clearances (refer to Figure 1.1) 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-IN001B-EN-P — July 2000
1-4 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
Use the following approximate equations as an aid in sizing an enclosure when
no active method of heat dissipation is available.
50.8 mm (2.00 in.) Clearance
for Airflow and Installation
Allow 12.7 mm (0.5 in.)
side clearance
50.8 mm (2.00 in.) Clearance
for Airflow and Installation
Allow 12.7 mm (0.5 in.)
side clearance
Minimum Cabinet Depth = 243.8 mm (9.6 in.)
Minimum Front Clearance = 76.2 mm (3.0 in.)
Motor cable entry area for ground clamp
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.
Metric Standard English
TC= 79.05 (Q/A) + 1.98 TF= 4.08 (Q/A) + 1.1
Where T is temperature difference between
inside air and outside ambient (°C), Q is
heat generated in enclosure (Watts), and A
is enclosure surface area (m2). The exterior
surface of all six sides of an enclosure is
calculated as
Where T is temperature difference between
inside air and outside ambient (°F), Q is
heat generated in enclosure (Watts), and A
is enclosure surface area (ft²). The exterior
surface of all six sides of an enclosure is
calculated as
A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height)
are in meters.
Where d (depth), w (width), and h (height)
are in inches.

Publication 2098-IN001B-EN-P — July 2000
Installing Your Ultra5000 1-5
Transformer Sizing
The Ultra5000 does not require isolation transformers. A transformer may be
required, however, to match the voltage requirements of the controller to the
available service. To size a transformer, the power output (KVA) of each axis
must be known. This can be derived by calculating the horsepower for each
axis and converting that horsepower into units of watts. If you are supplying
power to more than one motor and an Ultra5000, simply add the KW ratings
together from each calculation to get a system KW total.
Definitions:
KW = power or real power
KVA = apparent power
Transformer KVA rating = (Sum of average output power of each axis) x 2.0.
Example: sizing a transformer to the voltage requirements of an
2098-IPD-020 and MPL-A320P motor:
The speed/torque curve information is based upon an Ultra5000 input voltage
of 230 VAC. For a 115 VAC input voltage, the maximum speed can be reduced
up to one half.
IMPORTANT If you are using the Allen-Bradley system sizing program,
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,
another approach is to look at the speed/torque curve for
your Ultra5000/motor combination and use the values for
the worst case continuous speed and torque.
IMPORTANT Calculations are multiplied by a factor to compensate for
the power and loss elements within a power system. A
factor of 2.0 is used with a single phase system and a factor
of 1.5 is used with a three phase system. This factor should
minimize the effects of the secondary line voltage sagging
in the transformer during peak current periods.
Intro
Intro
Intro
Intro
Intro
Intro
Intro
Intro
Intro
Intro
Intro
KVA Speed RPM()Torque lb in–()×
63 025,
-------------------------------------------------------------------------------- 746Watts
HP
------------------------
×KVA
1000Watts
---------------------------
×2.0×=
KVA 5000RPM()
,26 lb in–()×
42 250,
----------------------------------------------------------
=
Transformer Size 3.1KVA=

Publication 2098-IN001B-EN-P — July 2000
1-6 Installing Your Ultra5000
Bonding Your System
Bonding is the practice of connecting metal chassis, assemblies, frames, shields
and enclosures to reduce the effects of electromagnetic interference (EMI).
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.
Improper bonding blocks that direct exit path and allows high-frequency
energy to travel elsewhere in the cabinet. Excessive high-frequency energy can
effect the operation of other microprocessor controlled equipment. The
illustrations that follow (refer to Figure 1.2) show details of recommended
bonding practices for painted panels, enclosures, and mounting brackets.
Figure 1.2
Recommended Bonding Practices
Back wall of
enclosure
Welded
stud
Use a wire brush to remove
paint from threads to
maximize ground connection.
Use plated panels or scrape paint on
front of panel
Stud-mounting the subpanel
to the enclosure back wall
Nut
Subpanel
Star washer
Subpanel
Welded stud
Scrape paint
Flat washer
Mounting bracket or
ground bus
Flat washer
Nut
Star washer
If the mounting bracket is coated with
a non-conductive material (anodized,
painted, etc.), scrape the material
around the mounting hole.
Stud-mounting a ground bus
or chassis to the subpanel
Subpanel
Tapped hole
Bolt
Scrape paint on both sides
of panel and use star washers.
Flat washer
Bolt-mounting a ground bus or chassis to the back-panel
Ground bus or
mounting bracket
Flat washer
Star washer
Nut
Nut
If the mounting bracket is coated
with a non-conductive material
(anodized, painted, etc.), scrape
the material around each
mounting hole.
Star washer
Star washer

Publication 2098-IN001B-EN-P — July 2000
Installing Your Ultra5000 1-7
Bonding Multiple Subpanels
Bonding multiple subpanels creates a common low impedance exit path for
the high frequency energy inside the cabinet. Subpanels that are not bonded
together may not share a common low impedance path. This difference in
impedance may affect networks and other devices that span multiple panels.
Refer to the figure below for recommended bonding practices.
Figure 1.3
Multiple Subpanels and Cabinet
Recommended:
Bond the top and bottom of each subpanel
to the cabinet using 25.4 mm (1.0 in.) by 6.35 mm (.25 in.) (minimum) wire braid
Scrape the paint around each fastener to maximize
Bonded cabinet
ground bus
to subpanel

Publication 2098-IN001B-EN-P — July 2000
1-8 Installing Your Ultra5000
Mounting Your Ultra5000
Drive
The procedures in this section assume you have prepared your panel and
understand how to bond your system.For installation instructions regarding
other equipment and accessories, refer to the instructions that came with each
of the accessories for their specific requirements.
To mount your Ultra5000 drive:
1. Layout the positions for the Ultra5000 and accessories in the enclosure.
Mounting hole dimensions for the Ultra5000 are shown in Appendix A.
2. Attach the Ultra5000 to the cabinet, first using the upper mounting slots
of the drive and then the lower. The recommended mounting hardware is
M5 metric (1/4-20) or #10 MS bolts. Observe bonding techniques as
described in Bonding Your System.
3. Tighten all mounting fasteners.

1Publication 2098-IN001B-EN-P — July 2000
Chapter
2
Connecting Your Ultra5000
Chapter Objectives
This chapter describes how to make wiring and cable connections for your
Ultra5000. This chapter includes:
•Understanding Ultra5000 connectors
•Understanding Ultra5000 I/O specifications
•Understanding encoder feedback specifications
•Understanding serial interfaces
•Understanding basic wiring requirements
•Grounding your Ultra5000
•Wiring your Ultra5000
Understanding Ultra5000
Connectors
This section provides an overview of the Ultra5000 front panel connectors.
Ultra5000 Block Diagram
The Ultra5000 uses a two-stage circuit card solution with the capability of
adding two additional option cards. The first stage is the processor circuit
board and the second stage handles I/O connections including a power
module interface, as shown in Figure 2.1.
Figure 2.1
Block Diagram of Ultra5000 Controller Functions
Interface
Interface
Interface
Interface
Interface
Interface
Interface
Interface
Digital Inputs
Digital Outputs
Auxiliary Encoder Inputs
Motor Encoder Outputs
Motor Encoder
Analog Inputs
Analog Outputs
Field
Programmable
Gate Array
Quad
ADC
Dual
DAC
Quad
ADC
POWER MODULE
Bus Voltage
Input Current
Inputs PWM Outputs
I/O CARD
512Kx8
Low Speed
Flash
EEPROM
256Kx32
System
Flash
128Kx32
High Speed
SRAM
64Kx8
Non-Volatile
SRAM
Interface
Serial
Interface
7-Segment
LED
Display
Rotary DIP
Switches
TMS320C32
DSP
Serial Port 1
Serial Port 2
Option Card Port 1
Option Card Port 2
PROCESSOR CARD

Publication 2098-IN001B-EN-P — July 2000
2-2 Connecting Your Ultra5000
Front Panel Connections
The following table provides a brief description of the Ultra5000 front panel
connectors and describes the connector type.
All connections on the Ultra5000 that require shielding use commonly
available D-Shell type connectors. To locate the Ultra5000 front panel
connectors, switches, and status LED, refer to the figure below.
Figure 2.2
Ultra5000 Front Panel Connections
Designator Description Connector
CN1A User Input/Output 28-Pin, 3.5mm, double-row, plugable spring clamp
CN1B User Input/Output 14-Pin, 3.5mm, double-row, plugable spring clamp
CN2 Motor Encoder 15-Pin, high-density D-shell
CN3A Main
Serial Port 1
9-Pin, standard D-shell
CN3B Auxiliary
Serial Port 2
9-Pin, standard D-shell
TB DC bus, Motor and
AC power
9 position screw style barrier terminal strip
CN1A 28-pin
Digital I/O Connector
CN1B 14-pin
Auxiliary Encoder and
Analog I/O Connector
DC Bus Connections for
Active Shunt Resistor Kit
AC Input Power
Connections
Motor Power
Connections
Seven Segment
Status LED
Communication
Address Selector
Switches
CN3A 9-pin
Main Serial Port
Connector
CN3B 9-pin
Auxiliary Serial Port
Connector
CN2 15-pin
Motor Encoder
Connector
Power Indicator