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Converting from

ULTRA 100 and 200


to Ultra3000
Catalog Numbers
1398-DDM-005, 1398-DDM-009,
1398-DDM-010, 1398-DDM-019,
1398-DDM-020, 1398-DDM-030,
1398-DDM-075, 1398-DDM-150
2098-DSD-005, 2098-DSD-010,
2098-DSD-020, 2098-DSD-030,
2098-DSD-075, 2098-DSD-150

Reference Manual

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 www.ab.com/manuals/gi) 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.
WARNING

IMPORTANT

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.

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
recognize the consequence

SHOCK HAZARD

Labels may be located on or inside the equipment (e.g., drive or


motor) to alert people that dangerous voltage may be present.

BURN HAZARD

Labels may be located on or inside the equipment (e.g., drive or


motor) to alert people that surfaces may be at dangerous
temperatures.

Allen-Bradley and Reliance are a registered trademarks of Rockwell Automation, Inc.


ULTRA 100, ULTRA 200, ULTRA Series, Ultra3000, Ultra Master, and Ultraware are trademarks of Rockwell Automation, Inc.

Introduction

Examining the Conversion Process . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Chapter 1
Engineering Review Essentials

Engineering Effort and Product Liability. . . . . . . . . . . . . . . . . . . . . .


Major Product Replacement Issues . . . . . . . . . . . . . . . . . . . . . . . . . .
Minor Product Replacement Issues . . . . . . . . . . . . . . . . . . . . . . . . . .
Potential Hardware Design Changes . . . . . . . . . . . . . . . . . . . . . . . . .

1-1
1-2
1-2
1-3

Chapter 2
Selecting a Replacement Drive

Factors Affecting Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-1


Drive Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Input Wiring and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
AC Input Power Wire Length and Routing . . . . . . . . . . . . . . . . . 2-3
Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Drive Interconnects and Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Motor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Motor Power Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cable Wire References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Motor Power Replacement Cables. . . . . . . . . . . . . . . . . . . . . 2-5
Encoder Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Encoder Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Custom Encoder Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
I/O Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
I/O Availability and Specifications . . . . . . . . . . . . . . . . . . . . 2-7
I/O Power Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
I/O Cable Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
I/O Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Accessories and Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Shunt Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Appendix A
Drive Connectors and Connections Serial Communication Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Encoder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Block (TB1) Connections . . . . . . . . . . . . . . . . . . . . . . . . . .
1398-DDM-005, -009, and -019 to
2098-DSD-005, -010, and -020 . . . . . . . . . . . . . . . . . . . . . . . . . .
1398-DDM-010, -020, and -030 to
2098-DSD-030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1398-DDM-075 and -150 to
2098-DSD-075 and -150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2
A-3
A-6
A-6
A-6
A-7

Publication 2098-RM005B-EN-P 2007

Appendix B
Specifications

I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1


Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Relay Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
General Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
ULTRA 100 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
ULTRA 200 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Ultra3000 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Appendix C
Software Conversion with the
Ultra Conversion Tool

About Software Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Using the ULTRA Conversion Tool . . . . . . . . . . . . . . . . . . . . . . . . .
How to Convert a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Host Command Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Command Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultra3000 Host Command Description . . . . . . . . . . . . . . . . . . .
Ultra3000 Drive Response Description . . . . . . . . . . . . . . . .
Ultra3000 Exception Responses . . . . . . . . . . . . . . . . . . . . . .
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-1
C-2
C-2
C-3
C-4
C-4
C-5
C-6
C-7
C-7

Appendix D
Related Documentation

Publication 2098-RM005B-EN-P 2007

Supplementary Information and Publications. . . . . . . . . . . . . . . . . . D-1

Introduction

This document is intended for engineers involved in redesigning hardware and


software for motion control systems using the Rockwell Automation products
listed below. Topics provide you with the information necessary to determine
what hardware design changes may be necessary. The objective of this manual
is to inform you about various aspects affecting a redesign, and to aide you in
doing that in a knowledgeable way.
If you do not have a basic understanding of the these drives and associated
configuration software, contact your local Allen-Bradley representative for
information or training on these products.
ULTRA 100 or ULTRA 200 1

Ultra3000 1

1398-DDM-005

2098-DSD-005

1398-DDM-009

2098-DSD-010

1398-DDM-019

2098-DSD-020

1398-DDM-010

2098-DSD-030

1398-DDM-020

2098-DSD-075

1398-DDM-030

2098-DSD-150

1398-DDM-075
1398-DDM-150
1 Including drives with the following feature sets: standard, indexing (X), DeviceNet (-DN), and indexing with
DeviceNet (X-DN).

Examining the Conversion


Process

Changing a motion system from a design based on the Allen-Bradley ULTRA


100 or ULTRA 200 drives to one utilizing the Ultra3000 drive products
requires a comprehensive review of the motion control system. There are a
number of drive replacement combinations, and an equal number of ways that
the drives may be installed and software applied. As a result, this guide is not
an all inclusive document. It does not describe all the redesign steps that may
be required, nor does it contain the detailed product information necessary to
finalize the redesign. The generalities of the replacement process are covered,
and the decision-making steps likely to be encountered in a typical replacement
scenario are described.
This document will help you evaluate:
the replacement of ULTRA 100 or ULTRA 200 digital drive
modules (i.e., 1398-DDMs) with Ultra3000 digital servo drives (i.e.,
2098-DSDs), and
migrate software application settings from UltraMaster to
Ultraware.

Publication 2098-RM005B-EN-P - February 2007

Introduction

Publication 2098-RM005B-EN-P - February 2007

Chapter

Engineering Review Essentials

Replacing an ULTRA 100 or ULTRA 200 drive with an Ultra3000 drive may
require product design changes.
To properly formulate the design changes:
Review the current products hardware and software design as it exists
with the ULTRA 100 or ULTRA 200 hardware, and UltraMaster
software.
Review the Ultra3000 hardware and software specifications.
Use this document as a basis for determining hardware design changes.
Convert and validate the application parameter settings.

Engineering Effort and


Product Liability

Only after thoroughly reviewing this document should you begin to evaluate
the design changes required to successfully switch to a product based on the
Ultra3000.

WARNING

Because of the variety of uses for the products described in


this publication, those responsible for the application and
use of these products 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. In no event will Rockwell Automation
be responsible or liable for indirect or consequential
damage resulting from the use or application of these
products.

The following sections highlight major and minor differences between the
ULTRA 100/200 and Ultra3000 products. Since there are additional
differences that are typically insignificant but could impact your application,
read this entire document before proceeding to qualify the Ultra3000 in your
machinery.

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1-2

Engineering Review Essentials

Major Product
Replacement Issues

In general, the Ultra3000 family of drives is very similar to the ULTRA


100/200 Series drives. Major replacement issues include:
Motor encoder and controller connectors. The Ultra3000 uses D-shell
connectors with pin/socket connections, whereas the ULTRA 100/200
uses mini-D connectors with leaf connections.
The 1398-DDM-010 and 1398-DDM-020 models of the ULTRA 200
can be replaced by the micro-sized Ultra3000 models 2098-DSD-010
and 2098-DSD-020. The micro-sized power structures are different, as
they not have an internal 24V power supply, built-in shunt, or auxiliary
AC power. A more straight forward upgrade is the 2098-DSD-030 drive,
which does not have the deficiencies, and provides additional power
capacity at a nominal expense.
The Ultra3000 drives have only one relay output, whereas the
ULTRA100/200 drives have two relay outputs. If dual relay functionality
is needed, an external relay will need to be added. Otherwise a digital
output can be substituted.
The Ultra3000 drives do not have a 24V dc output for powering external
devices, which the ULTRA 200 drives provided. The user must supply
an external 12-24V dc power source for I/O connections when using
Ultra3000 drives.

Minor Product
Replacement Issues

An Ultra3000 is an enhanced version of the ULTRA 100/200, and most of the


features are identical. The following list summarizes issues that may influence a
replacement decision.
The Ultra3000 has a slightly different serial protocol for host
communications. Applications that communicate with the drive via its
serial port will need modification.
The Ultra3000 has only one (1) analog output, whereas the ULTRA 200
has two (2) and the ULTRA 100 has one (1).
The Ultra3000 does not support the use of a touchpad for parameter
editing or status monitoring. Ultraware or host serial communications
are the only methods of human-machine interface (HMI) supported.
Ultra3000 firmware performance (e.g., timing, behavior, bandwidth)
may be different than the ULTRA 100/200 in some applications.
Functional qualification will identify any differences that impact your
design. The Ultra3000 generally has higher performance than the
ULTRA 100/200, but this could impact some applications.
Ultra3000 drives do not provide induction motor support available with
ULTRA 200 drives.
The Ultra3000 drives do not support line loss detection available on
ULTRA 200 drives.
The Ultra3000 Motor Configuration tool must be used to support some
Reliance B-series and P-series legacy motors.

Publication 2098-RM005B-EN-P - February 2007

Engineering Review Essentials

1-3

Ultra 3000 drives and servo motors equipped with Stegmann


high-resolution encoders are not compatible with HSRV and IMC
controllers. The buffered encoder outputs from the Ultra 3000 drive are
incompatible with the encoder inputs on these controllers. A possible
solution is to use an motor equipped with an optical-based incremental
encoder and an 2090-U3BB-D44 breakout board mounted on the CN1
connector to transfer the unbuffered outputs from pins 10 through 15
to the HSRV or IMC controller.

Potential Hardware Design


Changes

The design changes required for converting to the Ultra3000 drive depend on
the original/replacement drive combination and the specifics of the
application. The objective is to determine which areas of a design may need
alteration. This should provide you with knowledge about the type and extent
of work that may be required in order to successfully change from an ULTRA
100 or ULTRA 200 to an Ultra3000 based system.
IMPORTANT

Due to the flexibility of drive installation and usage, it is not


feasible to cover all possible issues that may be
encountered. In addition to the items described below, the
engineering design team should pay particular attention to
unique features and functions in the ULTRA 100 or
ULTRA 200 design.

The following sections cover the majority of hardware design changes that
may be required when selecting a replacement Ultra3000 drive.

Drive Sizing beginning on page 2-2


Input Wiring and Fusing on page 2-3
Drive Interconnects and Cabling beginning on page 2-4
Serial Communications on page 2-10
Accessories and Auxiliary Power beginning on page 2-10

Publication 2098-RM005B-EN-P - February 2007

1-4

Engineering Review Essentials

Publication 2098-RM005B-EN-P - February 2007

Chapter

Selecting a Replacement Drive

Drive Sizing is the primary factor for choosing a replacement drive. Identifying
the correct replacement drive size requires knowing factors such as the
continuous and peak output current rating.
In general, the following rules apply:
1398-DDM-005, -009, -019, -030, -075, and -150 drives can be replaced
with an Ultra3000 drive of very similar size and output current
capability.
1398-DDM-010, and -020 drives do not have a direct replacement in the
Ultra3000 drive family. They can be replaced by either a drive with a
larger output current capacity, or a physically smaller drive with
performance or design limitations.
Note: The 2098-DSD-030 drive provides nearly identical hardware
connections and significantly greater power.

Factors Affecting Drive


Replacement

Factors affecting a redesign effort, include the following:

Drive Sizing, both electrical and physical


Input Wiring and Fusing
Drive Interconnects and Cabling
Serial Communications
Accessories and Auxiliary Power

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2-2

Selecting a Replacement Drive

The following table lists the suggested replacement drives, along with the
output ratings of the drives. Information in this document is based on and
discusses these drive combinations. Drive power and physical size is
summarized in the table below.

Drive Sizing

Drive Output Current


The performance capabilities of the replacement drive should be reviewed to
ensure that the replacement drive is capable of delivering the required level of
peak and continuous current to the motor.
ULTRA 100 or
ULTRA 200

ULTRA 100/200
Recommended
Output Current Rating Ultra3000
Replacement

Ultra3000
Ultra3000 Outline Differences
Output Current Rating

Continuous Peak

Continuous Peak

1398-DDM-005 1

2.5 A

7.5 A

2098-DSD-005

2.5 A

7.5 A

1398-DDM-009 1

5A

15 A

2098-DSD-010

5A

15 A

1.5 mm (0.06 in.) wider

1398-DDM-019 1

10 A

30 A

2098-DSD-020

10 A

30 A

1.5 mm (0.06 in.) wider

10 A

2098-DSD-030 3

15 A

30 A

12.7 mm (0.5 in.) narrower

15 A

30 A

12.7 mm (0.5 in.) narrower

1398-DDM-010 2

5A

1398-DDM-020 2

10 A

20 A

2098-DSD-030 4

15A

30 A

2098-DSD-030

15 A

30 A

12.7 mm (0.5 in.) narrower

1398-DDM-075 2

35 A

75 A

2098-DSD-075

35 A

75 A

14.2 mm (0.56 in.) narrower,


5.6 mm (0.22 in.) deeper

1398-DDM-150 2

65 A

150 A

2098-DSD-150

65 A

150 A

14.2 mm (0.56 in.) narrower,


5.6 mm (0.22 in.) deeper

1398-DDM-030

1 Includes drives with the following feature sets: standard, indexing (X), DeviceNet (-DN), and indexing with DeviceNet (X-DN).
2 Includes drives with the following feature sets: standard, and indexing (X).
3 2098-DSD-010 micro-size drive provides comparable output power and smaller profile, but is not recommended due to reduced interface capabilities.
4 2098-DSD-020 micro-size drive provides comparable output power and smaller profile, but is not recommended due to reduced interface capabilities.

Publication 2098-RM005B-EN-P - February 2007

Selecting a Replacement Drive

2-3

Input Wiring and Fusing

AC Input Power Wire Length and Routing


Wire length for the AC line input can be determined once the drive location
and any changes to routing are finalized. In general, the recommended drive
replacement should not require changes in wiring length and/or routing.
Refer to Terminal Block (TB1) Connections on page A-6 for a comparison of
ULTRA 100, ULTRA 200 and Ultra3000 power terminals.
Note: Drives replaced by the micro-sized drives 2098-DSD-005,
2098-DSD-010, and 2098-DSD-020 may require changes in wiring length
and/or routing.

Fusing
Fusing requirements will be comparable for similar drive sizes. However,
fusing requirements should be reviewed as a matter of course when changing
drives.
The Ultra3000 is listed by Underwriters Laboratories, Inc. with fuses sized as
four times the continuous output current of the drives (FLA), according to UL
508C. In most cases, fuses selected to match the drive input current rating will
meet the NEC requirements and provide the full drive capabilities. Dual
element, time delay (slow acting) fuses should be used to avoid nuisance trips
during the inrush current of power initialization. Refer to the Ultra3000
Installation Manual (publication 2098-IN003x-EN-P) for input current and
inrush current specifications. Verify that the fuse size used for the ULTRA 100
or ULTRA 200 drive meets the Ultra3000 requirements, and conforms to
NEC and all other applicable local codes.
Note: Drives replaced by the micro-sized drives 2098-DSD-005,
2098-DSD-010, and 2098-DSD-020 may require changes in wiring length
and/or routing.

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2-4

Selecting a Replacement Drive

Drive Interconnects and


Cabling

Motor Power
In general, an ULTRA Series motor power cable (P/N 9101-xxxx) should
connect to an Ultra3000 drive. The following sections provided information
on various aspects of the motor power interconnects and cabling.
Motor Power Wire Gauge
Cable Wire References
Motor Power Replacement Cables
Refer to the Motor Power Replacement Cables table on page 2-5 for more
information.

Motor Power Wire Gauge


The table below compares the range recommended wire gauges, and the
following general requirements apply to all power cables.
If the wire gauge currently in use falls outside of the range listed for the
replacement drive (e.g., 1398-DDM-010 to 2098-DSD-030, and
1398-DDM-020 to 2098-DSD-030), it will need to be changed.
Refer to the note below the following table for additional information.
If a new wire gauge is going to be used, verify that the capacity of the
new wire is capable of handling the current.
75 C copper wire is specified for ULTRA 100, ULTRA 200, and
Ultra3000 drives.
ULTRA 100/200

Recommended
mm

Ultra3000

(AWG)

Recommended
mm2

(AWG)

1398-DDM-005

1.5

(16)

2098-DSD-005

1.5

(16)

1398-DDM-009

2.5

(14)

2098-DSD-010

2.5

(14)

1398-DDM-019

(12)

2098-DSD-020

(12)

1398-DDM-010

2.5

(14)

2098-DSD-030

(10)

1398-DDM-020

(12)

2098-DSD-030

(10)

1398-DDM-030

(10)

2098-DSD-030

(10)

1398-DDM-075

(10)

2098-DSD-075

(10)

1398-DDM-150

10

(8)

2098-DSD-150

10

(8)

Note: 2098-DSD-010 and 2098-DSD-020 drives require the same wire gauge as the
1398-DDM-010 and 1398-DDM-020, but are not recommended replacements due to
reduced interface capabilities.

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Selecting a Replacement Drive

2-5

Cable Wire References


The naming convention for motor power phasing changed between drive
designs.
The following table references the motor power signal names labelled on the
ULTRA 100, ULTRA 200 and Ultra3000 products:
ULTRA 100/200

Ultra3000

Refer to Terminal Block (TB1) Connections on page A-6 for ULTRA 100, ULTRA
200 and Ultra3000 power terminal connections.

Motor Power Replacement Cables


Motors

Cable

ULTRA 100/200
Power Cable

Ultra 3000 Shielded


Power Cable 1

Cable Length
meters 2

mm2

(AWG)

F2000, F3000

1.8

(16)

9101-1381-xxx

2090-UXPAH-16Sxx

1, 3, 9, 15, 30

F4000

2.5

(14)

9101-1382-xxx

2090-UXPAHF-14Sxx

1, 3, 9, 15, 30

F6000

(10)

9101-1383-xxx

2090-UXPAHF-10Sxx

1, 3, 9, 15, 30

F6300

10

(8)

9101-1389-xxx

2090-UXPAHF-8Sxx

1, 3, 9, 15, 30

H2000, H3000

1.8

(16)

9101-1381-xxx

2090-UXPAH-16Sxx

1, 3, 9, 15, 30

H4000

2.5

(14)

9101-1382-xxx

2090-UXPAHF-14Sxx

1, 3, 9, 15, 30

H6000

(10)

9101-1383-xxx

2090-UXPAHF-10Sxx

1, 3, 9, 15, 30

H6300

10

(8)

9101-1389-xxx

2090-UXPAHF-8Sxx

1, 3, 9, 15, 30

H8000

16

(6)

9101-1384-xxx

2090-UXPAHF-6Sxx

1, 3, 9, 15, 30

N (all)

1.8

(16)

9101-1467-xxx

2090-UXPAN-16Sxx

1, 3, 9, 15, 30

Y (all)

1.8

(16)

9101-1385-xxx

2090-UXPAY-16Sxx

1, 3, 9, 15, 30

1 Right angle motor connector versions may be available by substituting R for S (straight) in the catalog number.
2 Length of cable xx is in meters; 1, 3, 9, 15, 30 (3.3, 9.8, 29.5, 49.2, or 98.5 ft)

Publication 2098-RM005B-EN-P - February 2007

2-6

Selecting a Replacement Drive

Encoder Cabling
Alterations to the encoder cables will be required. Connector types, pinouts,
and connectivity are different. Refer to Encoder Connections on page A-2 for
ULTRA 100, ULTRA 200, and Ultra3000 connector pinouts.

Encoder Cables
Encoder cables may be obtained directly from Allen-Bradley or may be custom
built. Verify the following conditions as they apply your encoder cable:
In applications where motor encoder cable assemblies purchased from
Rockwell Automation are used, a direct replacement cable suitable for the
Ultra3000 can likely be used. Refer to the Replacement Encoder Cable table
below.
Motors

ULTRA 100/200
Encoder Cable

Ultra 3000
Shielded Encoder Cable 1

Lengths
meters 2

H, F

9101-1366-xxx

2090-UXNFBHF-Sxx

1, 3, 9, 15, 30

H,F

9101-1365-xxx

2090-UXNFDHF-Sxx (motor to flying leads) 1, 3, 9, 15, 30

9101-1468-xxx

2090-UXNFBN-Sxx

1, 3, 9, 15, 30

9101-1469-xxx

2090-UXNFDN-Sxx (motor to flying leads)

1, 3, 9, 15, 30

9101-1375-xxx

2090-UXNFBY-Sxx

1, 3, 9, 15, 30

9101-1373-xxx

2090-UXNFDY-Sxx (motor to flying leads)

1, 3, 9, 15, 30

1 Right angle motor connector versions may be available by substituting R for S in the catalog number.
2 Length of cable xx is in meters; 1, 3, 9, 15, 30 (3.3, 9.8, 29.5, 49.2, or 98.5 ft)
Refer to Encoder Connections on page A-2 for ULTRA 100, ULTRA 200, and Ultra3000 connector pinouts.

Custom Encoder Cables


Applications using a custom motor encoder cable need to address the
following changes regarding the motor encoder:
connector type and pinout
encoder signals utilized
If non-standard cabling is used, contact the factory to ensure that the cable
design meets the following basic requirements:

power/ground connection voltage drop


twisted pair signal wire usage
signal shielding
cable length restrictions

Refer to Encoder Connections on page A-2.

Publication 2098-RM005B-EN-P - February 2007

Selecting a Replacement Drive

2-7

I/O Cabling
ULTRA 100, ULTRA 200, and Ultra3000 drives use the same signals to
interface to the auxiliary encoder, digital I/O, and analog interconnections.
However, the connector on the drive end of the cable is different:
ULTRA 100 and ULTRA 200 drives have a 50 pin mini-D connector for
the controller interface (J1).
ULTRA 200 drives have a 26-pin mini-D connector for the auxiliary
encoder interface (J3).
Ultra3000 drives have a 44-pin, 3.5 mm, double-row, plugable spring
clamp connector for the I/O and Auxiliary Encoder interface (CN1).
Replacement or modification of the cable assembly is required. While
replacement with a cable not having the 50 pin D-type connector is the better
solution, an existing cable may be modified by careful planning. Review the
I/O count, specifications, power, and wire terminations when converting to an
Ultra3000 drive. The following sections provide the detail necessary to
examine the conversion:

I/O Availability and Specifications


I/O Power Sources
I/O Cable Termination
I/O Pinouts

I/O Availability and Specifications


The Ultra3000 drives present a comprehensive set of digital and analog I/O.
To verify operation with a Ultra3000 drive, an analysis of the I/O circuitry
should be undertaken to verify proper operation.
Differences existing between I/O on the ULTRA 100 and ULTRA 200 and
Ultra3000 include:
Ultra3000 drives contain 8 general purpose digital inputs, ULTRA 100
drives contain 3 general purpose and 2 dedicated (ENABLE and
FAULT RESET) inputs, and ULTRA 200 drives contain 4 general
purpose plus 2 dedicated (ENABLE and FAULT RESET) inputs.
Ultra3000 drives contain 4 transistor outputs; ULTRA 100 drives
contain 2, and ULTRA 200 drives contain 4 transistor outputs.
Ultra3000 drives contain a single, normally open, relay contact
connection (user assigned); ULTRA 100 and ULTRA 200 drives contain
2 dedicated relay outputs (READY and BRAKE).
Ultra3000 drives and ULTRA 100 drives contain 1 analog limit input;
ULTRA 200 drives contain 2 analog limit inputs.

Publication 2098-RM005B-EN-P - February 2007

2-8

Selecting a Replacement Drive

Answering yes to any of the following questions may warrant changes, and at
the minimum, should trigger a review to determine whether design changes
are required based on I/O differences:
Is the ULTRA 100 and ULTRA 200 internal +24V dc supply (J1-26)
used to power external I/O equipment AND is the replacement drive a
2098-DSD-005, 2098-DSD-010, or 2098-DSD-020?
Are both relay outputs being used?
Refer to Digital I/O, Analog I/O, and Auxiliary Encoder Pinouts for a
comparison between ULTRA 100 and ULTRA 200 J1 connector and the
Ultra3000 CN1 connector. ULTRA 100, ULTRA 200, and Ultra3000 drives
use the same signals to interface to the auxiliary encoder, and I/O. However,
the connector on the drive end of the cable is different:

I/O Power Sources


The only combinations of ULTRA 100/200 - Ultra3000 replacement pairs that
may require changes to I/O power methodology are the following:
1398-DDM-010 to 2098-DSD-010
1398-DDM-020 to 2098-DSD-020
Note: These are not recommended drive replacements. Refer to Drive Output
Current on page 2-2 for the recommended drive replacements.
In the above instances a standard size drive is being replaced with a micro size
drive. The standard size drive contains a 24v power supply that may be used
for powering I/O which is not available in the micro size drives. If the internal
24v supply from the ULTRA 200 was being used, another power supply will be
required if switching to one of these Ultra3000 drives. If this is a problem, then
switching to a standard size drive Ultra3000 drive (2098-DSD-030) is
recommended.
Refer to Digital and Analog I/O Pinouts for ULTRA 100, ULTRA 200, and
Ultra3000 connector pinouts.

Publication 2098-RM005B-EN-P - February 2007

Selecting a Replacement Drive

2-9

I/O Cable Termination


Different connectors are utilized on the Ultra3000 drives. Pinout and
terminating hardware for I/O on these drives will need to be changed.
Different methods for I/O wire termination at the CN1 connector are
supported for the Ultra3000 drives:
44-pin D shell connector
(mating connector kit catalog number 2090-U3CK-D44)
Breakout board connected directly to CN1
(breakout board catalog number 2090-U3BB2-DM44)
The acceptable wire gauge for I/O wiring may differ from that which is
currently being used for the ULTRA 100 or ULTRA 200 installation.
Additional changes to wiring will be required if the wire currently used for I/O
falls outside the Ultra3000 ranges specified below:
Ultra3000 44-pin D-shell pins accept 0.08 to 4 mm2 (22 to 12 AWG)
wire.
Breakout board (2090-U3BB2-DM44)terminals accept:
0.08 to 1.5 mm2 (28 to 16 AWG) stranded wire
0.10 to 1.5 mm2 (26 to 16 AWG) solid wire
Since the termination method and location may change when moving to an
Ultra3000 drive, I/O wire preparation and relative wire lengths may also
require adjustment.

I/O Pinouts
Refer to Control Connections on page A-3 for a table defining I/O pinouts for
the ULTRA 100 and ULTRA 200 drives and the replacement Ultra3000 drives.

Publication 2098-RM005B-EN-P - February 2007

2-10

Selecting a Replacement Drive

Serial Communications

ULTRA 100, ULTRA200, and Ultra3000 drives all contain one serial port, but
the ULTRA 200 routes this port to two connectors for ease of daisy-chaining.
The serial ports are capable of either RS232 or RS422 communications.
Refer to Serial Communication Pinouts on page A-1 for ULTRA 100, ULTRA
200, and Ultra3000 connector pinouts.

Accessories and Auxiliary


Power

Application specific accessories, such as dissipative shunts, and CE marking of


products, as well as the need to retain logic functions while the machine is
powered-down, can impact drive replacement. The following sections include:
Shunt Resistors
AC Line Filters
Auxiliary Power

Shunt Resistors
Changes to shunt capacity or methodology will not be encountered, except
except in the following drive exchange combinations:
1398-DDM-010 with a 2098-DSD-010
1398-DDM-020 with a 2098-DSD-020
Note: These are not recommended drive replacements. Refer to Drive Output
Current on page 2-2 for the recommended drive replacements.
In this case a standard size drive is replaced with a micro-size drive, and the
micro-size drives do not contain an internal shunt resistor. Micro-size
Ultra3000 drives are limited to utilizing an external active shunt module
(2090-UCSR-A300) since they do not contain shunt control circuitry.
If a micro-sized Ultra3000 replacement drive is used, an analysis of the
shunting solution should be conducted. System sizing software available
from Rockwell Automation will help identify suitable replacements.
If shunting is needed, the 2098-DSD-030 (standard and indexing) drives
may be a better choice, as it has shunting support identical to the
1398-DDM-010, -010X, -020, and -020X drives.

Publication 2098-RM005B-EN-P - February 2007

Selecting a Replacement Drive

2-11

AC Line Filters
AC line filters perform a key role for Ultra drives to meet CE radiation
standards. The need for CE compliance should be examined prior to
conversion to the Ultra3000 drives:
If CE compliance is not required and the current design does not
include line filters, line filters should not be needed with the
replacement Ultra3000 drive. However, performance of the Ultra3000
drive in the system should be verified to ensure that a line filter is not
required.
If CE compliance is required, the use of a line filter is should be
evaluated. CE compliance will need to be verified after conversion to
the Ultra3000 drives.
The Ultra3000 line of drives were tested for CE compliance using the line
filters outlined in the table below. Other brands of filters may yield acceptable
results but have not been tested as such for the Ultra3000 drive family by
Rockwell Automation.
AC Line Filter Description Catalog Number

AC Line Filter Fuse Block

6 Amp, single phase

2090-UXLF-106

6 Amp

10 Amp, single phase

2090-UXLF-110

10 Amp

23 Amp, single phase

2090-UXLF-123

23 Amp

36 Amp, single phase

2090-UXLF-136

36 Amp

50 Amp, single phase

2090-UXLF-150

50 Amp

36 Amp, three phase

2090-UXLF-336

36 Amp

50 Amp, three phase

2090-UXLF-350

50 Amp

70 Amp, three phase

2090-UXLF-370

70 Amp

Auxiliary Power
The Auxiliary Power feature allows an ULTRA 200 drive to retain logic power
when main power is removed. (This feature is not available on ULTRA 100
drives.) The Auxiliary Power feature is often used to retain feedback position
from the motor, and in doing so eliminate the need to home the motor at
power-up. Replace ULTRA 200 drives that require separate logic power
(1398-DDM-010, and 1398-DDM-020) with a 2098-DSD-030 which supports
the feature in an identical manner.

Publication 2098-RM005B-EN-P - February 2007

2-12

Selecting a Replacement Drive

Publication 2098-RM005B-EN-P - February 2007

Appendix

Drive Connectors and Connections

The following tables compare the signal and power connections between
ULTRA 100 and ULTRA 200 drives to those of Ultra3000 drives.

The following table defines the serial communication signal pinouts for:

Serial Communication
Pinouts

ULTRA 100 connector J4, the ULTRA 200 connectors J4 and J5, and
the comparable Ultra3000 connector CN3.
ULTRA 100 or ULTRA 200

J4 or J5
Pin

Signal

RCV+

Description

Ultra3000
Signal

CN3
Pin

RS-422/RS-485 Input+

RCV+

RCV

RS-232 Input

RCV

XMT

RS-232 Output

XMT

XMT+

RS-422/RS-485 Output+

XMT+

COM

Common

COM

N/C

Reserved

N/C

RCV-

RS-422/RS-485 Input-

RCV-

XMT-

RS-422/RS-485 Output-

XMT-

N/C

Reserved

N/C

Publication 2098-RM005B-EN-P - February 2007

A-2

Drive Connectors and Connections

Encoder Connections

The following table defines the encoder signal pinouts for:


ULTRA 100 and ULTRA 200 connector J2, and
the comparable Ultra3000 connector CN2.

ULTRA 100 or ULTRA 200


J2
Pin

Description

+5V Encoder Power

Signal

Ultra3000
CN2
Pin

Description

EPWR +5V

14

+5V Encoder Power

Encoder Common

ECOM

Encoder Common

+5V Encoder Power

EPWR +5V

see CN2-14 and CN2-6 above

Encoder Common

ECOM

+5V Encoder Pwr / Encoder Pwr Sense 1

EPWR +5V / SENSE +

Encoder Common / Encoder Pwr Sense 1

ECOM / SENSE -

Channel A +

A+

Channel A + / Sine Input +

Channel A -

A-

Channel A - / Sine Input -

Channel B +

B+

Channel B + / Cosine Input +

10

Channel B -

B-

Channel B - / Cosine Input -

11

Channel I +

I+

Channel I + / Index Pulse +

12

Channel I -

I-

10

Channel I - / Index Pulse -

13

Hall A

Hall A

12

Commutation Channel S1

14

Hall B

Hall B

13

Commutation Channel S2

15

Hall C

Hall C

Commutation Channel S3

16

Absolute Position

ABS 4

17

N/C

Reserved

18

N/C

Reserved

19

Thermal Switch +

TS+

11

Thermostat

20

Thermal Switch - 2

TS- 3

EPWR +9V 2

N/C / +9V Encoder Power

+LIMIT

Positive Overtravel Limit

-LIMIT

15

Negative Overtravel Limit

1 Encoder power sense functionality available only with ULTRA 200. This function is not supported by the ULTRA 100 and Ultra3000 drives.
2 +9V Encoder capability only available on standard size Ultra 3000 (2098-DSD-030 or larger).
3 Ultra3000 cables internally connect TS- to ground.
4 The all-in-one Hall sensor signal is not supported by the Ultra3000 drive.

Publication 2098-RM005B-EN-P - February 2007

Drive Connectors and Connections

A-3

Control Connections

The following table defines the digital, analog, and auxiliary encoder signal
pinouts for:
ULTRA 100 and ULTRA 200 connector J1, and
the comparable Ultra3000 connector CN1.
Where possible, the table aligns the signal name for an ULTRA 100 and
ULTRA 200 drive with the comparable signal on the Ultra3000.

ULTRA 100 or ULTRA 200

Signal

Ultra3000

J1
Pin

Description

Description

CN1
Pin

Encoder +5V DC Power

EPWR +5V

Encoder +5V DC Power

Encoder Common

ECOM

ECOM

Encoder +5V DC Power

EPWR +5V

Encoder Common

ECOM

External I/O 12-24V DC Power

I/O PWR

I/O Power

29

External I/O Common

I/O COM

I/O Common

27

Encoder Output A+

AM+

Buffered Motor Encoder A+

16

Encoder Output A-

AM-

Buffered Motor Encoder A-

17

Encoder Output B+

BM+

Buffered Motor Encoder B+

18

10

Encoder Output B-

BM-

Buffered Motor Encoder B-

19

11

Encoder Output I+

IM+

Buffered Motor Encoder I+

20

12

Encoder Output I-

IM-

Buffered Motor Encoder I-

21

13

External I/O Common

IOCOM

I/O Common

28

14

Aux Encoder Input A+

AX+

Aux Encoder Input A+

15

Aux Encoder Input A-

AX-

Aux Encoder Input A-

16

Aux Encoder Input B+

BX+

Aux Encoder Input B+

17

Aux Encoder Input B-

BX-

Aux Encoder Input B-

18

Aux Encoder Input I+

IX+

Aux Encoder Input I+

19

Aux Encoder Input I-

IX-

Aux Encoder Input I-

20

Drive Enable 1, 2

ENABLE

21

Fault Reset 1, 2

RESET

22

Analog Command+

CMND+

Analog Command+

25

23

Analog Command-

CMND-

Analog Command-

26

24

Drive Ready+ 2

READY+

25

Drive Ready- 2

READY-

26

External I/O 12-24V DC Power

IOPWR

I/O Power

30

Publication 2098-RM005B-EN-P - February 2007

A-4

Drive Connectors and Connections

ULTRA 100 or ULTRA 200


J1
Pin

Description

27

Current Limit /Current Limit + 3

28

Signal

Ultra3000
Description

CN1
Pin

I LIMIT/I LIMIT+

Analog Current Limit

24

Analog Common

ACOM

Analog Common

22

29

Unused/Current Limit- 3

RESERVED /I LIMIT-

30

Unused/Analog Output1 4

RESERVED /I ANALOG

31

Analog Output1/Analog Output2 4

ANALOG/ ANALOG

Programmable Analog Output

23

32

Programmable Input1 5

INPUT1

Digital Input 1

31

33

Programmable Input2 5

INPUT2

Digital Input 2

32

34

Programmable Input3 5

INPUT3

Digital Input 3

33

35

Unused/Programmable Input4 5

RESERVED/INPUT4

Digital Input 4

34

36

Unused

RESERVED

37

Unused

RESERVED

38

Unused

RESERVED

39

Unused

RESERVED

40

Unused

RESERVED

41

Unused

RESERVED

42

Programmable Output1 6

OUTPUT1

Digital Output 1

39

43

Programmable Output2 6

OUTPUT2

Digital Output 2

40

44

Unused/Programmable Output 3 6

RESERVED/OUTPUT3

Digital Output 3

41

45

Unused/Programmable Output 4 6

RESERVED/OUTPUT4

Digital Output 4

42

46

Unused

RESERVED

47

Unused

RESERVED

48

Unused

RESERVED

49

Brake Enable+ 2

BRAKE+

50

Brake Enable- 2

BRAKE-

AUXPWR

Auxiliary Logic Power 5V DC

AMOUT+

Unbuffered Motor Encoder A+

10

AMOUT-

Unbuffered Motor Encoder A-

11

BMOUT+

Unbuffered Motor Encoder B+

12

BMOUT-

Unbuffered Motor Encoder B-

13

IMOUT+

Unbuffered Motor Encoder I+

14

IMOUT-

Unbuffered Motor Encoder I-

15

RELAY+

Relay Output+ (Norm. Open)

43

RELAY-

Relay Output- (Norm. Open)

44

Publication 2098-RM005B-EN-P - February 2007

Drive Connectors and Connections

ULTRA 100 or ULTRA 200


J1
Pin

Description

A-5

Signal

Ultra3000
Description

CN1
Pin

INPUT5

Digital Input 5

35

INPUT6

Digital Input 6

36

INPUT7

Digital Input 7

37

INPUT8

Digital Input 8

38

Pin usage varies between ULTRA 100 drive and ULTRA 200 drive, both are provided: ULTRA 100 first / ULTRA 200 last (e.g., U100/U200)
1 Enable and Fault Reset input functionality can be programmed to any of the general purpose inputs on the Ultra3000.
2 The Ultra3000 has a single, programmable normally open relay output (that can be configured via Ultraware software for READY or BRAKE functionality, among others).
The ULTRA 100 and ULTRA 200 have two fixed relay outputs (READY and BRAKE).
3 The ULTRA 100 and Ultra3000 contain a single analog current limit input for both positive and negative current. The ULTRA 200 has separate limit inputs for positive and
negative current flow.
4 The ULTRA 100 and Ultra3000 contain a single analog output. The ULTRA 200 has two analog outputs.
5 The ULTRA 100 has three programmable digital inputs, the ULTRA 200 has 4 programmable digital inputs, and Ultra3000 has eight programmable digital inputs.
6 The ULTRA 100 has two digital (transistor) outputs, the ULTRA 200 and Ultra3000 have four digital outputs.

Publication 2098-RM005B-EN-P - February 2007

A-6

Drive Connectors and Connections

The following tables define the power terminal connectors for ULTRA 100
and ULTRA 200 drives, and the comparable connectors on Ultra3000 drives.

Terminal Block (TB1)


Connections

1398-DDM-005, -009, and -019 to


2098-DSD-005, -010, and -020
ULTRA 100
DC Bus

100-240 VAC
50/60 Hz
Single Phase
Motor

Terminal

Ultra3000

DC BUS+

DC Bus

DC BUS-

L1

L2/N

Safety Earth Ground

Motor Case Ground

Motor Case Ground

DC BUS+
DC BUS-

100-240 VAC
50/60 Hz
Single Phase

L1
L2/N
Safety Earth Ground

Motor

1398-DDM-010, -020, and -030 to


2098-DSD-030
ULTRA 200
Motor

DC Bus

100-240 VAC
50/60 Hz
Single Phase
Auxiliary Power
100-240 VAC
50/60 Hz

Terminal

Ultra3000

Motor

Motor Case Ground

Motor Case Ground

DC BUS+

DC BUS-

L1

L2

Safety Earth Ground

L1 AUX

10

L2/N AUX

11

Publication 2098-RM005B-EN-P - February 2007

DC Bus

DC BUS+
DC BUS-

100-240 VAC
50/60 Hz
Single Phase

L1
L2/N
Safety Earth Ground

Auxiliary Power
100-240 VAC
50/60 Hz

L1 AUX
L2 AUX

Drive Connectors and Connections

A-7

1398-DDM-075 and -150 to


2098-DSD-075 and -150
ULTRA 200
Motor

DC Bus

100-240 VAC
50/60 Hz
Three Phase

Auxiliary Power
100-240 VAC
50/60 Hz

Terminal

Ultra3000

Motor

Motor Case Ground

Motor Case Ground

DC BUS+

DC BUS-

L1

L2/N

L3

L3

Safety Earth Ground

10

Safety Earth Ground

L1 AUX

11

L2 AUX

12

DC Bus

DC BUS+
DC BUS-

100-240 VAC
50/60 Hz
Three Phase

Auxiliary Power
100-240 VAC
50/60 Hz

L1
L2/N

L1 AUX
L2 AUX

Publication 2098-RM005B-EN-P - February 2007

A-8

Drive Connectors and Connections

Publication 2098-RM005B-EN-P - February 2007

Appendix

Specifications

I/O Specifications

The following tables compare the input and output specifications between
ULTRA 100 and ULTRA 200 drives to those of Ultra3000 drives.

Digital Inputs
Parameter

ULTRA 100

ULTRA 200

Ultra 3000

On State Voltage (V)

10.8 to 28.0

20.0 to 28.0

10.8 to 26.4

On State Current (mA)

3.0 to 10.0

3.5 to 5.5

3.0 to 12.0

Off State Voltage (V)

-1.0 to 2.0

-1.0 to 3.0

-1.0 to 3.0

Off State Current (mA)

-0.5 to +0.5

-0.5 to +0.5

not specified

Digital Outputs
Parameter

ULTRA 100

ULTRA 200

Ultra 3000

ON State Current (mA)

0 to 50

0 to 50

0 to 50

Off State Leakage Current (mA)

-0.1 to +0.1

-0.1 to +0.1

-0.1 to +0.1

On State Voltage (V)

0.0 to 1.5

0.0 to 1.5

0.0 to 1.5

Off State Voltage (V)

0 to 50

0 to 50

0 to 50

Relay Outputs

Parameter

ULTRA 100
Brake
Output

ULTRA 100
Ready
Output

UlLTRA 200
Brake
Output

ULTRA 200
Ready
Output

Ultra3000
Relay
Output

Max. ON State Current (A)

0.10

Max. ON State Resistance (Ohm)

Max Off State Voltage (V)

30

30

50

50

30

Max Off State Leakage (mA)

0.01

0.01

0.01

0.01

not specified

Publication 2098-RM005B-EN-P - February 2007

B-2

Specifications

Analog Inputs
Parameter

ULTRA 100
Command
Input

ULTRA 100
Limit Input

ULTRA 200
Command
Input

ULTRA 200 Ultra3000


Limit Inputs Command
Input

Ultra3000
Limit Input

Resolution

14 bits

10 bits

16 bits

10 bits

14 bits

10 bits

Input Impedance (kOhms)

13.3

not specified

13.3

not specified

20

10

Input Signal Range (V)

-10.0 to +10.0 0.0v to +10.0

-10.0v to
+10.0

0.0v to +10.0

-10.0v to
+10.0

0.0v to +10.0

Max. Offset Error (mV)

not specified

not specified

not specified

not specified

50

50

Max. Gain Error (%)

not specified

not specified

not specified

not specified

Max. Propagation Delay (uS)

not specified

not specified

not specified

not specified

100

100

Analog Outputs
Parameter

ULTRA 100
Analog Output

ULTRA 200
Analog Output 1

ULTRA 200
Analog Output 2

Ultra3000
Analog Output

Resolution (bits)

12

Max. Output Current (mA)

-2.0 to +2.0

-2.0 to +2.0

-2.0 to +2.0

-2.0 to +2.0

Output Signal Range (V)

-10.0 to +10.0

-10.0 to +10.0

-10.0 to +10.0

-10.0 to +10.0

Max. Offset Error (mV)

not specified

not specified

not specified

100

Max. Gain Error (%)

not specified

not specified

not specified

Min. Bandwidth (Hz)

not specified

not specified

not specified

50

Publication 2098-RM005B-EN-P - February 2007

Specifications

B-3

General Power
Specifications

The following tables provide power specifications for ULTRA 100 and
ULTRA 200 drives, and the Ultra3000 drives.

ULTRA 100 Drives


1398-DDM-xxx

-005

-009

-019

AC Input Voltage:
Single Phase

V acrms 100-240

100-240

100-240

AC Input Frequency

Hz

47 - 63

47 - 63

47 - 63

AC Input Current
Nominal
Maximum Inrush (at 240V ac)

Arms
A

5.0
100

9.0
100

18.0
100

Output Peak Current 1

7.5

15

30

Continuous Output Current 1


Single Phase

2.5

10

1 Peak to peak.

ULTRA 200 Drives


1398-DDM-xxx

-010

-020

-030

-075

-150

AC Input Voltage
Single Phase
Three Phase

V acrms 100-240
V acrms

100-240

100-240

100-240
100-240

100-240

AC Input Frequency

Hz

47 - 63

47 - 63

47 - 63

47 - 63

47 - 63

AC Input Current:
Nominal
Maximum Inrush (at 240V ac)

A
A

10.0
50

19.0
50

28.0
50

30.0
50

46.0
68

Output Peak Current 1


Single Phase
Three Phase

A
A

10

20

30

50
75

150

Continuous Output Current 1


Single Phase
Three Phase

A
A

10

15

15
35

65

Internal Shunt Power


Continuous
Peak

Watts
Watts

50
6,000

50
6,000

50
6,000

50
10,000

180
19,000

1 Peak to peak.

Publication 2098-RM005B-EN-P - February 2007

B-4

Specifications

Ultra3000 Drives
2098-DSD-xxx

005

010

-020

-030

-075

-150

V ac
V ac

100 - 240

100 - 240

100 - 240

100 - 240

100 - 240

100 - 240

AC Input Frequency

Hz

47 - 63

47 - 63

47 - 63

47 - 63

47 - 63

47 - 63

AC Input Current:
Nominal
Max Inrush 2

Arms
A

5
100

9
100

18
100

28
50

30
50

46
68

7.5

15

30

30

75

150

2.5

10

15

35

65

Watts
Watts

50
6,000

50
10,000

180
19,000

AC Input Voltage
Single Phase
Three Phase

Output Peak Current 3


Continuous Output Current
Internal Shunt Power
Continuous
Peak

1 Specification is for nominal voltage. The absolute limits are 88 to 265 V acrms.
2 At 230V ac, 0 to peak
3 0 to peak

Publication 2098-RM005B-EN-P - February 2007

Appendix

Software Conversion with the


Ultra Conversion Tool

The Ultra Conversion Tool is a on-line tool that supports the process of
changing a motion system from a design based on the Allen-Bradley ULTRA
100 and 200 Series drives (i.e., 1398-DDMs) to one utilizing the Ultra3000
Family (i.e., 2098-DSDs) of drive products.

About Software
Conversions

The ULTRA Conversion Tool contained in the UltraBridge software assists in


migrating application parameter settings from Allen-Bradley ULTRA 100 and
ULTRA 200 drives to the Ultra3000 drives. The conversion tool reads an
UltraMaster configuration file (*.par), converts the data into similar
Ultra3000 parameters, and saves the data as an Ultraware (*.udb) file.
Help files explain the conversion protocol. They provide the information
necessary to understand the software conversion process, and to effectively
review and troubleshoot the resulting motion program.

Publication 2098-RM005B-EN-P - February 2007

C-2

Software Conversion with the Ultra Conversion Tool

Using the ULTRA


Conversion Tool

The following sections provide instructions on how to use the Ultra


Conversion Tool to convert parameter settings from UltraMaster to Ultraware.
The conversion tool reads an UltraMaster configuration file (*.par), converts
the data into similar Ultra3000 parameters, and saves the data as an
Ultraware (*.udb) file.

How to Convert a File


The Ultra Conversion Tool is accessed through the File/Import menu of
Ultraware.
1. Open Ultraware, and click on File in the menubar.
2. Select Import from the drop down menu.
3. To import an UltraMaster file, select the following within the Import
From dialog, shown below:
a. Select an UltraMaster file (*.par) from the dialog.
b. Click the Open button, to have Ultraware:
Verify that the file exists.
Verify the file is a valid UltraMaster file (*.par)

After opening and reading the UltraMaster file (*.par), Ultraware will create a
new Ultra3000 drive containing the converted data in the User Data Exchange
File (*.uxf) format.

Publication 2098-RM005B-EN-P - February 2007

Software Conversion with the Ultra Conversion Tool

C-3

Warnings and Errors


Warnings or errors encountered during the conversion are displayed in a
Report window, as shown below. You can save the report and refer to it when
finalizing the converted Ultraware program.

If the conversion tool encounters an invalid or unsupported parameter in the


ULTRA 100 or ULTRA 200 file, a warning is logged and the converter
continues with the conversion. All unsupported parameters in the Ultra3000
remain in the default state, as if a new file was created.
IMPORTANT

A corrupt ULTRA 100 or ULTRA 200 file may cause a


fatal error, and no Ultraware file will be created.

Publication 2098-RM005B-EN-P - February 2007

C-4

Software Conversion with the Ultra Conversion Tool

Host Command Protocols

The following sections provide a brief comparison of the UltraMaster


(ULTRA 100 and 200) and a short description of the Ultraware (Ultra3000)
command protocols. Consult the on-line Ultra Family Conversion Tool for a
more extensive comparison of the software parameters.

Command Format
The ULTRA 100, ULTRA 200, and Ultra3000 drive command protocols are
master - slave protocols where the host computer is the master and the drive is
the slave. The command formats for ULTRA 100, ULTRA 200 and Ultra3000
drives are compared in the following table:
Start

Address

Parameter Function

Data

Checksum

End

ULTRA 100/200

aa

ppp

dd

cc

<cr>

Ultra3000

aa

ppp

dd

cc

<cr>

Each letter represents a single ASCII character. In the address, parameter,


function, data, and checksum fields, the characters should all be ASCII hex
values. (i.e., They should be in the range 0 through 9 and A through F [upper
case only], as shown in the above table.)
The only structural difference between ULTRA 100, ULTRA 200, and
Ultra3000 host commands is the Function fields: The ULTRA 100 and
ULTRA 200 do not have a Function field, as the function to be performed is
implied by the Parameter number.
All commands begin with a colon (0x3A), and terminate with a carriage return
(0x0D).

Publication 2098-RM005B-EN-P - February 2007

Software Conversion with the Ultra Conversion Tool

C-5

Ultra3000 Host Command Description


The address field is made up of two characters. These characters supply the
address of the drive that the command is intended for. For example, a host
addressing drive #2 would have 0x02. The address field allows drive addresses
from 0x00 through 0xFD, or 254 individual drives.
The parameter field specifies the parameter in the Ultra3000 drive that is
being accessed, which can range from 000 to 7FF, or 2048 possible
parameters.
The function field specifies what is to be done with the parameter, and
is defined as follows:
Function

Action

0x0

Read working value

0x1

Write working value

0x2

Read non-volatile value

0x3

Write non-volatile and working values

0x4

Copy non-volatile value to working value

0x5

Copy working value to non-volatile value

0x6

Read default value

0x7

Copy default value to non-volatile values and working values

0x8

Read minimum value

0x9

Read maximum value

0xA

Read array index minimum

0xB

Read array index maximum

0xC - 0xF

Reserved

The data field provides any data necessary for the drive to implement
the command, and can have a variable number of characters. When
strings are used in the data field, two ASCII hex characters represent the
ASCII character. (e.g., The # character is represented by two characters,
a 2 followed by a 3.) For some commands, the data field is not used.
Also, if the function code specifies to copy the non-volatile value to the
working value or vice versa, the data field is absent.
The checksum field contains an ASCII hex version of the 8-bit
checksum of the Address, Parameter, Function, and Data fields. The
sum of the Address, Parameter, Function, Data, and Checksum field
should result in a value of zero. When computing the sum, the
characters of the Address, Parameter, Function, and Data fields are
summed with the 8-bit value represented by the characters of the
checksum field.

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Software Conversion with the Ultra Conversion Tool

Ultra3000 Drive Response Description


If the drive receives the host's command with a communication error (e.g.,
parity or checksum errors), the drive does not respond. The host should
assume a communication error occurred if a response from the drive does not
occur within a time-out period. If the drive receives the command without a
communication error, the response is in the same format as the host
command.
The Parameter field contains the drive address, so the host can verify the
proper drive responded.
The Parameter field of the response is the same as that of the command,
unless the drive is unable to execute the command, in which case it
returns an exception response. (Examples of exception causes are
invalid function number, illegal data, etc.). An exception response is
generated from the command parameter code by setting the most
significant bit of the parameter code field. (Equivalently, it is generated
by adding 0x800 to the command parameter code.)
The Function field of the response is the same as the command.
The Data field contains data requested from the drive, if any. If an
exception occurred, the data field is made up of two characters, which
identify the type of exception.
The Checksum field is generated in the same manner as in the host
command, with the sum of the Address, Parameter, Function, Data, and
Checksum field set equal to zero.

Publication 2098-RM005B-EN-P - February 2007

Software Conversion with the Ultra Conversion Tool

C-7

Ultra3000 Exception Responses


If a command is received by the drive without a communication error, but
cannot be processed normally, an exception response is generated. The
possible exception responses are as follows:
Response Exception Type
Data

Description

01

Invalid Data

The command data parameter was unacceptable,


and the parameter was not changed in the drive.

02

Command Not Enabled The command is disabled and is dependent on


another command for enabling.

03

EEPROM Write Error

The command required a write to EEPROM, and the


data could not be written

04

Data Below Minimum

The command data was less than the minimum


value, and the parameter was not changed in the
drive.

05

Data Above Maximum The command data was greater than the maximum
value, and the parameter was not changed in the
drive.

06

Command Disabled

When Drive is Enabled, the command cannot be


compiled because the drive is enabled.

07

Invalid Array Index

The array index is out of range.

08

Invalid Function Code

The host function code was not recognized by the


drive.

09

Invalid Parameter
Number

The host parameter number was not recognized by


the drive.

Additional Information
Refer to the following for additional information about Ultra3000 software:
The on-line Ultra Family Conversion Tool for a more extensive
comparison of the software parameters.
Ultraware On-line Help files available on the Ultraware CD.

Publication 2098-RM005B-EN-P - February 2007

C-8

Software Conversion with the Ultra Conversion Tool

Publication 2098-RM005B-EN-P - February 2007

Appendix

Related Documentation

The following documents contain additional information concerning related


Allen-Bradley products.

Supplementary Information
and Publications

To obtain a copy, of these publications contact your local Allen-Bradley office,


distributor, or download them from
http://www.rockwellautomation.com/literature

For:

Read This Document:

Catalog Number:

Information on installing, configuring and


troubleshooting your ULTRA 100 drive

ULTRA 100 Series Drives Installation Manual

1398-5.2 - mmyyyy

Information on installing, configuring and


troubleshooting your ULTRA 200 drive

ULTRA 200 Series Digital Servo Drives User Manual

1398-5.0 - mmyyyy

ULTRA 100 or ULTRA 200 software programming and


reference material.

UltraMaster On-line Help

On-line help file

Ultraware Installation Instructions

Ultraware CD Installation Instructions

2098-IN002x-EN-P

Information on installing and setting-up your


Ultra3000

Ultra3000 Installation Manual

2098-IN003x-EN-P

Information on configuring and troubleshooting your


Ultra3000

Ultra3000 Digital Servo Drives Integration Manual

2098-IN005x-EN-P

Programming reference materials on Ultra3000


software

Ultraware On-line Help

On-line help file

A description and specifications for the Ultra Family


including motors and motor accessories

Motion Control Selection Guide

GMC-SG001x-EN-P

Application sizing and configuration information

Motion Analyzer CD (v4.1 or above)

PST-SG003x-EN-C

Information on installing an external shunt module

900 Watt Passive Shunt Module Installation Manual

2090-IN001x-EN-P

300 Watt Active Shunt Regulator Installation Manual

2090-IN002x-EN-P

200 Watt Passive Shunt Module Installation Manual

2090-IN003x-EN-P

2090 Series (460V) Passive Shunts Installation Manual

2090-IN004x-EN-P

Information, examples, and techniques designed to


minimize system failures caused by electrical noise

System Design for Control of Electrical Noise Reference


Manual

GMC-RM001x-EN-P

For declarations of conformity (DoC) currently


available from Rockwell Automation

Rockwell Automation Product Certification website

http://www.ab.com/c
ertification/ce/docs

An article on wire sizes and types for grounding


electrical equipment

National Electrical Code


Published by the National Fire Protection Association of Boston, MA.

A glossary of industrial automation terms and


abbreviations

Allen-Bradley Industrial Automation Glossary

AG-7.1

Publication 2098-RM005B-EN-P - February 2007

D-2

Related Documentation

Publication 2098-RM005B-EN-P - February 2007

C
certifications
Rockwell Automation product
certification D-1
conversion tool
engineering review 1-1
hardware design changes 1-3
major issues 1-2
controller connector 1-2
encoder connector 1-2
I/O power 1-2
power structures 1-2
relay outputs 1-2
minor issues 1-2
analog outputs 1-2
drive performance 1-2
high resolution encoder 1-3
host communications 1-2
HSRV and IMC controllers 1-3
induction motors 1-2
line loss detection 1-2
Reliance B-series motors 1-2
Reliance P-series motors 1-2
touchpad (HMI) support 1-2
hardware comparison
analog interface A-3
encoder connections A-2
I/O interface A-3
power terminals A-6
serial interface A-1

H
hardware replacement
encoder cables 2-6
fusing 2-3
I/O cables 2-7
line filters 2-11
motor power 2-4
motor power cables 2-5
motor power wire gauge 2-4

output current 2-2


physical dimensions 2-2
serial interface 2-10
shunt resistors 2-10
wiring ac power 2-3

R
related documentation
literature library D-1
motion analyzer D-1
Motion Control Selection Guide D-1
noise controlled by design D-1
ULTRA 100 Installation Manual D-1
ULTRA 200 User Manual D-1
Ultra3000 integration manual D-1
Ultraware CD installation instructions

D-1

S
software conversion
checksum field C-5
command description C-5
command formats C-4
data fields C-5
drive responses C-6
exception responses C-7
function fields C-5
host command protocol comparison C-4
importing files to Ultraware C-2
parameter fields C-5
warnings and errors C-3
specifications
analog inputs B-2
analog outputs B-2
digital inputs B-1
digital outputs B-1
I/O B-1
power B-3
relay outputs B-1

Publication 2098-RM005B-EN-P - February 2007

Rockwell Automation
Support

Rockwell Automation provides technical information on the web to assist you


in using its products. At http://support.rockwellautomation.com, you can find
technical manuals, a knowledge base of FAQs, technical and application notes,
sample code and links to software service packs, and a MySupport feature that
you can customize to make the best use of these tools.
For an additional level of technical phone support for installation,
configuration and troubleshooting, we offer TechConnect Support programs.
For more information, contact your local distributor or Rockwell Automation
representative, or visit http://support.rockwellautomation.com.

Installation Assistance
If you experience a problem with a hardware module within the first 24 hours
of installation, please review the information that's contained in this manual.
You can also contact a special Customer Support number for initial help in
getting your module up and running:
United States

1.440.646.5800
Monday Friday, 8am 5pm EST

Outside United
States

Please contact your local Rockwell Automation representative for any


technical support issues.

New Product Satisfaction Return


Rockwell tests all of its products to ensure that they are fully operational when
shipped from the manufacturing facility. However, if your product is not
functioning and needs to be returned:
United States

Contact your distributor. You must provide a Customer Support case


number (see phone number above to obtain one) to your distributor in
order to complete the return process.

Outside United
States

Please contact your local Rockwell Automation representative for


return procedure.

Publication 2098-RM005B-EN-P - February 20073


Supersedes publication 2098-RM005A-EN-P August 2004.

Copyright 2007 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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