Month: September 2025

Understanding Serial Interfaces

The Ultra5000 contains two identical serial port connectors (Main Serial Port

CN3A and Auxiliary Serial Port CN3B) that implement the standard NRZ

asynchronous serial format, and support RS-232. RS-422. and RS-485

communication standards.

Standard baud rates include 1.200. 2.400. 4.800. 9.600. 19.200. and 38.400

baud. Data lengths of 7 and 8 bits are supported.

The connector pinout dedicates separate pins for the RS-232 and RS-422/

RS-485 signals, so that the communication standard can be changed by just

using a different cable. Refer to Figure 2.7 for the serial interface hardware

configuration.

Routing High and Low Voltage Cables

Be aware that when you connect and route power and signal wiring on a

machine or system, radiated noise from nearby relays (relay coils should have

surge suppressors), transformers, and other electronic drives can be induced

into motor or encoder feedback, communications, or other sensitive, low

voltage signals. This can cause system faults and communication problems. To

minimize the levels of radiated noise, route machine power and signal lines

separately.

Auxiliary Encoder Interface

All encoder input signals (CN1B) are filtered using analog and digital filtering,

including illegal state change detection.

The input circuitry includes pull-up and pull-down resistors for compatibility

with single-ended and open collector signals, in addition to differential signals.

A single channel schematic of the auxiliary encoder interface is shown in the

figure below.

Understanding Serial Interfaces

The Ultra5000 contains two identical serial port connectors (Main Serial Port

CN3A and Auxiliary Serial Port CN3B) that implement the standard NRZ

asynchronous serial format, and support RS-232. RS-422. and RS-485

communication standards.

Standard baud rates include 1.200. 2.400. 4.800. 9.600. 19.200. and 38.400

baud. Data lengths of 7 and 8 bits are supported.

The connector pinout dedicates separate pins for the RS-232 and RS-422/

RS-485 signals, so that the communication standard can be changed by just

using a different cable. Refer to Figure 2.7 for the serial interface hardware

configuration.

Encoder Interface

The Ultra5000 main encoder feedback connector is CN2. The motor encoder

interface circuitry features include:

• 2.5 MHz maximum line frequency

• RS-485 serial channel for communicating with intelligent encoders

• Hall input for start-up commutation only

• Interpolation of sine/cosine encoders

All encoder signals are filtered using analog and digital filtering. The inputs

also include illegal state change detection. Refer to Figure 2.5 for a schematic

of the motor encoder inputs.

Hardware latches can be used for latching the encoder position based on an

index input or a digital input transition.

Auxiliary Encoder Interface

All encoder input signals (CN1B) are filtered using analog and digital filtering,

including illegal state change detection.

The input circuitry includes pull-up and pull-down resistors for compatibility

with single-ended and open collector signals, in addition to differential signals.

A single channel schematic of the auxiliary encoder interface is shown in the

figure below.

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.

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.

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.

Definitions:

KW = power or real power

KVA = apparent power

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.

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.

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.