Servo Power,

Performance, and Flexibility

in a Universal Drive

ULTRA Series Digital Servo Drives


The ULTRA Series provides five
standard and two optional interfaces.
• +/- 10V analog input
• step/direction input (also step up/step
down) with electronic gearing
• auxiliary master encoder input with
electronic gearing
• 8 preset speeds/torques selected via
3 digital input lines
• RS232/485 commands
• DeviceNet (optional)
• 8 preset position/indexer
(optional)
We designed the ULTRA Series for a
wide variety of motors, applications
and industries.
Everywhere in your plant, everywhere
on your machines, ULTRA Series
universal drives can handle a broad
range of motion applications.
2 ULTRA Series can even follow a master encoder with electronic gearing.
ULTRA Family of Universal Drives Sets the Standard
The ULTRA Series now offers a wider range of power and greater flexibility
than ever before. ULTRA Series spans a wide power range, from 500W all
the way up to 15kW. Moreover, the ULTRA Series provides universal
compatibility, minimizing training and maintenance costs, reducing life cycle
costs, and improving productivity. ULTRA Series. One standard. A multitude
of advantages.
The Only Drive You’ll Ever Want
Finally there’s a universal drive with the power, performance and flexibility
to handle almost anything – any motor, any application, any machine.
The ULTRA Series is a feature-rich, high-performance family of versatile
drives that covers a wide range of applications – anything from an analog
input velocity servo or a variable speed drive, all the way to a stepper drive
replacement, a master encoder follower, or stand-alone position indexer.
With the ULTRA drives, you also have the option to simplify your system
by using DeviceNet (ULTRA 100 only) and indexing. The DeviceNet option
allows you to reduce wiring and installation expenses, operate with other
manufacturer’s components, rapidly troubleshoot, and modify individual
parameters remotely via the network. The Indexing feature allows you to
obtain performance and flexibility where complex motion control systems
are not cost-effective.
It doesn’t matter how many different kinds of motors or drives are on your
machine or in your plant – AC or DC brushless servo drives, flux vector
drives, permanent magnet brushless motors, induction motors – the
ULTRA Series is the one drive that can do it all. No matter what application.
No matter what industry. No matter how you control it.
The Only Drive You’ll Ever Need
The ULTRA Series of drives is more than just the one drive for all your
applications. It’s also the one drive for just about any type of controller.
With the click of a mouse, the ULTRA Series can be configured for almost
any controller. With its high-resolution, 16-bit A/D converter, your drive is
ready for precise control as an analog input drive for high-performance servo
applications. Click again and it can accept standard digital step and direction
inputs from an indexer, giving you a high-power, high-performance alternative
to a stepper drive without having to replace or re-program your controller. And
with its built-in pre-set speeds and digital I/O functions, you can also use the
ULTRA Series to control an induction motor as a variable speed drive. The
 ULTRA Standardization

Minimize Maintenance and Training Costs

Standardizing on ULTRA Series drives for all your applications means
greater flexibility and less wear and tear on your most important asset –
your people. The efficient, point and click interface means all your
maintenance, engineering and production people quickly understand and
support all your drives. And that means fewer maintenance headaches and
more time for your machines, which saves you money.

Decrease Inventory Requirements

Common cables and accessories for the ULTRA Series reduce inventory
requirements. With ULTRA Series drives on your machines, you’ll have
less inventory on your shelves, fewer spare parts to track, fewer manuals
to read through, and less risk of not having the right spare part when you
need it.

Minimize Life Cycle Costs

When it comes to motion control systems, installation, training and
maintenance expenses can cost more than the drive.
The ULTRA Series drives are easy to set-up and even easier to maintain.
The Windows-based ULTRA Master software comes with a complete set
of troubleshooting and diagnostic tools, all just a point and click away.
That makes commissioning all the drives in your shop faster, easier and
less expensive.
With its surface mount electronics, all digital design (no pots to tweak or
drift out of tune) and use of highly integrated custom ASIC’s and
Intelligent Power Modules (IPM’s), there are fewer things to go wrong. In
addition, the ULTRA Series is UL and cUL listed and CE marked, so it
meets the international requirements you need for a global product solution.
The ULTRA Series – the new standard for motion control. 3
 ULTRA Series

The ULTRA Series is a family of single axis digital servo and positioning
servo drives designed to offer flexibility and performance for a wide range
of applications. The ULTRA 100 and 200 Digital Servo Drives offer drive
users new versatility and ease of use. Drive setup, commisioning, and
troubleshooting are quickly accomplished using the Windows-based ULTRA
Master software. The ULTRA Plus Positioning Servo Drives combine control
and drive to create a powerful single axis motion controller. Application
programming, commisioning, and troubleshooting are done with the graphical,
Windows-based GML™ ULTRA software.

ULTRA Series Digital Servo Drives

There are two powerful members of the ULTRA Series Digital Servo Drive
family, the ULTRA 100 and the ULTRA 200. They share standard ULTRA Series
features but offer a choice of two package styles. The ULTRA 100 starts at 72 x 165
x 130 mm for 5 peak Amps, the ULTRA 200 at 104 x 360 x 227 mm for 10
peak amps.

Finally, a feature-rich,
high-performance drive
you can depend on.

All ULTRA Series drives are designed and manufactured for peak performance,
rugged reliability, and unmatched versatility.

4
 ULTRA Series Digital Servo Drives

ULTRA 100 (5, 9, and 19 Peak Amps)

The ULTRA 100 is an easy-to-use, high-performance, digital servo drive in a
compact package. Reduced size, high-performance and low cost make the
ULTRA 100 an attractive solution for a wide variety of applications. In fact,
it’s ideal for stepper, stand-alone indexer, or standard velocity control servo
applications that require improved performance as well as those that would
benefit from closed loop technology. And it’s compatible with the entire
ULTRA Series family of drives.
ULTRA 200 (10, 20, 30, 75, and 150 Peak Amps)
The ULTRA 200 delivers full-featured flexibility and impressive power and
performance. Whether you need an analog input velocity servo, a variable
speed drive, a stepper drive replacement, or a master encoder follower, the
ULTRA Series is the one drive that can do it all.
• 230V AC single-phase input (single-phase or three-phase for the 75, and 150 Amp version)
• Internal or external resistive shunt (ULTRA 200); active external shunt (ULTRA 100)
• Built-in auxiliary AC input to power logic only (ULTRA 200)
• Built-in power supplies – no external source required except AC line (ULTRA 200)
• Drives either sinusoidal AC brushless or induction motors
• DC bus available externally for power leveling or use of shared power supplies
• Advanced processor design for improved velocity loop update rate, all digital
current, velocity and position loops
• Large-scale integration with custom ASIC’s and IPM’s for performance and liability
• 16-bit A/D for precise velocity command input (14-bit on ULTRA 100)
• Flash memory for simple field upgrades
• Removable personality module to store set-up parameters and simplify
drive replacement
• Reduced component count for reliability
• Internally shielded filters for electromagnetic compatibility (EMC)
• 4 dedicated I/O plus 8 user-programmable (ULTRA 200), or 3 dedicated and
6 user-programmable (ULTRA 100) optically isolated digital inputs and outputs
(sourcing/active high)
• Analog inputs for external current limit (2 ULTRA 200, 1 ULTRA 100)
• Analog outputs for variable monitoring or torque sharing (2 ULTRA 200,
1 ULTRA 100)
• Serial connectors to simplify RS485 multi-dropping and host communications
• Choice of command source:
• +/- 10V analog input
• step/direction input (also step up/step down) with electronic gearing
• auxiliary master encoder input with electronic gearing
• 8 preset speeds/torques selected via 3 digital input lines
• RS232/485 commands
• 8 preset index via 3 digital input lines
• DeviceNet
• Scalable motor encoder output
5
• UL, cUL listed and CE marked

ULTRA Master’s easy-to-use, Windows-
based interface reduces your learning
curve and makes setup, diagnostics and
tuning a snap.
ULTRA Master puts a full array of
Windows-based productivity tools right
at your fingertips.
6
ULTRA Master Software - Pure Productivity
When you standardize on the ULTRA Series of universal drives, you’re also
standardizing on ease-of-use. ULTRA Master software is an intuitive,
Windows™-based interface that comes complete with online help and quick
startup windows that simplify your setup.
But ULTRA Master is more than just a configuration tool. It also comes with
powerful, field-tested productivity tools such as:
• On-screen digital oscilloscope for fast tuning and diagnosis
• A full array of on-screen meters and other software tools for rapid debugging
and measurement
• Instant access to critical information with complete online help
• Diagnostic and setup tools to make system integration a snap
ULTRA Master even keeps error messages in its own non-volatile message
buffer, making tracking down what went wrong effortless.
ULTRA Master software means there’s only one interface to learn, only one set
of diagnostic tools to remember, and only one name to call when you do need
help. So you save time, reduce your learning curve, and simplify the integration
and debugging of your system. And that means fewer maintenance headaches,
less downtime, and a lower life cycle cost for all your drives.
Easy Maintenance Puts Your Process
Back On Track - Instantly
Even the best drives need some attention from time to time. By standardizing on
the ULTRA Series, when you do have to service a drive, you’re sure to have the
replacement up and running in no time. With ULTRA Master software, you’re
always just a point and click away from downloading all your replacement
drive’s setup parameters – all without making a single adjustment. Or, when you
need an alternative to the powerful ULTRA Master software, the ULTRA Series
drives also use a replaceable, nonvolatile personality module. Parameters can be
quickly transferred to the replacement drive without a
PC, just by swapping a chip. Which means your off-
the-shelf drive performs exactly like your old
drive. So your machine, your process, and
your people are back up and
running in no time – exactly
as before.
 A Drive Smart Enough To Protect Itself

The unexpected can happen in any application. That’s where a drive smart
enough to monitor critical parameters can make the difference between an
unexpected shutdown and catastrophic machine failure.
The ULTRA Series drives are designed from the start to protect themselves
and your machine against the unexpected. Built-in short circuit protection
(phase-to-phase and phase-to-ground), overcurrent, overvoltage, and
overtemperature protection all safeguard your system.

The TouchPad Gives You Full

Strength Control – Right at
the Machine
The optional TouchPad interface
device gives you all the power and
flexibility of the ULTRA Master
software on a removable compact
display – right on the drive. The menu
structure and on-screen prompts mirror
the ULTRA Master software, so there’s
no extra learning curve for the
TouchPad. You can leave TouchPads
plugged into the ULTRA Series drives
for continuous instant access or plug
them into operating drives as needed to
monitor parameters and make on-the-
ULTRA Master built-in protection circuitry can mean the difference between an fly adjustments.
orderly shutdown and an uncontrolled breakdown. The TouchPad is perfect for
maintenance people, engineers, or
anyone who has to troubleshoot or
configure a drive and wants a compact
No Drive is An Island alternative to the ULTRA Master
software.

Host Language Connectivity Keeps Your Drives Connected

The ULTRA Series host language connectivity provides the communication
link between your drives and PLC®’s, PC’s, or smart controllers – anything
that can access and communicate over a fast RS232/485 serial connection.
The host language gives you remote access to all drive parameters – setup
values, tuning, custom scaling, diagnostics, and allows on-the-fly changes
including real time velocity or torque commands – just as if you were there.
With ULTRA Series host language you can quickly and easily download or
upload drive personality data – instantly transforming your new drive without
downtime or additional setup.
7

Intelligent Power Modules (IPM’s)
make the ULTRA Series tough enough
for your application.
Standardizing on the ULTRA Series
means all your drives share the same
cables and accessories.
8 you to meet the European Community’s Machinery Directive.
Proven Reliability
The ULTRA Series of versatile drives is designed for the brutal environments
that tough drives have to endure. That’s why the ULTRA Series makes
extensive use of large scale integration both on the lower side with third
generation Intelligent Power Modules (IPM’s) and with high density custom
ASIC’s (Application Specific Integrated Circuits) for low component count
reliability.
We put our drives through rigorous environmental chamber testing for vibration,
shock, humidity, and temperature as well as an extensive array of electrical and
performance tests to ensure the drive you put on your machine will do the job,
year after year. Allen-Bradley products endure extensive thermally-cycled life
testing for a minimum of 20,000 hours under aggressive conditions rarely seen
on a real machine.
Standardized Cables and Accessories
When it comes to motion control systems, efficient commissioning and superior
uptime are a direct result of simple, easy to understand interconnects and
integrity in every component. You'll find that using the standardized cables and
accessories designed specifically for the ULTRA Series means fewer problems,
more efficient operation, less downtime, and quicker troubleshooting. We've
taken great care to ensure that ULTRA Series accessories provide
unquestionably sound connections, long life, and superior performance. So
design for success from start to finish, use only ULTRA Series cables and
accessories.
A Global Commitment to Excellence
The ULTRA Series of universal drives is
designed for global markets to meet
global standards. Extensive laboratory
testing against stringent requirements
earned the ULTRA Series UL and cUL
listings, as well as the CE mark for
compliance with the European directives
for low voltage and electromagnetic
compatibility (EMC). All ULTRA Series
drives are hardened against the
electrically noisy environments typical
of industrial applications, positioning
 Motors and the ULTRA Series

H-Series – Low Inertia Brushless Servo Motors

H-Series motors use a Neodymium-iron-boron magnet to provide low inertias
and high accelerations. Available in five frame sizes, the H-Series motors range
in continuous torque capability from 5 to 450 lb-in (0.5 to 50 Nm) and speeds
up to 6000 rpm. The H-Series motors use an optical 2000-line incremental
encoder with the 5000-line option for superior low speed performance with the
ULTRA Series. Typical applications for the H-Series include smart conveyors,
packaging machinery, material feeding, pick-and-place machines and high
duty cycle applications. An extruded aluminum housing and environmental
connectors create an IP65 design ready for the toughest environments.

F-Series – Medium Inertia Brushless Servo Motors The ULTRA Series offers the unique
F-Series motors, mechanically interchangeable with the H-Series, use a Ferrite flexibility to operate a wide variety
magnet that provides nearly four times greater inertia than the H-Series family of motors so you can optimize the
for matching larger load inertias. Available in two frame sizes, the F-Series motor/drive system for your
motors range in continuous torque capability from 31 lb-in to 245 lb-in application. Through ULTRA Master
or the optional TouchPad, a standard
(3.5 to 28 Nm) and speeds up to 4000 rpm. The F-Series motors use an
motor file can be selected with the
optical 2000-line incremental encoder with a 5000-line option for superior
click of the mouse or the push of a
low speed performance with the ULTRA Series. Typical applications for the
button. The drive then automatically
F-Series include Web processing, machine tool, textile machinery and CAM configures itself to the specific motor
replacements. An extruded aluminum housing and environmental connectors parameters. The motors and
create an IP65 design ready for the toughest environments. connectors have been designed so your
system will meet UL, cUL and CE
requirements. Additionally, the ULTRA
Y-Series – Small, Low Inertia Brushless Servo Motors
Series is capable of operating a custom
Y-Series motors, available in either 115V or 230V windings, use a high
motor by entering the motor data in the
energy Neodymium magnet that provides low inertias for fast acceleration.
ULTRA Master custom motor file.
Available in three popular metric frame sizes, the Y-Series motors range in These motors are available in a wide
continuous torque capability from 1.5 lb-in to 22 lb-in (.17 to 2.5 Nm) and variety of inertias, torque and
speeds up to 4500 rpm. Their outstanding torque-to-size ratios make the mounting schemes.
Y-Series a powerful combination with the ULTRA 100. Typical applications
for the Y-Series include robotics, material handling, X-Y tables, specialty
machinery and semiconductor manufacturing. The Y-Series motors offer
the flexibility of either 115 or 230V windings.

N-Series – NEMA Style Brushless Servo Motors

N-Series motors use a high energy ring magnet rotor construction for
outstanding torque-to-size ratio. Available in four common NEMA style
frame sizes, N-Series motors matched with an ULTRA Series drive create
a high performance alternative to stepper systems. The nine motors in the
N-Series family range in continuous torque capability from 1.6 lb-in to
47 lb-in (.18 to 5.3 Nm) and speeds up to 7000 rpm. Typical applications
for the N-Series include Web processing, machine tool, textile machinery
and CAM replacements. An extruded aluminum housing and environmental
connectors create an IP65 design ready for the toughest environments. 9
 ULTRA DeviceNet and Indexing – Powerful Automation Features
Features of the ULTRA 100 with
DeviceNet are:
• Status LEDs for easy local assessment
of module and network status
• Rotary selector switches for setting
node address and network status
• Standard Network Connection using
a pluggable terminal block
• Unconnected Message Manager
(UCMM) for dynamically
establishing both explicit messaging
and I/O connections
• Support for the Open DeviceNet
Vendor Association (ODVA),
Release 2.0
Three different types of indexing moves
are available:
• Incremental–a distance move that
executes relative to the current position motion control systems were just not cost effective. ULTRA indexing drives
• Registration–a distance move that
executes relative to the registration
sensor digital input
• Absolute–a position move that executes
in reference to the home position
The indexing drives provide maximum
flexibility by allowing the user to define
the following parameters for each
individual index:
• Index Type
• Distance (position)
• Batch count
• Action when complete
• Registration distance
• Velocity
• Acceleration
• Deceleration
• Dwell time
10
ULTRA 100 with DeviceNet
The ULTRA 100 with DeviceNet gives you the ability to easily integrate
low-cost motion control capabilities into applications where DeviceNet is
already used. DeviceNet, an open, low-cost network based on Controller
Area Network (CAN) technology, is a device-level network that can connect
individual components, such as drives, switches, and operator panels. The
ULTRA 100, with the factory installed DeviceNet option, provides all of the
basic ULTRA 100 features, and can be remotely commissioned, tuned, and
re-programmed on the fly from any compatible control, such as a PLC.
Benefits of the ULTRA 100 with Industry Applications
DeviceNet are: Include:
• Simplified commissioning • Web processing
• Remote programming on the fly • Material Handling
• Reduced wiring needs • Robotics
• Simplified open network connection • Textile Machinery
• Rapid troubleshooting and
equipment repair
• Interoperability with a wide range
of other DeviceNet-capable
components
ULTRA 100 / ULTRA 200 with Indexing
If your application requires simple point-to-point positioning, the ULTRA
drives can simplify your solution. With ULTRA indexing, you can obtain
performance and flexibility in applications where, in the past, full-function
have positioning capability that allows you to do simple indexing moves
without the need for a complex motion controller. Indexing functionality
allows the drive to execute up to eight different trapezoidal position moves
initiated by the use of digital I/O or Touchpad.
The indexing feature also includes user-defined routines that allow the user to
select one of three different homing sequences to satisfy their application:
• Home to sensor/then marker
• Home to marker
• Home to sensor
When combined with the DeviceNet option or host command, an unlimited
number of indexing moves can be performed. DeviceNet provides the ability
to access all parameters remotely.
 ULTRA Series Specifications

General ULTRA 100 ULTRA 200

Catalog number (1398-DDM-XXX) DDM-005 DDM-009 DDM-019 DDM-010 DDM-020 DDM-030 DDM-075 DDM-075 DDM-150
1ø input 3ø input
Peak Output Current (Amps) 7.5 15 30 10 20 30 50 75 150
Continuous Output Current (Amps) 2.5 5 10 5 10 15 15 35 65
Continuous Output Power (kW) 0.5 1.0 2.0 1.0 2.0 3.0 3.0 7.0 15
Continuous Shunt Power (Built-in Resistor) – – – 50W 50W 50W 50W 50W 180W
Peak Shunt Power (Built-in Resistor) – – – 4.5 kW 4.5 kW 4.5 kW 10 kW 10 kW 18 kW
Continuous Shunt Power (External Resistor) – – – 2.4 kW 2.4 kW 2.4 kW 4 kW 4 kW 8 kW
Peak Shunt Power (External Resistor) – – – 6.0 kW 6.0 kW 6.0 kW 10 kW 10 kW 19 kW
Active Shunt Module 300W 300W 300W – – – – – –
Peak Active Shunt Module 4kW 4 kW 4 kW – – – – – –

Power Input
Input voltage ■ 100 to 240VAC RMS nominal (88 to 265 volts) 1ø (1ø or 3ø for DDM-075)
Input Frequency ■ 47 – 63 Hz

Command Sources
Analog Velocity Input ■ +/- 10 volt, 16-bit resolution (14-bit on ULTRA 100)
Presets ■ 8 presets, binary selection by digital inputs
Step and Direction, Step Up/Step Down ■ 1 MHz maximum frequency
■ differential or single-ended line drivers
Master Encoder Following ■ 1 MHz maximum line frequency
■ Differential or single-ended line drivers
Digital Serial Commands ■ Via serial port and ULTRA Series host language

Communications
Serial
Type ■ RS-232, RS-485
Baud Rate ■ 1200 to 19,200
Multi-Drop Addressing ■ 0 to 10 via front panel rotary dip switch, 0 to 255 via software
DeviceNet
Connectivity ■ Standard Network Connection using a pluggable terminal block
Communication rates (baud) ■ 125 k per second, 250 k per second, 500 k per second

Control Loops
Modes ■ Torque, velocity and position control
Type ■ All loops digital
Position Loop ■ 1.0 msec update rate
Velocity Loop Bandwidth (Maximum) ■ 400 Hz ULTRA 200, 300 Hz ULTRA 100
Current Loop ■ 100 microsec update rate

Inputs and Outputs

Programmable Digital Inputs ■ 4 Optically isolated, 24V, active high for ULTRA 200, 3 for ULTRA 100
■ User programmable as: Drive Mode Select, Integrator Inhibit, Follower Enable, Forward Clamp, Reverse Clamp, Preset
Select, Analog Override
Programmable Digital Outputs ■ 4 Optically isolated, 24V, active high for ULTRA 200, 2 for ULTRA 100
■ User programmable as: In Position, Within Position Window, Zero Speed, Within Speed Window, At Speed, Current Limit,
Drive Enabled, Bus Charged, various fault indications
Dedicated Digital Inputs ■ Enable, Fault Reset, (Optically Isolated, 24V, active high)
Dedicated Relay Outputs ■ Ready, Not Faulted, Brake Output
Analog Inputs ■ 2 External Analog Current Limits, 0 to 10V for ULTRA 200, 1 for ULTRA 100
■ 10 bit resolution
Analog Outputs ■ 2 User programmable, +/- 10V for ULTRA 200, 1 for ULTRA 100
■ 12 bit and 8 bit resolution
Encoder Output ■ 1 MHz maximum line frequency
■ Differential line drivers
■ Scalable by 1, 2, 4, 8
Motor Feedback ■ Encoder

Connectors Environmental
Serial ■ 9 pin D-shell Storage Temperature ■ -40° C to 70° C
Control and Feedback ■ 20, 26 and 50 pin high density Mini D Operating Temperature ■ -5° C to 55° C
Power ■ Screw terminal block Humidity ■ 5% to 90% non-condensing
Altitude ■ 1500m / 5000 ft.
Vibration ■ 10 to 500 Hz at 2 g
Shock ■ 15 g 11 msec half sine
 World Class Motion Control with Worldwide Support

To put the ULTRA Series – along with any other Allen-Bradley motion control
equipment – to work for you, Allen-Bradley has a worldwide network of sales
and service engineers and authorized system integrators. Together, they offer
the industry’s broadest range of support services to help you implement your
motion control solution.

• Allen-Bradley Motion Control Area Managers are specialists in motion

control, CNC and servo drive technology. They have the expertise to
evaluate your application requirements and help you achieve the
optimum solution.

• The Allen-Bradley Global Technical Services offers application

engineering services, system startup, training, field service and ongoing
product support. They also offer an emergency HELP line – a 24-hour,
toll-free evaluation and service connection.

• Our network of authorized motion control system integrators can

provide complete integration services for new, retrofit or rebuild
requirements worldwide.

For more information on the ULTRA Series or any of our support services,
contact your nearest Allen-Bradley sales office or motion control distributor.

For more information refer to our web site: www.ab.com/motion

Publication 1398-1.0 Ñ March 1999

Supersedes 1398-1.0 Ñ July 1996 © 1998 Rockwell International Corporation. All Rights Reserved. Printed in USA.