ABB MicroFlex e100 e100 servo drive User's manual

MicroFlex e100 servo drive
Contents
Contents
1
General Information
2
Introduction
2.1
2.2
MicroFlex e100 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3
Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1
3
Identifying the catalog number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Basic Installation
3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
Mechanical installation and cooling requirements . . . . . . . . . . . . . 3-3
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.3
Front panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Top panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
MN1942
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Mounting and cooling the MicroFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Derating characteristic - 3 A model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Derating characteristic - 6 A model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Derating characteristic - 9 A model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Overtemperature trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Heat dissipation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.3.1
3.3.2
3.4
Power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tools and miscellaneous hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Other information needed for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Earthing / grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Earth leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Single-phase or three-phase power connections . . . . . . . . . . . . . . . . . . . . 3-14
Input power conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Power disconnect and protection devices. . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Recommended fuses, circuit breakers and wire sizes . . . . . . . . . . . . . . . . 3-17
Drive overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
24 V control circuit supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Contents i
3.5
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.6
Brake (regeneration) resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3.6.1
3.7
Required information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Braking energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Braking power and average power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Resistor choice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Resistor derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Resistor pulse load rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Duty cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
Feedback
4.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
5
Braking capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Brake resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
3.7.7
4
Motor circuit contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Motor power cable pin configuration - Baldor BSM rotary motors . . . . . . . .3-21
Motor cable pin configuration - Baldor linear motors . . . . . . . . . . . . . . . . . .3-22
Sinusoidal filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Thermal switch connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Motor brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Incremental encoder feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
BiSS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
SSI feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
SinCos feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
EnDat (absolute encoder) feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Input / Output
5.1
5.2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Digital I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
Drive enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
General purpose digital input DIN0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
General purpose digital inputs DIN1 & DIN2 . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Special functions on inputs DIN1 & DIN2. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
General purpose / status output DOUT0 . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
General purpose output DOUT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5.3
USB communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5.4
RS485 communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5.5
Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5.3.1
5.4.1
5.5.1
5.5.2
5.5.3
ii Contents
USB port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
RS485 port (2-wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Ethernet POWERLINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Ethernet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
MN1942
5.6
CAN interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.6.1
5.6.2
5.6.3
5.7
Other I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.7.1
5.8
6
Node ID selector switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Connection summary - recommended system wiring . . . . . . . . . 5-26
Configuration
6.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1
6.1.2
6.2
6.3
Starting MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.5
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Power on checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Configuring the TCP/IP connection (optional). . . . . . . . . . . . . . . . . . . . . . . . 6-4
Mint Machine Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.1
6.4
Connecting the MicroFlex e100 to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installing Mint WorkBench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Starting the MicroFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1
6.2.2
6.2.3
6.2.4
Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Further tuning - no load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Further tuning - with load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Optimizing the velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Performing test moves - continuous jog . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Performing test moves - relative positional move . . . . . . . . . . . . . . . . . . . . 6-22
Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.5.1
6.5.2
6.5.3
6.5.4
7
CAN connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
CAN wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
CANopen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Fine-tuning tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Parameters tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Spy window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Other tools and windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Troubleshooting
7.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1
7.1.2
7.1.3
7.2
MicroFlex e100 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2.1
7.2.2
7.2.3
7.2.4
MN1942
Problem diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Power-cycling the MicroFlex e100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
STATUS LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
CAN LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
ETHERNET LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Contents iii
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
8
Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Mint WorkBench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Specifications
8.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.1.12
8.1.13
8.1.14
8.1.15
8.1.16
AC input power and DC bus voltage (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
24 V control circuit supply input (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Motor output power (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Braking (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Digital inputs - drive enable and DIN0 general purpose (X3). . . . . . . . . . . . .8-4
Digital inputs DIN1, DIN2 - high speed general purpose (X3) . . . . . . . . . . . .8-4
Digital outputs DOUT0, DOUT1 - status and general purpose (X3) . . . . . . .8-4
Incremental encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
BiSS interface (X8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
SSI encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
SinCos / EnDat encoder feedback option (X8) . . . . . . . . . . . . . . . . . . . . . . .8-6
Ethernet interface (E1 / E2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
CAN interface (OPT 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
RS485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Appendices
A Accessories
A.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1.1
A.1.2
A.1.3
A.1.4
A.1.5
A.2
Fan tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Footprint filter (single-phase only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 V power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
A-3
A-3
A-4
A-7
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
A.2.1
A.2.2
A.2.3
A.2.4
A.2.5
A.2.6
iv Contents
Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Feedback cable part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
SSI feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Encoder / Hall feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
BiSS, EnDat and SinCos feedback cables . . . . . . . . . . . . . . . . . . . . . . . . A-12
Ethernet cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
MN1942
B Control System
B.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.1.1
B.1.2
Servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Torque servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
C Mint Keyword Summary
C.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1.1
Keyword listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
D CE & UL
D.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
D.1.1
D.1.2
D.1.3
D.1.4
D.1.5
D.1.6
EMC Conformity and CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
MicroFlex e100 compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Use of CE compliant components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
EMC wiring technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
EMC installation suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Wiring of shielded (screened) cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
D.2
UL file numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
MN1942
Contents v
vi Contents
MN1942
General Information
1 General Information
LT0262A04
1
Copyright ABB (c) 2012. All rights reserved.
This manual is copyrighted and all rights are reserved. This document or attached software may not,
in whole or in part, be copied or reproduced in any form without the prior written consent of ABB.
ABB makes no representations or warranties with respect to the contents hereof and specifically
disclaims any implied warranties of fitness for any particular purpose. The information in this
document is subject to change without notice. ABB assumes no responsibility for any errors that may
appear in this document.
Mint™ and MicroFlex™ are registered trademarks of Baldor, a member of the ABB group.
Windows XP, Windows Vista and Windows 7 are registered trademarks of the Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.
MicroFlex e100 is UL listed; file NMMS.E128059.
ABB Ltd
Motion Control
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone:
+44 (0) 1454 850000
Fax:
+44 (0) 1454 859001
E-mail:
[email protected]
Web site:
www.abbmotion.com
See rear cover for other international offices.
MN1942
General Information 1-1
Product notice
Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are
controlled by this equipment. Improper use can cause serious or fatal injury.
Safety Notice
Intended use: These drives are intended for use in stationary ground based applications in industrial
power installations according to the standards EN60204 and VDE0160. They are designed for
machine applications that require variable speed controlled three-phase brushless AC motors. These
drives are not intended for use in applications such as:

Home appliances

Medical instrumentation

Mobile vehicles

Ships

Airplanes.
Unless otherwise specified, this drive is intended for installation in a suitable enclosure. The
enclosure must protect the drive from exposure to excessive or corrosive moisture, dust and dirt or
abnormal ambient temperatures. The exact operating specifications are found in section 8 of this
manual. The installation, connection and control of drives is a skilled operation, disassembly or repair
must not be attempted. In the event that a drive fails to operate correctly, contact the place of
purchase for return instructions.
Precautions
WARNING
Do not touch any circuit board, power device or electrical connection before you first
ensure that no high voltage is present at this equipment or other equipment to which it is
connected. Electrical shock can cause serious or fatal injury. Only qualified personnel
should attempt to start-up, program or troubleshoot this equipment.
The motor circuit might have high voltages present whenever AC power is applied, even
when the motor is not moving. Electrical shock can cause serious or fatal injury.
WARNING
WARNING
WARNING
WARNING
If a motor is driven mechanically, it might generate hazardous voltages that are
conducted to its power terminals. The enclosure must be earthed/grounded to prevent
possible shock hazard.
Be sure the system is properly earthed/grounded before applying power. Do not apply
AC power before you ensure that earths/grounds are connected. Electrical shock can
cause serious or fatal injury.
Be sure that you are completely familiar with the safe operation and programming of this
equipment. This equipment may be connected to other machines that have rotating parts
or parts that are controlled by this equipment. Improper use can cause serious or fatal
injury.
1-2 General Information
MN1942
WARNING
MEDICAL DEVICE / PACEMAKER DANGER: Magnetic and electromagnetic fields in the
vicinity of current carrying conductors and industrial motors can result in a serious health
hazard to persons with cardiac pacemakers, internal cardiac defibrillators,
neurostimulators, metal implants, cochlear implants, hearing aids, and other medical
devices. To avoid risk, stay away from the area surrounding a motor and its current
carrying conductors.
Be sure all wiring complies with the National Electrical Code and all regional and local
codes. Improper wiring may result in unsafe conditions.
CAUTION
CAUTION
CAUTION
The stop input to this equipment should not be used as the single means of achieving a
safety critical stop. Drive disable, motor disconnect, motor brake and other means
should be used as appropriate.
Improper operation or programming of the drive may cause violent motion of the motor
and driven equipment. Be certain that unexpected motor movement will not cause injury
to personnel or damage to equipment. Peak torque of several times the rated motor
torque can occur during control failure.
If the drive enable signal is already present when power is applied to the MicroFlex e100,
the motor could begin to move immediately.
CAUTION
CAUTION
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The metal heatsink on the left side of the MicroFlex e100 can become very hot during
normal operation.
When operating a rotary motor with no load coupled to its shaft, remove the shaft key to
prevent it flying out when the shaft rotates.
A brake resistor may generate enough heat to ignite combustible materials. To avoid fire
hazard, keep all combustible materials and flammable vapors away from the brake
resistors. Some brake resistors are neither internally fused nor thermally protected and
under extreme conditions, can cause a fire hazard if not suitably protected or rated for
the application
To prevent equipment damage, be certain that the input power has correctly sized
protective devices installed.
To ensure reliable performance of this equipment be certain that all signals to/from the
drive are shielded correctly.
Suitable for use on a circuit capable of delivering not more than the RMS symmetrical
short circuit amperes listed here, at the rated maximum voltage:
Horsepower
RMS Symmetrical Amperes
1-50
5,000
Avoid locating the drive immediately above or beside heat generating equipment, or
directly below water or steam pipes.
Avoid locating the drive in the vicinity of corrosive substances or vapors, metal particles
and dust.
NOTICE
MN1942
General Information 1-3
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Do not connect AC power to the drive terminals U, V and W. Connecting AC power to
these terminals may result in damage to the drive.
ABB does not recommend using “Grounded Leg Delta” transformer power leads that
may create earth/ground loops and degrade system performance. Instead, we
recommend using a four wire Wye.
Drives are intended to be connected to a permanent main power source, not a portable
power source. Suitable fusing and circuit protection devices are required.
The safe integration of the drive into a machine system is the responsibility of the
machine designer. Be sure to comply with the local safety requirements at the place
where the machine is to be used. In Europe these are the Machinery Directive, the
ElectroMagnetic Compatibility Directive and the Low Voltage Directive. In the United
States this is the National Electrical code and local codes.
Drives must be installed inside an electrical cabinet that provides environmental control
and protection. Installation information for the drive is provided in this manual. Motors
and controlling devices that connect to the drive should have specifications compatible to
the drive.
Failure to meet cooling air flow requirements will result in reduced product lifetime and/or
drive overtemperature trips.
Violent jamming (stopping) of the motor during operation may damage the motor and
drive.
Operating the MicroFlex e100 in Torque mode with no load attached to the motor can
cause the motor to accelerate rapidly to excessive speed.
Do not tin (solder) exposed wires. Solder contracts over time and may cause loose
connections. Use crimp connections where possible.
Electrical components can be damaged by static electricity. Use ESD (electrostatic
discharge) procedures when handling this drive.
If the drive is subjected to high potential (‘hipot’) testing, only DC voltages may be
applied. AC voltage hipot tests could damage the drive. For further information please
contact your local ABB representative.
Ensure that encoder wires are properly connected. Incorrect installation may result in
improper movement.
The threaded holes in the top and bottom of the case are for cable clamps. The holes are
11.5 mm deep and accept M4 screws, which must be screwed in to a depth of at least
8 mm.
Removing the cover will invalidate UL certification.
NOTICE
1-4 General Information
MN1942
Introduction
2 Introduction
2
2.1 MicroFlex e100 features
The MicroFlex e100 is a versatile brushless servo drive, providing a flexible and powerful
motion control solution for rotary and linear motors. Standard features include:
Single axis AC brushless drive.
Range of models with continuous current ratings of 3 A,
6 A or 9 A.
 Direct connection to 115 V AC or 230 V AC singlephase or 230 V AC three-phase supplies.
 Universal feedback interface supporting incremental
encoder, BiSS, SSI, EnDat or SinCos feedback.
 Position, velocity and current control.
 Auto-tuning wizard (including position loop) and
software oscilloscope facilities provided by Mint
WorkBench configuration software.
 3 optically isolated general purpose digital inputs. Two
inputs have ‘fast input’ capability, providing real-time
position capture.
 1 optically isolated drive enable input.
 1 optically isolated general purpose digital output.
 1 optically isolated digital output to indicate error
conditions.
 USB 1.1 serial port (compatible with USB 2.0 and USB
3.0).
 CANopen protocol for communication with Mint
controllers and other third party CANopen devices.
 Ethernet POWERLINK & TCP/IP support: Twin Ethernet
ports with integrated hub for communication with host
PC or other Ethernet POWERLINK devices.
 Programmable in Mint.
MicroFlex e100 will operate with a large range of brushless rotary and linear servo motors. It
can also operate induction motors using closed-loop vector control. For information on
selecting Baldor servo motors, please see the sales brochure BR1202 available from your
local ABB representative.


This manual is intended to guide you through the installation of MicroFlex e100. The sections
should be read in sequence.
The Basic Installation section describes the mechanical installation of the MicroFlex e100,
the power supply connections and motor connections. The other sections require knowledge
of the low level input/output requirements of the installation and an understanding of
computer software installation. If you are not qualified in these areas you should seek
assistance before proceeding.
MN1942
Introduction 2-1
2.2 Receiving and inspection
When you receive your MicroFlex e100, there are several things you should do immediately:
1. Check the condition of the shipping container and report any damage immediately to the
carrier that delivered your MicroFlex e100.
2. Remove the MicroFlex e100 from the shipping container and remove all packing
material. The container and packing materials may be retained for future shipment.
3. Verify that the catalog number of the MicroFlex e100 you received is the same as the
catalog number listed on your purchase order. The catalog number is described in the
next section.
4. Inspect the MicroFlex e100 for external damage during shipment and report any damage
to the carrier that delivered your MicroFlex e100.
5. If MicroFlex e100 is to be stored for several weeks before use, be sure that it is stored in
a location that conforms to the storage humidity and temperature specifications shown in
section 8.1.15.
2.2.1 Identifying the catalog number
The MicroFlex e100 is available with different current ratings. The catalog number is marked
on the side of the unit. It is a good idea to look for the catalog number (sometimes shown as
ID/No:) and write it in the space provided here:
Catalog number:
MFE_____________________________
Installed at: ______________________________________
Date: _____________
A description of a catalog number is shown here, using the example MFE230A003x:
Meaning
Alternatives
MFE
MicroFlex e100 family
-
230
Requires an AC supply voltage of 115-230 Volts, 1Φ or 3Φ -
A003
x
Continuous current rating of 3 A
A006=6 A; A009=9 A
A letter indicating the hardware revision.
This does not affect the capabilities of the MicroFlex e100
unless otherwise stated.
2-2 Introduction
MN1942
2.3 Units and abbreviations
The following units and abbreviations may appear in this manual:
V . . . . . . . . . . . . . . . .Volt (also V AC and V DC)
W . . . . . . . . . . . . . . .Watt
A . . . . . . . . . . . . . . . .Ampere
Ω . . . . . . . . . . . . . . . .Ohm
μF . . . . . . . . . . . . . . .microfarad
pF . . . . . . . . . . . . . . .picofarad
mH . . . . . . . . . . . . . .millihenry
Φ . . . . . . . . . . . . . . . .phase
ms . . . . . . . . . . . . . . .millisecond
μs . . . . . . . . . . . . . . .microsecond
ns . . . . . . . . . . . . . . .nanosecond
mm . . . . . . . . . . . . . .millimeter
m . . . . . . . . . . . . . . . .meter
in . . . . . . . . . . . . . . . .inch
ft . . . . . . . . . . . . . . . .feet
lbf-in . . . . . . . . . . . . .pound force inch (torque)
N·m . . . . . . . . . . . . . .Newton meter (torque)
ADC . . . . . . . . . . . . .Analog to Digital Converter
ASCII . . . . . . . . . . . .American Standard Code for Information Interchange
AWG . . . . . . . . . . . . .American Wire Gauge
CAL . . . . . . . . . . . . . .CAN Application Layer
CAN . . . . . . . . . . . . .Controller Area Network
CDROM . . . . . . . . . .Compact Disc Read Only Memory
CiA . . . . . . . . . . . . . .CAN in Automation International Users and Manufacturers Group e.V.
CTRL+E . . . . . . . . . .on the PC keyboard, press Ctrl then E at the same time.
DAC . . . . . . . . . . . . .Digital to Analog Converter
DS301 . . . . . . . . . . . .CiA CANopen Application Layer and Communication Profile
DS401 . . . . . . . . . . . .CiA Device Profile for Generic I/O Devices
DS402 . . . . . . . . . . . .CiA Device Profile for Drives and Motion Control
DS403 . . . . . . . . . . . .CiA Device Profile for HMIs
EDS . . . . . . . . . . . . .Electronic Data Sheet
EMC . . . . . . . . . . . . .Electromagnetic Compatibility
EPL . . . . . . . . . . . . . .Ethernet POWERLINK
HMI . . . . . . . . . . . . . .Human Machine Interface
ISO . . . . . . . . . . . . . .International Standards Organization
Kbaud . . . . . . . . . . . .kilobaud (the same as Kbit/s in most applications)
LCD. . . . . . . . . . . . . .Liquid Crystal Display
Mbps . . . . . . . . . . . . .megabits/s
MB . . . . . . . . . . . . . .megabytes
MMC . . . . . . . . . . . . .Mint Machine Center
(NC) . . . . . . . . . . . . .Not Connected
RF . . . . . . . . . . . . . . .Radio Frequency
SSI . . . . . . . . . . . . . .Synchronous Serial Interface
TCP/IP . . . . . . . . . . .Transmission Control Protocol / Internet Protocol
UDP . . . . . . . . . . . . .User Datagram Protocol
MN1942
Introduction 2-3
2-4 Introduction
MN1942
Basic Installation
3 Basic Installation
3
3.1 Introduction
You should read all the sections in Basic Installation to ensure safe installation.
This section describes the mechanical and electrical installation of the MicroFlex e100 in the
following stages:

Location considerations

Mounting the MicroFlex e100

Connecting the AC power supply

Connecting the 24 V DC control circuit supply

Connecting the motor

Installing a brake resistor

Connecting the feedback device
These stages should be read and followed in sequence.
3.1.1 Power sources
A 115 - 230 V AC power source (IEC1010 over-voltage category III or less) in the installation
area is required. This may be single-phase or three-phase. An AC power filter is required to
comply with the CE directive for which the MicroFlex e100 was tested (see section 3.4.8).
The 24 V DC control circuit supply must be a regulated power supply with a continuous
current supply capability of 1 A (4 A power on surge).
3.1.2 Hardware requirements
The components you will need to complete the basic installation are:

24 V DC power supply.

AC power supply filter (for CE compliance).

The motor that will be connected to the MicroFlex e100.

A motor power cable.

An incremental encoder feedback cable, SSI cable, or BiSS / EnDat / SinCos cable.
A separate Hall cable might also be required for linear motors.

A USB cable.

(Optional) A brake resistor might be required, depending on the application. Without the
brake resistor, the drive may produce an overvoltage fault. All MicroFlex e100 models
have overvoltage sensing circuitry. Brake resistors may be purchased separately - see
Appendix A.

A cooling fan may be required to allow operation of the MicroFlex e100 at full rated
current (see section 3.2.2).
MN1942
Basic Installation 3-1

A PC that fulfills the following specification:
Minimum specification
Processor
1 GHz
RAM
512 MB
Hard disk space
CD-ROM
2 GB
A CD-ROM drive
USB port
or
Ethernet* port
Serial port
Screen
1024 x 768, 16-bit color
Mouse
A mouse or similar pointing device
Operating
system
Windows XP or newer, 32-bit or 64-bit
* The Ethernet configuration used by a normal office PC is not suitable for direct
communication with the MicroFlex e100. It is recommended to install a separate dedicated
Ethernet adapter in the PC, which can be configured for use with the MicroFlex e100. See
section 6.2.4.
3.1.3 Tools and miscellaneous hardware

Your PC operating system user manual might be useful if you are not familiar with
Windows.

Small screwdriver(s) with a blade width of 3 mm or less for connector X1, and 2.5 mm
(1/10 in) or less for connector X3.

M5 screws or bolts for mounting the MicroFlex e100.
3.1.4 Other information needed for installation
This information is useful (but not essential) to complete the installation:

The data sheet or manual provided with your motor, describing the wiring information of
the motor cables/connectors.

Knowledge of whether the digital input signals will be ‘Active Low’ or ‘Active High’.
3-2 Basic Installation
MN1942
3.2 Mechanical installation and cooling requirements
It is essential that you read and understand this section before beginning the
installation.
To prevent equipment damage, be certain that the input power has correctly
rated protective devices installed.
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To prevent equipment damage, be certain that input and output signals are
powered and referenced correctly.
To ensure reliable performance of this equipment be certain that all signals to/
from the MicroFlex e100 are shielded correctly.
Avoid locating the MicroFlex e100 immediately above or beside heat generating
equipment, or directly below water steam pipes.
Avoid locating the MicroFlex e100 in the vicinity of corrosive substances or
vapors, metal particles and dust.
Failure to meet cooling air flow requirements will result in reduced product
lifetime and/or drive overtemperature trips.
NOTICE
The safe operation of this equipment depends upon its use in the appropriate environment.
The following points must be considered:












MN1942
The MicroFlex e100 must be installed indoors, permanently fixed and located so that it
can only be accessed by service personnel using tools.
The maximum suggested operating altitude is 1000 m (3300 ft).
The MicroFlex e100 must be installed where the pollution degree according to IEC664
shall not exceed 2.
The 24 V DC control circuit supply must be installed so that the 24 V DC supplied to the
unit is isolated from the AC supply using double or reinforced insulation.
The input of the control circuit must be limited to Safety Extra Low Voltage circuits.
Both the AC supply and the 24 V DC supply must be fused.
The atmosphere must not contain flammable gases or vapors.
There must not be abnormal levels of nuclear radiation or X-rays.
To comply with CE directive 89/336/EEC an appropriate AC filter must be installed.
The MicroFlex e100 must be secured by the slots in the flange. The protective earth/
ground (the threaded hole on the top of the MicroFlex e100) must be bonded to a safety
earth/ground using either a 25 A conductor or a conductor of three times the peak
current rating - whichever is the greater.
The threaded holes in the top and bottom of the case are for cable clamps. The holes are
threaded for M4 bolts no longer than 11 mm (0.43 in) in length.
The D-type connectors on the front panel of the MicroFlex e100 are secured using two
hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is removed
accidentally or lost it must be replaced with a #4-40 UNC jack screw with an external
male threaded section no longer than 10 mm (0.4 in).
Basic Installation 3-3
3.2.1 Dimensions
80
(3.2)
63.5
(2.5)
5
(0.2)
6
(0.24)
11
(0.4)
Mounting hole and slot detail
180
(7.1)
167.7
(6.6)
5.5 mm
Dimensions shown as: mm (inches).
6
(0.24)
Depth: 157 mm (6.2 in)
Weight: 3A: 1.45 kg (3.2 lb)
6A: 1.50 kg (3.3 lb)
9A: 1.55 kg (3.4 lb)
Figure 1: Mounting and overall dimensions
3-4 Basic Installation
MN1942
3.2.2 Mounting and cooling the MicroFlex e100
Ensure you have read and understood the Mechanical installation and location requirements
in section 3.2. Mount the MicroFlex e100 vertically on its rear side, the side opposite the front
panel. M5 bolts or screws should be used to mount the MicroFlex e100. Detailed dimensions
are shown in section 3.2.1.
For effective cooling, the MicroFlex e100 must be mounted upright on a smooth vertical
metal surface. The MicroFlex e100 is designed to operate in an ambient temperature of 0 °C
to 45 °C (32 °F to 113 °F). Output current must be derated between 45 °C (113 °F) and the
absolute maximum ambient temperature of 55 °C (131 °F). Within the ambient temperature
range:
The 3 A model is designed to operate without any additional cooling methods.
The 6 A and 9 A models require a forced air flow, passing vertically from the bottom to the
top of the MicroFlex e100 case, to allow full rated current at 45 °C (113 °F).
Temperature derating characteristics are shown in sections 3.2.3 to 3.2.5.
Note: Failure to meet cooling air flow requirements will result in reduced product lifetime and/or drive overtemperature trips. It is recommended to check periodically
the operation of the cooling equipment. Optional fan tray FAN001-024, mounted
exactly as shown in section A.1.1., ensures that correct cooling is provided and
allows the MicroFlex e100 to be UL listed.
Metal backplane
Hot
The proximity of the MicroFlex e100 to other
components could affect cooling efficiency. If
the MicroFlex e100 is mounted beside another
MicroFlex e100 (or other obstruction), there
should be a minimum space of 15 mm to
maintain effective cooling.
15 mm
If the MicroFlex e100 is mounted above or
below another MicroFlex e100 (or other
obstruction), there should be a minimum space
of 90 mm to maintain effective cooling.
Remember that when a MicroFlex e100 is
mounted above another MicroFlex e100 or heat
source, it will be receiving air that has been
already heated by the device(s) below it.
Multiple MicroFlex e100 units mounted above
each other should be aligned, not offset, to
promote air flow across the heatsinks.
It is recommended to allow approximately
60 mm at the front to accommodate wiring and
connectors.
90 mm
15 mm
Cool
Forced air flow
The derating characteristics assume the
MicroFlex e100 is mounted on 3 mm thick (or
less) metal plate. If the MicroFlex e100 is
mounted on 10 mm plate then the current
characteristics shown in sections 3.2.3 to 3.2.5
may be increased by up to 7% if there is no
forced air cooling, or 15% if forced air cooling is
present.
Warm
3.2.2.1 Effects of mounting surface and proximity
Fan
Fan
Figure 2: Cooling and proximity
MN1942
Basic Installation 3-5
3.2.3 Derating characteristic - 3 A model
The following derating characteristics are for model MFE230A003.
Single-phase AC supply
Rated output current (Arms)
1m/s forced air
Natural cooling
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
1m/s forced air
Natural cooling
Ambient temperature (°C)
Notes:
Load power factor = 0.75
Overload limit for model MFE230A003 is 6 A
3-6 Basic Installation
MN1942
3.2.4 Derating characteristic - 6 A model
The following derating characteristics are for model MFE230A006.
Single-phase AC supply
Rated output current (Arms)
1.5m/s forced air
1m/s forced air
Natural cooling
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
1.5m/s forced air
1m/s forced air
Natural cooling
Ambient temperature (°C)
Notes:
Load power factor = 0.75
Overload limit for model MFE230A006 is 12 A
MN1942
Basic Installation 3-7
3.2.5 Derating characteristic - 9 A model
The following derating characteristics are for model MFE230A009.
Single-phase AC supply
Rated output current (Arms)
3.5m/s forced air
2.5m/s forced air
1.5m/s forced air
1m/s forced air
Natural cooling
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
3.5m/s forced air
2.5m/s forced air
1.5m/s forced air
1m/s forced air
Natural cooling
Ambient temperature (°C)
Notes:
Load power factor = 0.78
Overload limit for model MFE230A009 is 18 A
3.2.6 Overtemperature trips
The MicroFlex e100 contains internal temperature sensors that will cause it to trip and
disable if the temperature exceeds 80 °C on the 3 A model, or 75 °C on the 6 A and 9 A
models. This limit can be read using the TEMPERATURELIMITFATAL keyword - see the Mint
help file for details.
3-8 Basic Installation
MN1942
3.2.7 Heat dissipation
The MicroFlex e100 emits heat during normal operation. The installation cabinet must
provide sufficient ventilation to maintain the air temperature within the operating limits of all
components in the cabinet. The power dissipation of the MicroFlex e100 can be calculated
from the following formulae:
P out =
3  V out  I out  0.85
where the DC bus voltage Vout = 305 V DC with a single phase AC supply or 321 V DC with
a three phase AC supply. Iout is the nominal output phase current (see section 8.1.3) and
0.85 is a typical power factor.
P in = P out  0.95
where 0.95 is the typical drive efficiency.
P diss = P in – P out
These formulae provide the figures shown in Table 1:
Heat dissipation (Pdiss)
MicroFlex e100
catalog number
AC input: 1Φ
W
BTU / hr
MFE230A003
50
172
MFE230A006
101
343
MFE230A009
151
515
Table 1: Typical heat dissipation at rated output current
MN1942
Basic Installation 3-9
3.3 Connector locations
3.3.1 Front panel connectors
LEDs
X1 Power
The STATUS, CAN and ETHERNET
LEDs are described in section 7.2.1.
Earth/Ground
Earth/Ground
(NC)
L1
AC Phase 1 / L
L2
AC Phase 2 / N
L3
ACPhase 3
U
Motor U
V
Motor V
W
Motor W
R1
Brake resistor
R2
Brake resistor
Node ID
These switches set the MicroFlex e100’s node ID
for Ethernet POWERLINK, and the final value of
the IP address when using TCP/IP. See sections
5.7.1 and 6.2.4.
USB
1 (NC)
2 Data3 Data+
4 GND
X6 RS485 port (2-wire)
1 TXA
2 TXB
3 GND
4 +7V out
5 (NC)
6 (NC)
X3 Input/Output
1 Status2 DGND
3 DOUT14 DIN25 DGND
6 DIN17 DIN08 DGND
9 Drive enable10 Shield
11 Status+
12 DGND
13 DOUT1+
14 DIN2+
15 DGND
16 DIN1+
17 DIN0+
18 DGND
19 Drive enable+
20 Shield
X8 Feedback In
X2 Control circuit power
0V
+24 V
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Shell
Incremental
CHA+
CHB+
CHZ+
Sense
Hall UHall U+
Hall VHall V+
CHACHBCHZ+5V out
DGND
Hall WHall W+
Shield
SinCos
(NC)
(NC)
(NC)
Sense
SinSin+
CosCos+
(NC)
(NC)
(NC)
+5V out
DGND
(NC)
(NC)
Shield
BiSS / SSI
Data+
Clock+
(NC)
Sense
(NC)
(NC)
(NC)
(NC)
DataClock(NC)
+5V out
DGND
(NC)
(NC)
Shield
EnDat
Data+
Clock+
(NC)
Sense
Sin-*
Sin+*
Cos-*
Cos+*
DataClock(NC)
+5V out
DGND
(NC)
(NC)
Shield
* EnDat v2.1 only. EnDat v2.2 does not use the
Sin and Cos signals
(NC) = Not Connected. Do not
make a connection to this pin
3-10 Basic Installation
Tightening torque for terminal block connections (X1 & X2) is 0.5-0.6 N·m
(4.4-5.3 lb-in). Maximum wire sizes: X1: 2.5 mm2; X3: 0.5 mm2. Connector
X3 is designed to accept bare wires only; do not use bootlace ferrules.
MN1942
3.3.2 Top panel connectors
OPT 1 CAN
1 (NC)
2 CAN3 CAN GND
4 (NC)
5 Shield
6 CAN GND
7 CAN+
8 (NC)
9 CAN V+
Ethernet
1 TX+
2 TX3 RX+
4 (NC)
5 (NC)
6 RX7 (NC)
8 (NC)
MN1942
Both connectors
have identical
pinouts.
Basic Installation 3-11
3.4 Power connections
This section provides instructions for connecting the AC power supply.
The installer of this equipment is responsible for complying with NEC (National Electric
Code) guidelines or CE (Conformite Europeene) directives and application codes that govern
wiring protection, earthing/grounding, disconnects and other current protection.
WARNING
Electrical shock can cause serious or fatal injury. Do not touch any power
device or electrical connection before you first ensure that power has been
disconnected and there is no high voltage present from this equipment or
other equipment to which it is connected.
MicroFlex e100 drives are designed to be powered from standard single and three-phase
lines that are electrically symmetrical with respect to earth/ground. The power supply module
within all MicroFlex e100 models provides rectification, smoothing and current surge
protection. Fuses or circuit breakers are required in the input lines for cable protection.
Note: A Residual Current Device (RCD) must not be used for fusing the drive.
An appropriate type of circuit breaker or fuse must be used.
All interconnection wires should be in metal conduits between the MicroFlex e100, AC power
source, motor, host controller and any operator interface stations. Use UL listed closed loop
connectors that are of appropriate size for the wire gauge being used. Connectors are to be
installed using only the crimp tool specified by the manufacturer of the connector.
3.4.1 Earthing / grounding
A permanent earth/ground bonding point is provided on the heatsink, which must be used as
the protective earth. It is labeled with the protective earth symbol in the casting and does not
form any other mechanical function.
Connector X1 contains earth terminals, but these must not be used as protective earth since
the connector does not guarantee earth connection first, disconnection last. Earthing
methods are shown in section 3.4.3.
Note: When using unearthed/ungrounded distribution systems, an isolation transformer with an earthed/grounded secondary is recommended. This provides
three-phase AC power that is symmetrical with respect to earth/ground and can
prevent equipment damage.
3-12 Basic Installation
MN1942
3.4.2 Earth leakage
Maximum earth leakage from the MicroFlex e100 is 3.4 mA per phase (230 V, 50 Hz supply).
This value does not include the earth leakage from the AC power filter, which could be much
larger (see section A.1.4).
If the MicroFlex e100 and filter are mounted in a cabinet, the minimum size of the protective
earthing conductor shall comply with the local safety regulations for high protective earthing
conductor current equipment. The conductor must be 10 mm2 (copper), 16 mm2 (aluminium),
or larger to satisfy EN61800-5-1.
3.4.2.1 Protection class
User protection has been achieved using Protective Class I (EN61800-5-1, 3.2.20), which
requires an earth connection to the unit whenever hazardous voltages are applied. The
equipment provides protection against electric shock by:

Means of connection of protective earth to accessible live conductive parts.

Basic insulation.
MN1942
Basic Installation 3-13
3.4.3 Single-phase or three-phase power connections
Location
Connector X1
(Mating connector:
Phoenix COMBICON
MSTB 2,5HC/11-ST-5,08)
Nominal input voltage 115 V AC or 230 V AC, 1Φ or 3Φ line to line
Minimum input voltage 105 V AC, 1Φ or 3Φ line to line (see Note*)
Maximum input voltage 250 V AC, 1Φ or 3Φ line to line
Note: * The MicroFlex e100 will operate at lower input voltages, although performance
could be impaired. The drive will trip if the DC-bus voltage falls below 50 V or
60% of the no-load voltage, whichever occurs first.
For three phase supplies, connect supply to L1, L2 and L3 as shown in Figure 3. For single
phase supplies, connect the supply and neutral to any two line inputs, for example L1 and
L2.
For CE compliance, an AC filter must be connected between the AC power supply and the
MicroFlex e100. If local codes do not specify different regulations, use at least the same
gauge wire for earth/ground as is used for L1, L2 and L3.
Tightening torque for terminal block connections is 0.5-0.6 N·m (4.4-5.3 lb-in). The threaded
hole in the top and bottom of the case may be used as an additional functional earth/ground
connection for signals on connector X3. They may also be used to attach shield or strain
relief clamps. The holes are threaded for M4 bolts no longer than 11 mm (0.43 in) in length.
AC
Supply
Route L1, L2, L3 and
earth/ground together
in conduit or cable
Circuit breaker or fuses.
See section 3.4.5
AC filter.
See section
3.4.8
Connect earth/
ground to
protective earth
on top of drive
Line (L1)
Line (L2)
Line (L3)
Isolating switch
Incoming safety earth/ground (PE)
To earth/ground outer shield,
use 360° clamps connected to
enclosure backplane
STAR POINT
Figure 3: Single or three-phase power connections
3-14 Basic Installation
MN1942
3.4.4 Input power conditioning
Certain power line conditions must be avoided; an AC line reactor, an isolation transformer or
a step up/step down transformer may be required for some power conditions:

If the feeder or branch circuit that provides power to the MicroFlex e100 has permanently
connected power factor correction capacitors, an input AC line reactor or an isolation
transformer must be connected between the power factor correction capacitors and the
MicroFlex e100 to limit the maximum symmetrical short circuit current to 5000 A.

If the feeder or branch circuit that provides power to the MicroFlex e100 has power factor
correction capacitors that are switched on line and off line, the capacitors must not be
switched while the drive is connected to the AC power line. If the capacitors are switched
on line while the drive is still connected to the AC power line, additional protection is
required. A Transient Voltage Surge Suppressor (TVSS) of the proper rating must be
installed between the AC line reactor (or isolation transformer) and the AC input to the
MicroFlex e100.
3.4.4.1 Input power-cycling and inrush
If AC power has been removed from the MicroFlex e100, it should remain disconnected for
the period specified in Table 2, before it is reapplied.
MicroFlex e100
current rating
Minimum power cycle delay period
(seconds)
3A
25
6A
45
9A
65
Table 2: Power cycle intervals
This delay allows the input surge protection circuit to perform correctly, ensuring that the
inrush current (typically 1.7 A) is below the drive rated current. Power-cycling the drive more
frequently could cause high inrush current and corresponding nuisance operation of circuit
breakers or fuses. Repeated failure to observe the delay period could reduce the lifetime of
the MicroFlex e100.
3.4.4.2 Discharge period
WARNING
After AC power has been removed from the MicroFlex e100, high voltages
(greater than 50 V DC) can remain on the brake resistor connections until
the DC-bus circuitry has discharged. The high voltage can remain for the
period specified in Table 3.
MicroFlex e100
current rating
Time for DC-bus to discharge to 50 V or less
(maximum, seconds)
3A
83
6A
166
9A
248
Table 3: DC-bus discharge periods
MN1942
Basic Installation 3-15
3.4.4.3 Supplying input power from a variac (variable transformer)
When AC power is supplied from a variac, the MicroFlex e100’s pre-charge circuit may not
operate correctly. To ensure that the pre-charge circuitry operates correctly, increase the
variac voltage to the desired level and then power cycle the 24 V DC control circuit supply.
This will restart the pre-charge circuit and allow it to operate correctly.
3.4.5 Power disconnect and protection devices
A power disconnect should be installed between the input power supply and the
MicroFlex e100 for a fail-safe method to disconnect power. The MicroFlex e100 will remain in
a powered condition until all input power is removed from the drive and the internal bus
voltage has depleted.
The MicroFlex e100 must have a suitable input power protection device installed, preferably
a fuse. Recommended circuit breakers are thermal magnetic devices (1 or 3 phase as
required) with characteristics suitable for heavy inductive loads (C-type trip characteristic).
Circuit breaker or fuses are not supplied - see section 3.4.6. For CE compliance, see
Appendix D.
Circuit Breaker
From
supply
From
supply
Fuse
L
L
L
L
N
N
N
N
Figure 4: Circuit breaker and fuse, single-phase
Circuit Breaker
From
supply
From
supply
L1
L1
L1
L2
L2
L2
L3
L3
L3
Fuses
Circuit Breaker or fuse are not supplied.
For CE Compliance, see Appendix D.
Figure 5: Circuit breaker and fuse, three-phase
Note: Metal conduit or shielded cable should be used. Connect conduits so the use of
a line reactor or RC device does not interrupt EMI/RFI shielding.
3.4.5.1 Using 2 phases of a 3-phase supply
Power may be derived by connecting two phases of an appropriate three-phase supply (L1
and L2 for example). When supplying AC power in this way, the voltage between the two
phases must not exceed the rated input voltage of the MicroFlex e100. A two pole breaker
must be used to isolate both lines. Fuses must be fitted in both lines.
3-16 Basic Installation
MN1942
3.4.6 Recommended fuses, circuit breakers and wire sizes
Table 4 describes the recommended fuses, circuit breakers and suitable wires sizes to be
used for power connections.
Catalog
Number
MFE..A003
MFE..A006
MFE..A009
Cont.
AC
Output
Supply
Amps
Type
(RMS)
Minimum
Circuit
Wire Gauge
breaker
(C-type) AWG mm2
Input Fuse
10 A
14
2.0
1Φ
Ferraz Shawmut:
6x32 FA series, 10 A (W084314P)
or
BS88 2.5 URGS 10 A (N076648)
8A
14
2.0
3Φ
Ferraz Shawmut:
6x32 FA series, 8 A (V084313P)
or
BS88 2.5 URGS, 7 A (M076647)
20 A
14
2.0
1Φ
Ferraz Shawmut:
6x32 FA series, 20 A (A084318P)
or
BS88 2.5 URGS, 20 A (L097507)
12.5 A
14
2.0
3Φ
Ferraz Shawmut:
6x32 FA series, 12.5 A
(X084315P)
or
BS88 2.5 URGS, 12 A (P076649)
1Φ
Ferraz Shawmut:
BS88 2.5 URGS, 25 A (R076651)
25 A
14
2.5
Ferraz Shawmut:
6x32 FA series, 20 A (A084318P)
or
BS88 2.5 URGS, 20 A (L097507)
20 A
14
2.0
3Φ
3A
6A
9A
Table 4: Protection device and wire ratings
Note: All wire sizes are based on 75 °C (167 °F) copper wire. Higher temperature
smaller gauge wire may be used per National Electric Code (NEC) and local
codes. Recommended fuses are based on 25 °C (77 °F) ambient, maximum
continuous control output current and no harmonic current. Earth/ground wires
must be the same gauge, or larger, than the Line wires.
3.4.7 Drive overload protection
The MicroFlex e100 will immediately trip and disable if there is an overload condition. The
parameters for managing drive overloads are configured automatically by the
Commissioning Wizard (see section 6.4.3). If they need to be changed, use the Parameters
tool in Mint WorkBench (see section 6.5.2).
MN1942
Basic Installation 3-17
3.4.8 Power supply filters
To comply with EEC directive 89/336/EEC, an AC power filter of the appropriate type must be
connected. This can be supplied by ABB and will ensure that the MicroFlex e100 complies
with the CE specifications for which it has been tested. Ideally, one filter should be provided
for each MicroFlex e100; filters should not be shared between drives or other equipment.
Table 5 lists the appropriate filters:
MicroFlex e100
current
230 V AC, 1Φ
rating
Input voltages
230 V AC, 3Φ
3 A FI0015A00 + line reactor
(see sections 3.4.8.1 and 3.4.8.2)
or
FI0029A00 (see section A.1.2)
FI0018A00
6 A FI0015A02 (see section 3.4.8.2)
or
FI0029A00 (see section A.1.2)
FI0018A00
9 A FI0029A00 (see section A.1.2)
FI0018A03
Table 5: Filter part numbers
Maximum earth leakage from the MicroFlex e100 is 3.4 mA per phase (230 V, 50 Hz supply).
This value does not include the earth leakage from the AC power filter, which could be much
larger (see section A.1.4).
3.4.8.1 Harmonic suppression
When operating the 3 A MicroFlex e100 (part MFE230A003) on a single-phase AC supply, a
13 mH, 4 Arms (10 A peak) line reactor is required to ensure compliance with EN61000-32:2000 class A limits, when the total equipment supply load is less than 1 kW.
3.4.8.2 Reversing the filter
When using filters FI0015A00 or FI0015A02 as specified in Table 5, they must be reversed to
ensure that the MicroFlex e100 complies with the CE specifications for which it has been
tested. The AC power supply should be connected to the filter terminals marked as the
outputs, with the MicroFlex e100 connected to the filter terminals marked as the inputs.
WARNING
This recommendation applies only to filters FI0015A00 and FI0015A02.
Alternative filters or protection devices must be connected as specified by
the manufacturer.
3-18 Basic Installation
MN1942
3.4.9 24 V control circuit supply
A 24 V DC supply must be provided to power the controlling electronics. This is useful for
safety reasons where AC power needs to be removed from the power stage but the
controlling electronics must remain powered to retain position and I/O information.
A separate fused 24 V supply should be provided for the MicroFlex e100. If other devices are
likely to be powered from the same 24 V supply, a filter (part FI0014A00) should be installed
to isolate the MicroFlex e100 from the rest of the system. Alternatively, a ferrite sleeve may
be attached to the supply cable near connector X2.
Location Connector X2
Nominal input 24 V DC
voltage
Range 20-30 V DC
Input current
Maximum 1 A continuous (4 A typical power on surge, limited by NTC)
Typical 0.5 A - 0.6 A (not powering feedback device)
0.6 A - 0.8 A (powering feedback device)
Tightening torque for terminal block connections is 0.5-0.6 N·m (4.4-5.3 lb-in).
Customer supplier
24 V DC
Ferrite
sleeve**
24 V filter
(optional)
Fuse *
+24 V
GND
Use a twisted pair cable, with
ferrite sleeve attached close to
connector X2.
Incoming safety earth/
ground (PE)
STAR
POINT
* Recommended fuse: Bussman S504 20 x 5 mm anti-surge 2 A
** Recommended ferrite sleeve: Fair-Rite part 0431164281 or similar
Figure 6: 24 V control circuit supply connections
MN1942
Basic Installation 3-19
3.5 Motor connections
MicroFlex e100 will operate with a large number of brushless servo motors. For information
on selecting Baldor servo motors please see the sales brochure BR1202, available from your
local ABB representative. The motor must be capable of being powered by an inverter PWM
output - see section 8.1.3 for details. The motor can be connected directly to the
MicroFlex e100 or through a motor contactor (M-Contactor). The motor outputs are
conditionally short-circuit proof. Motors should ideally have a minimum inductance of 1 mH
per winding; for motors with lower inductance an output reactor may be fitted in series with
the motor.
When using a Baldor motor, the parameters for managing motor overloads are configured
automatically by the Commissioning Wizard (see section 6.4.3). If they need to be changed,
or you are using an alternative motor, use the Parameters tool in Mint WorkBench (see
section 6.5.2).
Location Connector X1
AC supply voltage 115 V AC, 1Φ
Output voltage range 0-115 V AC, 3Φ
Motor
230 V AC, 1Φ
230 V AC, 3Φ
0-230 V AC, 3Φ
0-230 V AC, 3Φ
Connect motor
earth/ground to
protective earth
on top of drive.
See Note.
Connect motor
earth/ground to
protective earth
on top of drive. *
Earth
U
V
W
Optional motor circuit
contactors
Unshielded
lengths should be
as short as
possible
* The threaded holes in the top and bottom of the case are for M4 bolts no longer than 11 mm (0.43 in) in length.
Figure 7: Motor connections
Do not connect supply power to the MicroFlex e100 UVW outputs. The
MicroFlex e100 might be damaged.
CAUTION
CAUTION
The motor leads U, V and W must be connected to their corresponding U, V or
W terminal on the motor. Misconnection will result in uncontrolled motor
movement.
The motor power cable must be shielded for CE compliance. The connector or gland used at
the motor must provide 360 degree shielding. The maximum recommended cable length is
30.5 m (100 ft).
Note: For CE compliance the motor earth/ground should be connected to the drive
earth/ground.
3-20 Basic Installation
MN1942
3.5.1 Motor circuit contactors
If required by local codes or for safety reasons, an M-Contactor (motor circuit contactor) may
be installed to provide a physical disconnection of the motor windings from the
MicroFlex e100 (see section 3.5). Opening the M-Contactor ensures that the MicroFlex e100
cannot drive the motor, which may be necessary during equipment maintenance or similar
operations. Under certain circumstances, it may also be necessary to fit a brake to a rotary
motor. This is important with hanging loads where disconnecting the motor windings could
result in the load falling. Contact your local supplier for details of appropriate brakes.
CAUTION
If an M-Contactor is installed, the MicroFlex e100 must be disabled at least
20 ms before the M-Contactor is opened. If the M-Contactor is opened while the
MicroFlex e100 is supplying voltage and current to the motor, the
MicroFlex e100 may be damaged. Incorrect installation or failure of the MContactor or its wiring may result in damage to the MicroFlex e100.
Ensure that shielding of the motor cable is continued on both sides of the contactor.
3.5.2 Motor power cable pin configuration - Baldor BSM rotary motors
Figure 8 shows the pin configuration for a typical Baldor motor cable, part number
CBL025SP-12:
Signal name
Motor / cable pin
Motor cable wire color
Motor U
1
Black, labeled ‘1’
Motor V
4
Black, labeled ‘2’
Motor W
3
Black, labeled ‘3’
Earth/ground
2
Green/Yellow
Thermal switch
A
Green
Thermal switch
B
White
Brake
C
Blue
Brake
D
Red
Note:
Not all motors
are fitted with a
brake so pins C
and D might not
be connected
A
C
B
D
C
4
1
B
A
D
4
3
2
Motor power connector
(male)
3
1
2
Cable connector end view
(female)
Figure 8: Baldor motor power cable pin configuration
MN1942
Basic Installation 3-21
3.5.3 Motor cable pin configuration - Baldor linear motors
The following table shows the pin colors used in a typical Baldor linear motor cable set, part
number AY1763A00:
Signal name
Motor cable wire color
Motor U
Black
Motor V
Red
Motor W
White
Motor ground
Green
Thermal switch
Blue
Thermal switch
Orange
Signal name
Hall cable wire color
Hall 1 (U)
White
Hall 2 (V)
Red
Hall 3 (W)
Black
Hall ground
Green
Hall +5 V DC
Brown
3.5.4 Sinusoidal filter
A sinusoidal filter is used to provide a better quality waveform to the motor, reducing motor
noise, temperature and mechanical stress. It will reduce or eliminate harmful dV/dt values
(voltage rise over time) and voltage doubling effects which can damage motor insulation.
This effect occurs most noticeably when using very long motor cables, for example 30 m
(100 ft) or more. Baldor motors intended to be used with drives are designed to withstand the
effects of large dV/dt and overvoltage effects. However, if very long motor cables are
unavoidable and are causing problems, then a sinusoidal filter may be beneficial.
3-22 Basic Installation
MN1942
3.5.5 Thermal switch connection
You might wish to wire the motor’s thermal switch contacts (normally closed), using a relay, to a
digital input on connector X3 (see section 3.3.1). Using the Mint WorkBench Digital I/O tool, the
input can be configured to be the motor trip input. This allows the MicroFlex e100 to respond to
motor over-temperature conditions. The Mint keyword MOTORTEMPERATUREINPUT can also
be used to configure a digital input for this purpose. A typical circuit, using DIN1 as the input, is
shown in Figure 9.
‘X3’
The relay has normally open contacts
and is shown deactivated (contacts open,
motor overheated).
DIN1+
16
A
motor
thermal
switch
Relay
B
DIN1+24 V
0V
Separate customer
supplied 24 V DC
supply
+24 V
6
0V
Customer
supplied 24 V
DC supply
Figure 9: Motor thermal switch circuit
CAUTION
The 24 V DC power supply connected to the thermal switch must be a separate
supply as shown in Figure 9. Do not use the 24 V DC supply used for the drive
enable signal, or the internally generated supply (if present). The thermal switch
wires often carry noise that could cause erratic drive operation or damage. The
thermal switch contacts must never be wired directly to a digital input or any part
of the logic supply for other components in the system.
The separate 24 V DC supply used for the thermal switch may also be used for
the motor brake circuit (section 3.5.6).
MN1942
Basic Installation 3-23
3.5.6 Motor brake connection
You might wish to wire a motor’s brake, via relays, to digital outputs on connector X3 (see
section 3.3.1). This provides a way for the MicroFlex e100 to control the motor’s brake. A
typical circuit is shown in Figure 10.
‘X3’
User supply V+
11
13
1
3
DOUT0+
The relays have normally open
contacts and are shown deactivated
(contacts open, brake engaged).
DOUT1+
C from motor brake
DOUT0-
D
DOUT1-
connections
Relay 1
The inner shield
surrounding the brake
wires should be earthed/
grounded at one point only
Relay 2
User supply GND
+24 V
0V
Separate
customer supplied
24 V DC supply
Figure 10: Motor brake control circuit
This circuit uses the drive enable signal (configured using DRIVEENABLEOUTPUT to appear
on DOUT0) in conjunction with DOUT1 (configured as the MOTORBRAKEOUTPUT). See the
Mint help file for details. With this configuration, the following sequences can be used to
control the brake.
To engage the brake:

The motor is brought to rest under normal control;

Relay 2 is deactivated, causing the brake to engage;

The drive is disabled. This removes power from the motor and causes Relay 1 to be
deactivated.
To disengage the brake:
The drive is enabled, activating Relay 1;


Power is applied to the motor to hold position under normal control;

Relay 2 is activated, causing the brake to be disengaged.
It may be necessary to include a small delay, after Relay 2 has been activated, before
starting motion. This delay will allow time for the relay contacts to engage and the brake to
release.
The 24 V DC power supply used to power the brake must be a separate supply
as shown in Figure 10. Do not use the supply that is powering the
MicroFlex e100 digital outputs. The brake wires often carry noise that could
CAUTION
cause erratic drive operation or damage. The brake contacts must never be
wired directly to the digital outputs. The relay(s) should be fitted with a protective
flyback diode, as shown. The separate 24 V DC supply used for the motor brake
may also be used to power the relay in the thermal switch circuit (section 3.5.5).
3-24 Basic Installation
MN1942
3.6 Brake (regeneration) resistor
An optional external brake resistor may be required to dissipate excess power from the
internal DC bus during motor deceleration. The brake resistor must have a resistance of at
least 39 Ω, an inductance of less than 100 μH, and a minimum power rating of 44 W. Care
should be taken to select the correct resistor for the application - see section 3.7. Suitable
brake resistors are listed in section A.1.5. The brake resistor output is conditionally shortcircuit proof.
Electrical shock hazard. DC bus voltages may be present at these
terminals. Use a suitable heatsink (with fan if necessary) to cool the brake
resistor. The brake resistor and heatsink (if present) can reach
WARNING
temperatures in excess of 80 °C (176 °F).
Brake resistor
Earth/ground outer shield,
using 360° conductive clamp
connected to enclosure
backplane
STAR
POINT
Figure 11: Brake resistor connections
3.6.1 Braking capacity
The braking capacity of the MicroFlex e100 can be calculated from the following formula:
(
)
E = 0.5 x DC bus capacitance x (Brake switching threshold)2 – ( 2 x Supply voltage)2
where the Brake switching threshold is 388 V. This gives the following typical values:
MicroFlex
catalog number
Braking capacity (J)
DC bus
capacitance (μF)
115 V AC supply
230 V AC supply
FMH2A01/3...
560
34.7
12.5
FMH2A06...
1120
69.4
25
FMH2A09...
1680
104.2
37.6
Table 6: Braking capacity
MN1942
Basic Installation 3-25
3.7 Brake resistor selection
The following calculations can be used to estimate the type of brake resistor that will be
required for the application.
3.7.1 Required information
To complete the calculation, some basic information is required. Remember to use the worstcase scenario to ensure that the braking power is not underestimated. For example, use the
maximum possible motor speed, maximum inertia, minimum deceleration time and minimum
cycle time that the application might encounter.
Requirement
a) Initial motor speed, before deceleration
begins, in radians per second.
Enter value here
Initial motor speed, U = _________ rad/s
Multiply RPM by 0.1047 to give radians
per second.
b) Final motor speed after deceleration is
complete, in radians per second.
Multiply RPM by 0.1047 to get radians
per second. This value will be zero if the
load is going to be stopped.
Final motor speed, V = _________ rad/s
c) The deceleration time from initial speed
to final speed, in seconds.
Decel time, D
= _________ s
d) The total cycle time (i.e. how frequently
the process is repeated), in seconds.
Cycle time, C
= _________ s
e) Total inertia.
This is the total inertia seen by the drive,
accounting for motor inertia, load inertia
and gearing. Use the Mint WorkBench
Autotune tool to tune the motor, with the
load attached, to determine the value.
This will be displayed in kg·m2 in the
Total inertia, J
Autotune tool. If you already know the
motor inertia (from the motor spec.) and
the load inertia (by calculation) insert the
total here.
= ________ kg·m2
Multiply kg·cm2 by 0.0001 to give kg·m2.
Multiply lb-ft2 by 0.04214 to give kg·m2.
Multiply lb-in-s2 by 0.113 to give kg·m2.
3-26 Basic Installation
MN1942
3.7.2 Braking energy
The braking energy to be dissipated, E, is the difference between the initial energy in the
system (before deceleration begins) and the final energy in the system (after deceleration
has finished). If the system is brought to rest then the final energy is zero.
The energy of a rotating object is given by the formula:
2
1
E = ---  J  
2
where E is energy, J is the moment of inertia, and ω is the angular velocity.
The braking energy, which is the difference between the initial energy and the final energy, is
therefore:
1
2
2
1
E =  ---  J  U  –  ---  J  V 
2
 2

1
2
2
= ---  J   U – V 
2
= ________________ J (joules)
Calculate E using the values for J, U and V entered in section 3.7.1. If E is less than the
drive’s braking capacity, shown in Table 6 on page 3-25, a brake resistor will not be required.
If E is greater than the drive’s braking capacity, then continue to section 3.7.3 to calculate the
braking and average power dissipation.
3.7.3 Braking power and average power
The braking power, Pr , is the rate at which the braking energy is dissipated. This rate is
defined by the deceleration period, D. The shorter the deceleration period, the greater the
braking power.
E
P r = ---D
= ________________ W (watts)
Although the resistors shown in Table 7 can withstand brief overloads, the average power
dissipation, Pav, must not exceed the stated power rating. The average power dissipation is
determined by the proportion of the application cycle time spent braking. The greater the
proportion of time spent braking, the greater the average power dissipation.
D
P av = P r  ---C
= ________________ W (watts)
MN1942
Basic Installation 3-27
3.7.4 Resistor choice
Pav is the value to use when assessing which brake resistor to use. However, a safety
margin of 1.25 times is recommended to ensure the resistor operates well within its limits, so:
Required resistor power rating = 1.25 x Pav
= ________________ W (watts)
The range of suitable brake resistors is shown in Table 7. Choose the resistor that has a
power rating equal to or greater than the value calculated above.
Resistor part
Resistance
Power rating
RGJ139
39 Ω
100 W
RGJ160
60 Ω
100 W
RGJ260
60 Ω
200 W
RGJ360
60 Ω
300 W
Table 7: Brake resistors
Dimensions are shown in section A.1.5.
* The brake resistors listed in Table 7 can withstand a brief overload of 10 times the rated
power for 5 seconds. Please contact ABB if larger power ratings are required.
3.7.5 Resistor derating
The brake resistors shown in Table 7 can achieve their stated power rating only when
mounted on a heatsink. In free air a derating must be applied. Furthermore, in ambient
temperatures greater than 25 °C (77 °F), a temperature derating must be applied.
Resistor
part
Nominal
power
rating
(W)
RGJ139
RGJ160
100
In free air
On heatsink
Derate power linearly from:
80% @ 25 °C (77 °F)
to
70% @ 55 °C (113 °F)
Derate power linearly from:
100% @ 25 °C (77 °F)
to
88% @ 55 °C (113 °F)
Typical heatsink:
200 mm x 200 mm x 3 mm
RGJ260
200
RGJ360
300
Derate power linearly from:
70% @ 25 °C (77 °F)
to
62% @ 55 °C (113 °F)
Derate power linearly from:
100% @ 25 °C (77 °F)
to
88% @ 55 °C (113 °F)
Typical heatsink:
400 mm x 400 mm x 3 mm
Table 8: Brake resistor derating
3-28 Basic Installation
MN1942
3.7.6 Resistor pulse load rating
The brake resistors shown in Table 8 can dissipate power levels greater than the stated
continuous power rating, provided the duty cycle (see section 3.7.7) is reduced, as shown in
Figure 12.
15000
14000
13000
12000
11000
10000
Power (W)
9000
8000
7000
6000
5000
4000
3000
3
2000
2
1
1000
0
absolute
0.08
0.17
0.25
0.33
0.42
0.5
on:off (s)
10:120
20:120
30:120
40:120
50:120
60:120
Duty cycle
1 100 W models: Maximum pulse 5 kW for 1 s, 120 s off.
2 200 W models: Maximum pulse 10 kW for 1 s, 120 s off.
3 300 W models: Maximum pulse 5 kW for 1 s, 120 s off.
Figure 12: Brake resistor pulse load rating
MN1942
Basic Installation 3-29
3.7.7 Duty cycle
The braking duty cycle is the amount of time taken braking as a proportion of the overall
application cycle time. For example, Figure 13 shows a system which performs a trapezoidal
move profile, with braking during part of the deceleration phase.
The braking duty is 0.2 (0.5 second braking / 2.5 second cycle time):
Braking active
Decel time
v
0.5 s
0.5 s
0.5 s
t
2.5 s
(Cycle time)
2.5 s
(Cycle time)
2.5 s
(Cycle time)
Figure 13: Duty cycle = 0.2
3-30 Basic Installation
MN1942
Feedback
4 Feedback
4
4.1 Introduction
MicroFlex e100 supports many feedback options for use with linear and rotary motors,
including incremental encoder, encoder with BiSS (Bi-directional Synchronous Serial
interface), encoder with SSI (Synchronous Serial Interface), EnDat absolute encoder or
SinCos encoder. All suitable types of feedback device can be connected to the universal
feedback interface available on connector X8.
There are some important considerations when wiring the feedback device:

The feedback device wiring must be separated from power wiring.

Where feedback device wiring runs parallel to power cables, they must be separated by
at least 76 mm (3 in)

Feedback device wiring must cross power wires at right angles only.

To prevent contact with other conductors or earths/grounds, unearthed/ungrounded ends
of shields must often be insulated.

Linear motors use two separate cables (encoder and Hall). The cores of these two
cables will need to be wired to the appropriate pins of the 15-pin D-type mating
connector.

The inputs are not isolated.
MN1942
Feedback 4-1
4.1.1 Incremental encoder feedback
The incremental encoder connections (ABZ channels and Hall signals) are made using the
15-pin D-type female connector X8. The encoder inputs (CHA, CHB and CHZ) accept
differential signals only. Twisted pairs must be used for each complementary signal pair e.g.
CHA+ and CHA-. The Hall inputs may be used as differential inputs (recommended for
improved noise immunity) or single ended inputs. When used as single ended inputs, leave
the Hall U-, Hall V- and Hall W- pins unconnected. The overall cable shield (screen) must be
connected to the metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin,
which is used to detect the voltage drop on long cable runs. This allows the MicroFlex e100
to increase the encoder supply voltage on pin 12 to maintain a 5 V supply at the encoder
(200 mA max).
Pin Incremental encoder function
1 CHA+
2 CHB+
3 CHZ+
4 Sense
5 Hall U6 Hall U+
7 Hall V1
8 Hall V+
9
9 CHA10 CHB11 CHZ-
8
15
12 +5 V out
13 DGND
14 Hall W15 Hall W+
MicroFlex e100
to encoder signal loss detection
CHA+
1
120R
CHA-
MAX3096
Differential line
receiver
to CPU
9
DGND
Figure 14: Encoder channel input circuit - Channel A shown
4-2 Feedback
MN1942
MicroFlex e100
+5V
Hall U+
6
MAX3096
Differential line
receiver
Hall U-
to CPU
5
DGND
Figure 15: Hall channel input circuit - U phase shown
4.1.1.1 Encoder cable configuration - Baldor rotary motors
Motor
Twisted pairs
Encoder
Feedback
Hall
Feedback
X8
1
9
2
10
3
11
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
12
13
4
+5V
DGND
Sense
6
5
15
14
8
7
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Connect overall shield to
connector backshells
Figure 16: Encoder cable connections - rotary motors
Note: If the Hall inputs are used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected; do not connect them to ground.
MN1942
Feedback 4-3
4.1.1.2 Encoders without Halls
Incremental encoders without Hall feedback connections may be connected to the
MicroFlex e100. However, if Hall connections are not present, it will be necessary for the
MicroFlex e100 to perform an automatic phase search sequence each time it is powered.
This will cause motor movement of up to 1 turn on rotary motors, or one pole-pitch on linear
motors.
Motor
X8
Twisted pairs
1
9
2
10
3
11
12
13
4
Encoder
Feedback
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
+5V out
DGND
Sense
Connect overall shield to
connector backshells
Figure 17: Encoder cable connections without halls - rotary motors
4.1.1.3 Halls-only feedback devices
Feedback devices using only Hall sensors may be connected to the MicroFlex e100.
However, since there are no encoder connections, the MicroFlex e100 will not be able to
perform smooth speed control or accurate positioning control.
X8
Motor
4
12
13
6
5
15
14
8
7
Hall
Feedback
Sense
+5V out
DGND
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Connect overall shield to
connector backshells
Figure 18: Halls-only feedback cable connections - rotary motors
Note: If the Hall inputs are used as single ended inputs, leave the Hall U-, Hall V- and
Hall W- pins unconnected; do not connect them to ground.
4-4 Feedback
MN1942
4.1.1.4 Encoder cable pin configuration - rotary motors
Figure 6 shows the pin configuration for a typical encoder feedback cable, part number
CBL025SF-E2.
MicroFlex e100
X8 pin
Motor / cable
pin
CHA+
1
3
Purple
CHA-
9
4
Purple / White
CHB+
2
5
Green
CHB-
10
6
Green / White
Signal name
Encoder cable
internal wire colors
CHZ+
3
7
Brown
CHZ-
11
8
Brown / White
Hall U+
6
10
Pink
Hall U-
5
11
Pink / Black
Hall V+
8
12
Yellow
Hall V-
7
13
Yellow / Black
Hall W+
15
14
Grey
Hall W-
14
15
Grey / Black
+5V
12
1
Red
DGND
13
2
Blue
11
10
Pins 9 and 16
are not
connected
9
16
13
15
8
7
14
6
1
1
12
2
2
3
4
5
Motor encoder connector
(male)
3
4
12
13
16
14
5
11
15
6
10
9
8
7
Cable connector end view
(female)
Figure 19: Baldor rotary motor encoder cable pin configuration
The maximum recommended cable length is 30.5m (100ft).
MN1942
Feedback 4-5
4.1.1.5 Encoder cable pin configuration - Baldor linear motors
Baldor linear motors use two separate cables (encoder and Hall). The cores of these two
cables must be wired to the appropriate pins of the 15-pin D-type mating connector:
Signal name
MicroFlex e100
X8 pin
CHA+
1
CHA-
9
CHB+
2
CHB-
10
CHZ+
3
CHZ-
11
Encoder cable internal wire colors
Please refer to MN1800 Linear Motors
Installation & Operating Manual for details.
Hall cable internal wire colors
Hall U+
6
White
Hall V+
8
Red
Hall W+
15
Black
+5V
12
Brown
Hall GND
13
Green
Motor
Twisted pairs
Encoder
Feedback
Hall
Feedback
X8
1
9
2
10
3
11
12
13
4
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
+5V
DGND
Sense
6
5
15
14
8
7
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Leave pins 5, 7 & 14
unconnected
Connect overall shield to
connector backshells
Figure 20: Encoder cable connections - linear motors
4-6 Feedback
MN1942
4.1.2 BiSS interface
The BiSS (Bi-directional Serial Synchronous interface) is an open-source interface that can
be used with many types of absolute encoder. The BiSS interface connections are made
using the 15-pin D-type female connector X8. Twisted pair cables must be used for the
complementary signal pairs e.g. Data+ and Data-. The overall cable shield (screen) must be
connected to the metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin,
which is used to detect the voltage drop on long cable runs. This allows the MicroFlex e100
to increase the supply voltage on pin 12 to maintain a 5 V DC supply at the encoder (200 mA
max).
Pin BiSS function
1 Data+
2 Clock+
3 (NC)
4 Sense
5 Sin6 Sin+
7 Cos8 Cos+
1
Note: If your cable has Sin and Cos
pairs they may be connected here.
However, these signals are not
required or used by the
MicroFlex e100 for BiSS operation.
9 Data-
9
10 Clock11 (NC)
8
12 +5 V out
15
13 DGND
14 (NC)
15 (NC)
Motor
Twisted pairs
BiSS
Interface
Absolute
Encoder
X8
1
9
2
10
12
13
4
Data+
DataClock+
Clock+5V out
DGND
Sense
Chassis
Connect internal
shields to pin 13.
Connect overall shield to
connector backshells
Figure 21: BiSS interface cable connections
MN1942
Feedback 4-7
4.1.2.1 BiSS interface cable pin configuration
Figure 15 shows the pin configuration for a typical BiSS feedback cable, part number
CBL025SF-D2.
MicroFlex e100
X8 pin
Motor / cable
pin
BiSS / EnDat / SinCos
cable internal wire
colors
Data-
9
1
Brown / White
Clock-
10
5
Pink / Black
Clock+
2
7
Pink
Signal name
Sense
4
9
Orange
+5V out
12
9
Red
DGND
13
10
Blue
Data+
1
12
Brown
1
2
9
10
12
11
3
4
8
8
7
6
5
Motor BiSS interface connector
(male)
7
9
12
1
10
11
6
5
2
3
4
Cable connector end view
(female)
Figure 22: Baldor rotary motor BiSS interface pin configuration
The maximum recommended cable length is 30.5m (100ft).
4-8 Feedback
MN1942
4.1.3 SSI feedback
The SSI (Synchronous Serial Interface) encoder interface is specifically designed for use
with Baldor SSI motors, which incorporate a custom Baumer SSI encoder. Correct operation
with other SSI interfaces cannot be guaranteed. The SSI encoder connections are made
using the 15-pin D-type female connector X8. Twisted pair cables must be used for the
complementary signal pairs e.g. Data+ and Data-. The overall cable shield (screen) must be
connected to the metallic shell of the D-type connector. Connector X8 includes a ‘Sense’ pin,
which is used to detect the voltage drop on long cable runs. This allows the MicroFlex e100
to increase the encoder supply voltage on pin 12 to maintain a 5 V supply at the encoder
(200 mA max).
Pin SSI function
1 Data+
2 Clock+
3 (NC)
4 Sense
5 (NC)
6 (NC)
7 (NC)
8 (NC)
1
9 Data-
9
10 Clock11 (NC)
8
12 +5 V out
15
13 DGND
14 (NC)
15 (NC)
Motor
Twisted pairs
X8
1
9
2
10
12
13
4
SSI
Interface
Absolute
Encoder
Data+
DataClock+
Clock+5V out
DGND
Sense
Connect internal
shields to pin 13.
Chassis
Connect overall shield to
connector backshells
Figure 23: SSI encoder cable connections
MN1942
Feedback 4-9
4.1.3.1 SSI cable pin configuration
Figure 11 shows the pin configuration for a typical SSI feedback cable, part number
CBL025SF-S2.
MicroFlex
X8 pin
Signal name
Motor / cable
pin
SSI cable
internal wire colors
+5 V out
12
1
Red
DGND
13
2
Blue
Clock+
2
3
Green
Clock-
10
4
Yellow
Data+
1
5
Pink
Data-
9
6
Grey
Sense
4
9
Orange
1
Pins 7-12 are
not used and
may not be
present
2
9
10
11
3
4
8
8
12
7
6
5
Motor SSI connector
(male)
7
9
12
1
10
11
6
5
2
3
4
Cable connector end view
(female)
Figure 24: Baldor motor SSI feedback cable pin configuration
The maximum recommended cable length is 30.5 m (100 ft).
4-10 Feedback
MN1942
4.1.4 SinCos feedback
The SinCos connections (Sin and Cos incremental channels only) are made using the 15-pin
D-type female connector X8. Twisted pair cables must be used for the complementary signal
pairs e.g. Sin+ and Sin-. The overall cable shield (screen) must be connected to the metallic
shell of the D-type connector. Connector X8 includes a ‘Sense’ pin, which is used to detect
the voltage drop on long cable runs. This allows the MicroFlex e100 to increase the encoder
supply voltage on pin 12 to maintain a 5 V supply at the encoder (200 mA max). The Sin and
Cos channel input circuits accept a nominal 1 V pk-pk sine wave centered on a 2.5 V
reference.
Pin SinCos function
1 (NC)
2 (NC)
3 (NC)
4 Sense
5 Sin6 Sin+
7 Cos8 Cos+
1
9 (NC)
9
10 (NC)
11 (NC)
8
12 +5 V out
15
13 DGND
14 (NC)
15 (NC)
Motor
X8
Twisted pairs
SinCos
Feedback
5
6
7
8
12
13
4
SinSin+
CosCos+
+5V out
DGND
Sense
Connect internal
shields to DGND.
Connect overall shield to
connector backshells
Figure 25: SinCos cable connections
MN1942
Feedback 4-11
4.1.4.1 SinCos cable pin configuration
Figure 13 shows the pin configuration for a typical SinCos feedback cable, part number
CBL025SF-D2.
MicroFlex e100
X8 pin
Motor / cable
pin
BiSS / EnDat / SinCos
cable internal wire
colors
(Not used)
9
1
Brown / White
Signal name
Sin+
6
2
Green
Cos+
8
4
Purple
(Not used)
10
5
Pink / Black
(Not used)
2
7
Pink
Cos-
7
8
Purple / White
Sense
4
9
Orange
+5V out
12
9
Red
DGND
13
10
Blue
Sin-
5
11
Green / White
(Not used)
1
12
Brown
1
2
9
10
11
3
4
8
8
12
7
6
5
Motor SinCos connector
(male)
7
9
12
1
10
11
6
5
2
3
4
Cable connector end view
(female)
Figure 26: Baldor motor SinCos feedback cable pin configuration
The maximum recommended cable length is 30.5 m (100 ft).
4-12 Feedback
MN1942
4.1.5 EnDat (absolute encoder) feedback
The absolute encoder interface supports both incremental and absolute (multi and single
turn) feedback using EnDat technology. It is possible to read and write information to the
encoder. The absolute encoder connections are made using the 15-pin D-type female
connector X8. Twisted pair cables must be used for the complementary signal pairs e.g. Sin+
and Sin-. The overall cable shield (screen) must be connected to the metallic shell of the Dtype connector. Connector X8 includes a ‘Sense’ pin, which is used to detect the voltage
drop on long cable runs. This allows the MicroFlex e100 to increase the encoder supply
voltage on pin 12 to maintain a 5 V supply at the encoder (200 mA max). Version 2.2 EnDat
encoders do not use the Sin and Cos channels.
Pin Absolute encoder function
1 Data+
2 Clock+
3 (NC)
4 Sense
5 Sin6 Sin+
7 Cos1
8 Cos+
9
9 Data10 Clock8
15
11 (NC)
12 +5 V out
13 DGND
14 (NC)
15 (NC)
Motor
Twisted pairs
Absolute
Encoder
X8
1
9
5
6
7
8
2
10
12
13
4
Data+
DataSinSin+
CosCos+
Clock+
Clock+5V out
DGND
Sense
Connect internal
shields to DGND.
Connect overall shield to
connector backshells
Figure 27: Absolute encoder cable connections
MN1942
Feedback 4-13
4.1.5.1 Absolute encoder cable pin configuration
Figure 15 shows the pin configuration for a typical absolute encoder feedback cable, part
number CBL025SF-D2.
MicroFlex e100
X8 pin
Motor / cable
pin
BiSS / EnDat / SinCos
cable internal wire
colors
Data-
9
1
Brown / White
Signal name
Sin+
6
2
Green
Cos+
8
4
Purple
Clock-
10
5
Pink / Black
Clock+
2
7
Pink
Cos-
7
8
Purple / White
Sense
4
9
Orange
+5V out
12
9
Red
DGND
13
10
Blue
Sin-
5
11
Green / White
Data+
1
12
Brown
1
2
9
10
12
11
3
4
8
8
7
6
5
Motor absolute encoder
connector (male)
7
9
12
1
10
11
6
5
2
3
4
Cable connector end view
(female)
Figure 28: Baldor rotary motor absolute encoder cable pin configuration
The maximum recommended cable length is 30.5 m (100 ft).
4-14 Feedback
MN1942
Input / Output
5 Input / Output
5
5.1 Introduction
This section describes the various digital and analog input and output capabilities of the
MicroFlex e100, with descriptions of each of the connectors on the front panel.
The following conventions are used to refer to the inputs and outputs:
I/O . . . . . . . . . . . .
DIN . . . . . . . . . . .
DOUT . . . . . . . . .
AIN . . . . . . . . . . .
MN1942
Input / Output
Digital Input
Digital Output
Analog Input
Input / Output 5-1
5.2 Digital I/O
The MicroFlex e100 provides as standard:

3 general purpose digital inputs.

1 dedicated drive enable input.

1 general purpose digital output.

1 general purpose / drive status output.
The general purpose digital inputs can be configured for typical input functions:

Error input

Reset input

Stop input

Forward / reverse limit input - see important details in section 5.2.2.1 or 5.2.3.1.

Home input.
5-2 Input / Output
MN1942
5.2.1 Drive enable input
Location
Connector X3, pins 9 & 19
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name Drive enable
9
19
Dedicated drive enable input.
Nominal input voltage: +24 V DC
Description
(input current not to exceed 50 mA)
Sampling interval:
1 ms
The drive enable input is buffered by a TLP280 opto-isolator, allowing the input signal to be
connected with either polarity.
MicroFlex e100
Drive
Enable+
19
Drive
Enable-
9
33R
Vcc
3k3
Mint
DRIVEENABLESWITCH
74LVC14
33R
TLP280
DGND
Figure 29: Drive enable input circuit
In normal use, the drive enable input controls the enabled status of the drive. However, when
the MicroFlex e100 is connected to Mint WorkBench, additional methods are available for
controlling the drive enable status. In all cases, the drive enable input must be active and
there must be no errors present before the MicroFlex e100 can be enabled. It is
recommended that an emergency stop switch or emergency stop control system is
incorporated in the drive enable circuit.

The drive enable button
on the motion toolbar toggles the enable/disable status.
Alternatively, the Mint command DRIVEENABLE(0)=1 can be used in the command
window to enable the MicroFlex e100. DRIVEENABLE(0)=0 will disable the
MicroFlex e100.

The Tools, Reset Controller menu item will clear errors and enable the MicroFlex e100.
Alternatively, the Mint command RESET(0) can be used in the command window to
perform the same action.
The state of the drive enable input is displayed in the Mint WorkBench Spy window.
Alternatively, the state of the drive enable input can be read (but not set) using the Mint
command Print DRIVEENABLESWITCH in the command window. See the Mint help file for
details.
MN1942
Input / Output 5-3
User
supply
24V
NextMove e100 / controller
MicroFlex e100
‘X11’
UDN2982
MintMT
DRIVEENABLEOUTPUT
9
1
‘X3’
USR V+
Drive
Enable+
DOUT0
Drive
Enable-
10k
10
19
9
TLP280
USR GND
User
supply
GND
Figure 30: Drive enable input - typical connection from an ABB NextMove e100
5-4 Input / Output
MN1942
5.2.2 General purpose digital input DIN0
Location
Connector X3, pins 7 & 17
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name DIN0
7
General purpose opto-isolated digital input.
Nominal input voltage: +24 V DC
Description
(input current not to exceed 50 mA)
Sampling interval:
1 ms
17
This general purpose digital input is buffered by a TLP280 opto-isolator, allowing the input
signal to be connected with either polarity. The state of the digital input is displayed in the
Mint WorkBench Spy window. The input can be can be configured for different user definable
functions.
MicroFlex e100
DIN0+
17
DIN0-
7
33R
Vcc
3k3
Mint
74LVC14
33R
TLP280
DGND
Figure 31: General purpose digital input circuit
When the MicroFlex e100 is connected to Mint WorkBench, the digital input can be configured
using the Digital I/O tool. Alternatively, Mint keywords including RESETINPUT, ERRORINPUT,
STOPINPUT, FORWARDLIMITINPUT, REVERSELIMITINPUT, POWERREADYINPUT and
HOMEINPUT can be used in the command window. The state of the digital input can be viewed
using the Mint WorkBench Spy window’s Axis tab. See the Mint help file for details.
5.2.2.1 Using a digital input as a home switch input
When the MicroFlex e100 is being controlled over EPL by a manager node (e.g.
NextMove e100), the home switch input must be wired to the MicroFlex e100, not the
manager node. This is because the manager node only triggers the homing sequence, which
is then performed entirely by the MicroFlex e100. It is therefore the MicroFlex e100 which
must receive the home switch input signal, otherwise it will not be able to complete its
homing routine. Similarly, it is the MicroFlex e100’s own HOME... keyword parameters that
define the homing sequence.
MN1942
Input / Output 5-5
NextMove e100 / controller
‘X11’
User
supply
24V
UDN2982
9
MintMT
OUTX.0
1
MicroFlex e100
USR V+
‘X3’
DOUT0
DIN0+
DIN0-
10k
10
17
7
TLP280
USR GND
User
supply
GND
Figure 32: Digital input - typical connection from an ABB NextMove e100
5-6 Input / Output
MN1942
5.2.3 General purpose digital inputs DIN1 & DIN2
Location
4
14
6
16
Connector X3, pins 6 & 16 (DIN1), 4 & 14 (DIN2)
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name DIN1, DIN2
General purpose fast opto-isolated digital inputs.
Nominal input voltage: +24 V DC
Description
(input current not to exceed 20 mA)
Maximum input frequency:
1 MHz maximum
These general purpose fast digital inputs are buffered by a TLP115 opto-isolator, allowing the
input signal to be connected with either polarity. The state of the digital input is displayed in
the Mint WorkBench Spy window. The inputs can be can be configured for different user
definable functions.
MicroFlex e100
Vcc
‘X3’
DIN1+
16
33R
3k3
Mint
74LVC14
TLP115A
DIN1-
6
33R
DGND
Figure 33: General purpose fast digital input circuit
When the MicroFlex e100 is connected to Mint WorkBench, the digital input can be configured
using the Digital I/O tool. Alternatively, Mint keywords including RESETINPUT, ERRORINPUT,
STOPINPUT, FORWARDLIMITINPUT, REVERSELIMITINPUT, POWERREADYINPUT and
HOMEINPUT can be used in the command window. The state of the digital input can be viewed
using the Spy window’s Axis tab. See the Mint help file for details.
5.2.3.1 Using a digital input as a home switch input
When the MicroFlex e100 is being controlled over EPL by a manager node (e.g.
NextMove e100), the home switch input must be wired to the MicroFlex e100, not the
manager node. This is because the manager node only triggers the homing sequence, which
is then performed entirely by the MicroFlex e100. It is therefore the MicroFlex e100 which
must receive the home switch input signal, otherwise it will not be able to complete its
homing routine. Similarly, it is the MicroFlex e100’s own HOME... keyword parameters that
define the homing sequence.
MN1942
Input / Output 5-7
NextMove e100 / controller
‘X11’
User
supply
24V
MicroFlex e100
UDN2982
9
Mint
OUTX.0
1
USR V+
‘X3’
DOUT0
DIN1+
DIN1-
10k
USR
GND
6
TLP115A
10
Shield
User
supply
GND
16
10
Connect overall
shield at one end only
Figure 34: Digital input - typical connection from an ABB NextMove e100
5.2.4 Special functions on inputs DIN1 & DIN2
DIN1 and DIN2 can be configured to perform special functions.
5.2.4.1 Step (pulse) and direction inputs
Using the MASTERSOURCE keyword, the MicroFlex e100 can be configured to use DIN1 and
DIN2 as step and direction inputs:

DIN1 is used as the step input. The step frequency controls the speed of the motor.

DIN2 is used as the direction input. The state of the direction input controls the direction
of motion. An active input will result in forward motion. An inactive input will result in
motion in the opposite direction.
5.2.4.2 Fast position capture
DIN1 or DIN2 can be configured using the LATCHTRIGGERCHANNEL keyword to become a
fast latch input. This allows the position of the axis to be captured in real-time and read using
the Mint keyword LATCHVALUE. The input can configured using the LATCHTRIGGEREDGE
keyword to be triggered either on a rising or falling edge. Further control of position capture is
provided by various other keywords beginning with LATCH... . See the Mint Help file for
details.
The maximum latency to read the fast position depends on the feedback device. For an
incremental encoder, the latency is approximately 150 - 300 ns. For other feedback devices
latency may be up to 62.5 μs, resulting from the 16 kHz sampling frequency used for these
types of feedback device. The fast interrupt will be latched on a pulse width of about 30 μs,
although a width of 100 μs is recommended to ensure capture. To prevent subsequent inputs
causing the captured value to be overwritten, the interrupt is latched in software.
Note: The fast inputs are particularly sensitive to noise, so inputs must use shielded
twisted pair cable. Do not connect mechanical switches, relay contacts or other
sources liable to signal ‘bounce’ directly to the fast inputs. This could cause
unwanted multiple triggering.
5-8 Input / Output
MN1942
User
supply
V+
PLC / controller
MicroFlex e100
‘X3’
16
Step
Output
STEP
Rp
6
Step
DIN1+
DIN1-
Direction
GND
14
Direction
Output
DIR
Rp
4
DIN2+
DIN2-
DGND
GND
User
supply
GND
Figure 35: Step and direction inputs - typical connections from an external controller
To operate at high frequencies, a pull up resistor Rp might be required to ensure that the
input operates correctly. The pull-up resistor depends on the user supply voltage and the
maximum input frequency required, as shown in the following table:
Resistor value, Rp
(None)
User supply voltage
24 V
12 V
5V
Low
15 kHz
100 kHz
470R
90 kHz
160 kHz
700 kHz
110R
250 kHz
500 kHz
2000 kHz
The pull up resistor Rp must have the correct minimum power rating, as shown in the
following table:
Resistor value, Rp
MN1942
User supply voltage
24 V
12 V
5V
470R
1.5 W
0.5 W
0.1 W
110R
6W
1.5 W
0.3 W
Input / Output 5-9
Incremental controller
MicroFlex e100
‘X3’
Twisted pairs
DIN1+ (Step)
A+
16
A-
6
B+
14
B-
4
DIN2-
5
DGND
GND
1
GND
24 V
2
24V
DIN1-
DIN2+ (Dir)
‘X2’
Connect shields at
one end only
Drive
supply
GND
Drive
supply
24V
Figure 36: Step and direction inputs - typical connection from an incremental encoder
Note: When using an incremental encoder source, do not connect the A- or B- outputs;
leave them unconnected as shown in Figure 36.
5-10 Input / Output
MN1942
5.2.5 General purpose / status output DOUT0
1
11
Location
Connector X3, pins 1 & 11
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name Status / DOUT0
General purpose opto-isolated digital output
Output current:
100 mA maximum
Description
User supply
+28 V DC maximum
Update interval:
1 ms
The optically isolated general purpose / status output is designed to source current from the
user supply as shown in Figure 37. The TLP127 has a maximum power dissipation of
150 mW at 25 °C.
The output includes a self-resetting fuse that operates at approximately 200 mA. The fuse
may take up to 20 seconds to reset after the load has been removed. If the output is used to
directly drive a relay, a suitably rated diode must be fitted across the relay coil, observing the
correct polarity. This is to protect the output from the back-EMF generated by the relay coil
when it is de-energized. The sense of the output can be configured in Mint WorkBench, and
its state is displayed in the Spy window.
User supply
V+
MicroFlex e100
‘X3’
Fuse
11
DOUT0+
200 mA
[Error]
TLP 127
1
DOUT0-
Load (Relay
with diode
shown)
User supply
GND
Figure 37: DOUT0 output circuit
By default, DOUT0 is configured as an error status output, which becomes inactive in the
event of an error. When the MicroFlex e100 is connected to Mint WorkBench, the active level
of the output can be configured using the Digital I/O tool. Alternatively, the Mint keyword
OUTPUTACTIVELEVEL can be used in the command window. See the Mint help file for
details.
MN1942
Input / Output 5-11
‘X3’
MicroFlex e100
11
1
User
supply
24V
NextMove e100 / controller
‘X9’
DOUT0+
DOUT0-
DIN4
8
TLP127
CREF1
9
User
supply
GND
TLP280
Figure 38: DOUT0 - typical connections to an ABB NextMove e100
5-12 Input / Output
MN1942
5.2.6 General purpose output DOUT1
Location
3
13
Connector X3, pins 3 & 13
(Mating connector: Weidmüller Minimate B2L 3.5/20)
Name DOUT1
General purpose opto-isolated digital output
Output current:
100 mA maximum
Description
User supply:
+28 V DC maximum
Update interval:
1 ms
The optically isolated general purpose output is designed to source current from the user
supply as shown in Figure 37. The TLP127 has a maximum power dissipation of 150 mW at
25 °C.
The output includes a self-resetting fuse that operates at approximately 200 mA. The fuse
may take up to 20 seconds to reset after the load has been removed. If the output is used to
directly drive a relay, a suitably rated diode must be fitted across the relay coil, observing the
correct polarity. This is to protect the output from the back-EMF generated by the relay coil
when it is de-energized. The sense of the output can be configured in Mint WorkBench, and
its state is displayed in the Spy window.
User supply
V+
MicroFlex e100
‘X3’
Fuse
13
DOUT1+
200 mA
[Error]
TLP 127
3
DOUT1-
Load (Relay
with diode
shown)
User supply
GND
Figure 39: DOUT1 output circuit
When the MicroFlex e100 is connected to Mint WorkBench, the active level of the output can
be configured using the Digital I/O tool. Alternatively, the Mint keyword
OUTPUTACTIVELEVEL can be used in the command window. See the Mint help file for
details.
MN1942
Input / Output 5-13
‘X3’
MicroFlex e100
13
3
User
supply
24V
NextMove e100 / controller
‘X9’
DOUT1+
DOUT1-
DIN4
8
TLP127
CREF1
9
TLP280
User
supply
GND
Figure 40: DOUT1 - typical connections to an ABB NextMove e100
5-14 Input / Output
MN1942
5.3 USB communication
5.3.1 USB port
Location
USB
Mating connector: USB Type B (downstream) plug
Pin Name
Description
1 VBUS
1
2
4
3
USB +5 V
2 D-
Data-
3 D+
Data+
4 GND
Ground
The USB connector is used to connect the MicroFlex e100 to a PC running Mint WorkBench.
The MicroFlex e100 is a self-powered, USB 1.1 (12 Mbps) compatible device. If it is
connected to a slower USB 1.0 host PC or hub, communication speed will be limited to the
USB 1.0 specification (1.5 Mbps). If it is connected to a faster USB 2.0 (480 Mbps) or
USB 3.0 (5 Gbps) host PC or hub, communication speed will remain at the USB 1.1
specification of the MicroFlex e100.
Ideally, the MicroFlex e100 should be connected directly to a USB port on the host PC. If it is
connected to a hub shared by other USB devices, communication could be affected by the
activity of the other devices. The maximum recommended cable length is 5 m (16.4 ft).
5.4 RS485 communication
5.4.1 RS485 port (2-wire)
Location
X6
Mating connector: RJ11 plug
Pin Name
1
6
Description
1 TXA
Transmit / receive +
2 TXB
Transmit / receive -
3 GND
Ground
4 +7 V out
7 V supply for ABB accessories
5 (NC)
-
6 (NC)
-
The RS485 2-wire port is used to connect third-party serial devices such as operator panels.
The Baldor Keypad and Baldor HMI panel range cannot be connected to this port. The 7 V
supply on pin 4 is provided for future ABB accessories, so care should be taken to ensure
this supply will not damage connected devices. The RS485 port could be damaged if a USB
plug is accidentally inserted while the drive is powered.
MN1942
Input / Output 5-15
The Mint keyword Print can be used to send characters to the attached device. The Mint
keyword InKey can be used to receive characters. The RS485 port can also be used to
exchange data using the Host Comms Protocol (HCP/HCP2). See the Mint WorkBench help
file for details.
MicroFlex e100
1
2
SN65HVD10D
Operator panel
‘X6’
3
TXA
TXA
TXB
TXB
GND
GND
Figure 41: RS485 port - typical connections to an RS485 2-wire operator panel
5-16 Input / Output
MN1942
5.5 Ethernet interface
The Ethernet interface provides TCP/IP and Ethernet POWERLINK (EPL) networking
capabilities.
5.5.1 TCP/IP
Transmission Control Protocol / Internet Protocol (TCP/IP) is a common set of protocols
used to transfer information between devices over a network, including the internet. TCP
enables two devices to establish a connection, and guarantees the delivery of packets
(datagrams) of information in the correct order. IP specifies the format of the individual
packets (which includes the destination address of the receiving device) but has no influence
on whether the packet is delivered correctly.
TCP/IP allows the MicroFlex e100 to support standard Ethernet communication with a host
PC running Mint WorkBench. The connection uses a high level ICM (Immediate Command
Mode) protocol to allow Mint commands, Mint programs and even firmware to be sent to the
controller over the Ethernet network.
When operating in standard Ethernet mode, TCP/IP cannot be used to communicate with a
controller on a daisy-chained network. This is due to cumulative timing errors caused by
each controller’s internal hub. It is necessary to connect the host PC to the controller either
directly or via a switch or hub, as shown in Figure 42. A switch is preferable to a hub as it will
provide faster performance when there is a large amount of data being transmitted.
Host PC
MicroFlex e100 drives
External switch
Figure 42: Connecting to drives using TCP/IP in standard Ethernet mode
When operating in EPL mode, in conjunction with an EPL compatible router, the host PC can
use TCP/IP to communicate with controllers on a daisy-chained network. In this situation, the
router will use TCP/IP only within EPL’s asynchronous time slots. See the Mint help file for
further details.
Host PC
NextMove e100
Master Node
MicroFlex e100 drives
Ethernet POWERLINK
compatible router
Figure 43: Connecting to daisy-chained drives using TCP/IP and EPL mode
MN1942
Input / Output 5-17
5.5.2 Ethernet POWERLINK
MicroFlex e100 supports the deterministic Ethernet POWERLINK (EPL) protocol. This
protocol provides very precise and predictable ‘real-time’ communication over a 100 Mbit/s
(100Base-T) Fast Ethernet (IEEE 802.3u) connection. This makes it suitable for the
transmission of control and feedback signals between the MicroFlex e100 and other EPL
enabled controllers such as NextMove e100. The EPL protocol implemented in Mint is based
on the CANopen DS402 Device Profile for Drives and Motion Control. The structure of the
physical network is informal so does not need to reflect the logical relationship between
nodes.
MicroFlex e100 incorporates a built-in repeating hub, providing two ports for connection to
other equipment. This allows nodes to be connected as a ‘daisy-chain’ network. Each node
introduces a delay of approximately 500 ns, so in time-critical applications this could limit the
number of nodes in a chain. Propagation delays due to cabling should also be considered.
Hubs may be used if necessary, but Ethernet switches must not be used in EPL networks as
their timing cannot be guaranteed.
NextMove e100
Manager Node
NextMove e100
Controlled Node
NextMove e100
Controlled Node
NextMove e100
Controlled Node
...
Figure 44: Simple daisy-chained EPL network
Machine 1
MicroFlex e100 drive group A (Controlled Nodes)
NextMove e100
Manager Node
...
1
External hub
2
3
4
5
6
7
8
9...
Machine 1
MicroFlex e100 drive group B (Controlled Nodes)
...
1
2
3
NextMove e100
Controlled Node
4
5
6
7...
Machine 2
MicroFlex e100 drive group C (Controlled Nodes)
...
1
2
3
4...
Figure 45: Example multi-branch EPL network
5-18 Input / Output
MN1942
5.5.3 Ethernet connectors
Ethernet connections are made using the identical RJ45 Ethernet receptacles.
Location E1 & E2
Pin Name
1
8
Description
1 TX+
Transmit+
2 TX-
Transmit-
3 RX+
Receive+
4 -
(NC)
5 -
(NC)
6 RX-
Receive-
7 -
(NC)
8 -
(NC)
To connect the MicroFlex e100 to other EPL devices use CAT5e Ethernet cables - either
S/UTP (screened unshielded twisted pairs) or preferably S/FTP (screened fully shielded
twisted pairs).
The MicroFlex e100 Ethernet interface is galvanically isolated from the rest of the
MicroFlex e100 circuitry by magnetic isolation modules incorporated in each of the Ethernet
connectors. This provides protection up to 1.5 kV. The connector/cable screen is connected
directly to the chassis earth of the MicroFlex e100. Termination components are incorporated
in each of the Ethernet connectors, so no further termination is required. To ensure CE
compliance, especially where Ethernet cables are frequently unplugged, all Ethernet cables
should be bonded to the metal backplane using conductive clamps at one point at least (see
section D.1.6). Cables longer than 3 m should be S/FTP cables bonded to the metal
backplane at both ends. Do not run Ethernet cables close to AC supply cables, motor power
cables, or other sources of noise as this can sometimes cause spurious errors to be
reported.
Cables may be up to 100 m (328 ft) long. Two varieties of CAT5e cable are available;
‘straight’ or ‘crossed’. Straight cables have the TX pins of the connector at one end of the
cable wired to the TX pins of the RJ45 connector at the other end of the cable. Crossover
cables have the TX pins of the connector at one end of the cable wired to the RX pins of the
RJ45 connector at the other end of the cable. Provided the network consists of only ABB
EPL controllers and drives (and any hub), straight or crossed cables may be used. This is
because many Ethernet devices, including hubs and all ABB EPL products, incorporate
Auto-MDIX switching technology which automatically compensates for the wiring of the
straight cable. However, if other manufacturer’s EPL nodes are included in the network,
crossover cables should be used as recommended by the Ethernet POWERLINK
Standardization Group (EPSG). Similarly, if a host PC does not provide Auto-MDIX on its
Ethernet port, then a crossed cable will be essential for the connection between the PC and
an EPL router, e.g. OPT036-501.
The EPL network supports the 100Base-TX (100 Mbit/s) system only, so attempting to
connect slower 10Base-T (10 Mbit/s) nodes will cause a network error.
MN1942
Input / Output 5-19
5.6 CAN interface
The CAN bus is a serial based network originally developed for automotive applications, but
now used for a wide range of industrial applications. It offers low-cost serial communications
with very high reliability in an industrial environment; the probability of an undetected error is
4.7x10-11. It is optimized for the transmission of small data packets and therefore offers fast
update of I/O devices (peripheral devices) connected to the bus.
The CAN protocol only defines the physical attributes of the network, i.e. the electrical,
mechanical, functional and procedural parameters of the physical connection between
devices. The higher level network functionality on MicroFlex e100 is defined by the CANopen
protocol, one of the most used standards for machine control.
5.6.1 CAN connector
Location OPT 1
Mating connector: 9-pin female D-type
Pin Name
6
1
9
5
Description
1 -
(NC)
2 CAN-
CAN channel negative
3 CAN GND
Ground/earth reference for CAN signals
4 -
(NC)
5 Shield
Shield connection
6 CAN GND
Ground/earth reference for CAN signals
7 CAN+
CAN channel positive
8 -
(NC)
9 CAN V+
CAN power V+ (12-24 V)
5.6.2 CAN wiring
A very low error bit rate over CAN can only be achieved with a suitable wiring scheme, so the
following points should be observed:

The two-wire data bus line may be routed parallel, twisted and/or shielded, depending on
EMC requirements. ABB recommends a twisted pair cable with the shield/screen
connected to the connector backshell, in order to reduce RF emissions and provide
immunity to conducted interference.

The bus must be terminated at both ends only (not at intermediate points) with resistors
of a nominal value of 120 Ω. This is to reduce reflections of the electrical signals on the
bus, which helps a node to interpret the bus voltage levels correctly. If the
MicroFlex e100 is at the end of the network then ensure that a 120 Ω resistor is fitted
(normally inside the D-type connector).

All cables and connectors should have a nominal impedance of 120 Ω. Cables should
have a length related resistance of 70 mΩ/m and a nominal line delay of 5 ns/m.
5-20 Input / Output
MN1942

The maximum bus length depends on the bittiming configuration (baud rate). The table
opposite shows the approximate maximum bus
length
(worst-case),
assuming
5 ns/m
propagation delay and a total effective device
internal in-out delay of 210 ns at 1 Mbit/s, 300 ns
at 500 - 250 Kbit/s, 450 ns at 125 Kbit/s and
1.5 ms at 50 - 10 Kbit/s.
(1)
For bus lengths greater than about 1000 m,
bridge or repeater devices may be needed.
CAN
Baud Rate
Maximum
Bus Length
1 Mbit/s
500 Kbit/s
250 Kbit/s
125 Kbit/s
100 Kbit/s
50 Kbit/s
20 Kbit/s
10 Kbit/s
25 m
100 m
250 m
500 m
600 m
1000 m
2500 m(1)
5000 m(1)

The compromise between bus length and CAN
baud rate must be determined for each
application. The CAN baud rate can be set using the BUSBAUD keyword. It is essential
that all nodes on the network are configured to run at the same baud rate.

The wiring topology of a CAN network should be as close as possible to a single line/bus
structure. However, stub lines are allowed provided they are kept to a minimum (<0.3 m
at 1 Mbit/s).

The 0 V connection of all of the nodes on the network must be tied together through the
CAN cabling. This ensures that the CAN signal levels transmitted by MicroFlex e100 or
CAN peripheral devices are within the common mode range of the receiver circuitry of
other nodes on the network.
5.6.2.1 Opto-isolation
On the MicroFlex e100, the CAN channel is opto-isolated. A voltage in the range 12-24 V DC
must be applied between pin 9 (+24 V) and pin 3 or 6 (0 V) of the CAN connector. From this
supply, an internal voltage regulator provides the 5 V at 100 mA required for the isolated
CAN circuit. To allow easy connection of the 12-24 V DC supply, adaptor part OPT-CNV002
can be used, allowing connection by ordinary CAT 5e Ethernet cables. The adaptor also
provides flying lead connections for the application of the CAN power supply.
Figure 46: OPT-CNV002
Alternatively, a connector such as the Phoenix Contact SUBCON-PLUS F3 (part 2761871)
provides a 9-pin D-type female connector with easily accessible terminal block connections
(see Figure 47). CAN cables supplied by ABB are ‘category 5’ and have a maximum current
rating of 1 A, so the maximum number of MicroFlex e100 units that may be used on one
network is limited to 10.
MN1942
Input / Output 5-21
5.6.3 CANopen
ABB has implemented a CANopen protocol in Mint (based on the ‘Communication Profile’
CiA DS-301) which supports both direct access to device parameters and time-critical
process data communication. The MicroFlex e100 complies with CANopen slave device
profile DS402, and can be a DS401 or DS403 master device (with limited functionality). It is
able to support and communicate with a variety of devices including:

Any third party digital and analog I/O device that is compliant with the ‘Device Profile for
Generic I/O Modules’ (CiA DS-401).

Baldor HMI (Human Machine Interface) operator panels, which are based on the ‘Device
Profile for Human Machine Interfaces’ (DS403).

Other ABB controllers with CANopen support for peer-to-peer access using extensions
to the CiA specifications (DS301 and DS302).
The functionality and characteristics of all ABB CANopen devices are defined in individual
standardized (ASCII format) Electronic Data Sheets (EDS) which can be found on the Mint
Motion Toolkit CD (OPT-SW-001), or downloaded from www.abbmotion.com. Figure 47
shows a typical CANopen network with a NextMove e100 manager node, one
MicroFlex e100 slave node and a Baldor HMI operator panel:
Baldor HMI
Operator Panel
NextMove e100
D-type
MicroFlex e100
D-type
End
node
7
7
7
7
2
2
2
CANopen
D-type
TR
Twisted pair
Twisted pairs
6
6
5
TR
2
6
6
9
9
9
5
5
Phoenix SUBCONPLUS F3
‘X1’
2
1
24 V
0V
Figure 47: Typical CANopen network connections
Note: The MicroFlex e100 CAN channel is opto-isolated, so a voltage in the range 1224 V must be applied between pin 9 and pin 6 of the OPT 1 connector.
The configuration and management of a CANopen network must be carried out by a single
node acting as the network manager (for example NextMove e100), or by a third party
CANopen manager device. Up to 126 CANopen nodes (node IDs 2 to 127) can be added to
the network by the manager node using the Mint NODESCAN keyword. If successful, the
nodes can then be connected to using the Mint CONNECT keyword. Any network and node
related events can then be monitored using the Mint BUS1 event.
Note: All CAN related Mint keywords are referenced to CANopen using the ‘bus’ dot
parameter. For CANopen the ‘bus’ dot parameter must be set to 1. Please refer
to the Mint help file for further details on CANopen, Mint keywords and dot
parameters.
5-22 Input / Output
MN1942
5.7 Other I/O
5.7.1 Node ID selector switches
The MicroFlex e100 has two selector switches which determine the unit’s
node ID on EPL networks. Each switch has 16 positions, allowing selection
of the hexadecimal values 0 - F. In combination, the two switches allow node
IDs of 0 - 255 (hexadecimal FF) to be selected. The switch labelled ‘HI’ sets
the high nibble (half byte), and the switch labelled ‘LO’ sets the low nibble.
The following table lists all node IDs from 0 to 255 with the equivalent HI and
LO switch settings:
MN1942
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
0
0
0
64
4
0
128
8
0
192
C
0
1
0
1
65
4
1
129
8
1
193
C
1
2
0
2
66
4
2
130
8
2
194
C
2
3
0
3
67
4
3
131
8
3
195
C
3
4
0
4
68
4
4
132
8
4
196
C
4
5
0
5
69
4
5
133
8
5
197
C
5
6
0
6
70
4
6
134
8
6
198
C
6
7
0
7
71
4
7
135
8
7
199
C
7
8
0
8
72
4
8
136
8
8
200
C
8
9
0
9
73
4
9
137
8
9
201
C
9
10
0
A
74
4
A
138
8
A
202
C
A
11
0
B
75
4
B
139
8
B
203
C
B
12
0
C
76
4
C
140
8
C
204
C
C
13
0
D
77
4
D
141
8
D
205
C
D
14
0
E
78
4
E
142
8
E
206
C
E
15
0
F
79
4
F
143
8
F
207
C
F
16
1
0
80
5
0
144
9
0
208
D
0
17
1
1
81
5
1
145
9
1
209
D
1
18
1
2
82
5
2
146
9
2
210
D
2
19
1
3
83
5
3
147
9
3
211
D
3
20
1
4
84
5
4
148
9
4
212
D
4
21
1
5
85
5
5
149
9
5
213
D
5
22
1
6
86
5
6
150
9
6
214
D
6
23
1
7
87
5
7
151
9
7
215
D
7
24
1
8
88
5
8
152
9
8
216
D
8
25
1
9
89
5
9
153
9
9
217
D
9
26
1
A
90
5
A
154
9
A
218
D
A
27
1
B
91
5
B
155
9
B
219
D
B
28
1
C
92
5
C
156
9
C
220
D
C
29
1
D
93
5
D
157
9
D
221
D
D
Input / Output 5-23
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
Node ID
HI
LO
30
1
E
94
5
E
158
9
E
222
D
E
31
1
F
95
5
F
159
9
F
223
D
F
32
2
0
96
6
0
160
A
0
224
E
0
33
2
1
97
6
1
161
A
1
225
E
1
34
2
2
98
6
2
162
A
2
226
E
2
35
2
3
99
6
3
163
A
3
227
E
3
36
2
4
100
6
4
164
A
4
228
E
4
37
2
5
101
6
5
165
A
5
229
E
5
38
2
6
102
6
6
166
A
6
230
E
6
39
2
7
103
6
7
167
A
7
231
E
7
40
2
8
104
6
8
168
A
8
232
E
8
41
2
9
105
6
9
169
A
9
233
E
9
42
2
A
106
6
A
170
A
A
234
E
A
43
2
B
107
6
B
171
A
B
235
E
B
44
2
C
108
6
C
172
A
C
236
E
C
45
2
D
109
6
D
173
A
D
237
E
D
46
2
E
110
6
E
174
A
E
238
E
E
47
2
F
111
6
F
175
A
F
239
E
F
48
3
0
112
7
0
176
B
0
240
F
0
49
3
1
113
7
1
177
B
1
241
F
1
50
3
2
114
7
2
178
B
2
242
F
2
51
3
3
115
7
3
179
B
3
243
F
3
52
3
4
116
7
4
180
B
4
244
F
4
53
3
5
117
7
5
181
B
5
245
F
5
54
3
6
118
7
6
182
B
6
246
F
6
55
3
7
119
7
7
183
B
7
247
F
7
56
3
8
120
7
8
184
B
8
248
F
8
57
3
9
121
7
9
185
B
9
249
F
9
58
3
A
122
7
A
186
B
A
250
F
A
59
3
B
123
7
B
187
B
B
251
F
B
60
3
C
124
7
C
188
B
C
252
F
C
61
3
D
125
7
D
189
B
D
253
F
D
62
3
E
126
7
E
190
B
E
254
F
E
63
3
F
127
7
F
191
B
F
255
F
F
Figure 48: Decimal node IDs and equivalent HI / LO hexadecimal switch settings
Note: If the node ID selector switches are set to FF, the node’s firmware will not run on
power up. However, Mint WorkBench will still be able to detect the
MicroFlex e100 and download new firmware.
5-24 Input / Output
MN1942
In many networking environments, the node ID may also be referred to as the address. On
EPL networks, limitations apply to the node IDs that may be selected:

Node ID 0 (00) is reserved for special purposes and cannot be used.

Node IDs 1 - 239 (01 - EF) cause the node to become a ‘controlled node’, a node that will
accept commands from the manager node.

Node ID 240 (F0) is reserved for the EPL manager node (for example NextMove e100)
so cannot be used by MicroFlex e100.

Node IDs 241 - 255 (F1 - FF) are reserved for special purposes and cannot be used.
For all other communication channels such as CANopen and USB, the node ID is set in
software. Each channel can have a different node ID, selected using the Mint WorkBench
Connectivity Wizard or the Mint BUSNODE keyword. See the Mint help file for details.
MN1942
Input / Output 5-25
5.8 Connection summary - recommended system wiring
As an example, Figure 49 shows the recommended wiring necessary for the MicroFlex e100
to control a motor, while conforming to the EMC requirements for ‘industrial’ environments.
AC power
L1
L2
L3
L1
L1
L2
L3
L2
L3
Filter
From
fuses
AC power in
Connect motor power cable
shield to metal backplane using
conductive shield clamp
Motion controller
Ethernet
Connect AC power cable shield to
metal backplane using conductive
shield clamp (see section D.1.6).*
PE
Star
point
Shielded twisted pair, clampled to
metal backplane near drive using
conductive shield earth/ground
clamp (see sections 3.6 and D.1.6).*
USB
Brake
Optional brake resistor
(Dynamic brake)
Motor power U V W
Ferrite
Motor feedback
+24 V DC 0V
Drive enable
input
See note 5
2A
Motor
+24 V DC 0V
Control circuit supply (fused). Use twisted
pair cable with a ferrite sleeve (see
section 3.4.9).*
Notes:
1.
The MicroFlex e100 should be mounted on an earthed metal backplane.
2.
Ensure cables do not obstruct airflow to the heatsink.
3.
Motor represents a typical Baldor BSM motor. Linear motors may also be controlled by MicroFlex e100
4.
Conductive shield earth/ground clamps are not supplied.
5.
The threaded holes in the top and bottom of the case are for M4 bolts no longer than 11 mm (0.43 in) in length.
6.
When using single phase supplies it may be necessary to reverse the AC power filter - see section 3.4.8.2.
Figure 49: Recommended system wiring
5-26 Input / Output
MN1942
Configuration
6 Configuration
6
6.1 Introduction
Before powering the MicroFlex e100 you will need to connect it to the PC using a USB or
Ethernet cable and install the Mint WorkBench software. This includes a number of
applications and utilities to allow you to configure, tune and program the MicroFlex e100.
Mint WorkBench and other utilities can be found on the Mint Motion Toolkit CD (OPT-SW001), or downloaded from www.abbmotion.com.
6.1.1 Connecting the MicroFlex e100 to the PC
The MicroFlex e100 can be connected to the PC using either USB (recommended) or TCP/IP.
To use USB, connect a USB cable between a PC USB port and the MicroFlex e100 USB
port. Your PC must be using Windows XP, Windows Vista or Windows 7.
To use TCP/IP, connect a CAT5e Ethernet cable between the PC and one of the
MicroFlex e100 Ethernet ports.
i
NOTICE
i
NOTICE
You cannot connect an ordinary office PC to the MicroFlex e100 without first
altering the PC’s Ethernet adapter configuration. However, if you have installed a
second Ethernet adapter dedicated for use with the MicroFlex e100, then this
adapter’s configuration can be altered without affecting the PC’s office Ethernet
connection. If you are unsure about making changes to your PC’s Ethernet
adapter configuration, or are prevented by user permission levels, ask your I.T.
administrator to assist you.
If there is a EPL manager node (node ID 240) on the Ethernet network, then the
network will be operating in EPL mode. This means any TCP/IP connection from
the PC must pass through an EPL compatible router.
6.1.2 Installing Mint WorkBench
The Windows user account requires administrative user rights to install Mint WorkBench.
6.1.2.1 To install Mint WorkBench from the CD (OPT-SW-001)
1. Insert the CD into the drive.
2. After a few seconds the setup wizard should start automatically. If the setup wizard does
not appear, select Run... from the Windows Start menu and type
d:\start
where d represents the drive letter of the CD device.
Follow the on-screen instructions to install Mint WorkBench.
6.1.2.2 To install Mint WorkBench from the website
To install Mint WorkBench from www.abbmotion.com, download the application and run it.
MN1942
Configuration 6-1
6.2 Starting the MicroFlex e100
If you have followed the instructions in the previous sections, you should now have
connected all the power sources, inputs and outputs, and the Ethernet cable or USB cable
linking the PC to the MicroFlex e100.
6.2.1 Preliminary checks
Before you apply power for the first time, it is very important to verify the following:

Disconnect the load from the motor until instructed to apply a load. If this cannot be
done, disconnect the motor wires at connector X1.

Verify that the AC line voltage matches the specification of the MicroFlex e100.

Inspect all power connections for accuracy, workmanship and tightness.

Verify that all wiring conforms to applicable codes.

Verify that the MicroFlex e100 and motor are properly earthed/grounded.

Check all signal wiring for accuracy.
6.2.2 Power on checks
If at any time the Status LED flashes red, the drive has detected a fault - see section 7.
1. Turn on the 24 V DC supply.
2. Turn on the AC supply.
3. Within approximately 20-30 seconds, the test sequence should complete and the Status
LED should illuminate red. If the Status LED is not lit then re-check the power supply
connections. If the Status LED flashes red, this indicates that the MicroFlex e100 has
detected a fault - see section 7. Note that after downloading firmware, startup may take
more than 1 minute.
4. If the motor wires were disconnected in section 6.2.1, turn off the AC supply and
reconnect the motor wires. Turn on the AC supply.
5. To allow the Commissioning Wizard to function, the drive enable signal will need to be
present on connector X3 to allow the MicroFlex e100 to be enabled (see section 5.2.1). If
you do not wish to enable the MicroFlex e100 yet, the Commissioning Wizard will inform
you when this step is necessary.
6-2 Configuration
MN1942
6.2.3 Installing the USB driver
When the MicroFlex e100 is powered, Windows will automatically detect the controller and
request the driver.
1. Windows will prompt for the driver. On Windows XP, click Next on the following dialogs
and Windows will locate and install the driver. For Windows Vista and newer, no
interaction should be necessary.
2. When installation is complete, a new Motion Control category will be listed in Windows
Device Manager.
The MicroFlex e100 is now ready to be configured using Mint WorkBench.
Note: If the MicroFlex e100 is later connected to a different USB port on the host
computer, Windows may report that it has found new hardware. Either install the
driver files again for the new USB port, or connect the MicroFlex e100 to the
original USB port where it will be recognized in the usual way.
MN1942
Configuration 6-3
6.2.4 Configuring the TCP/IP connection (optional)
If you have connected the MicroFlex e100 to the PC using the Ethernet connection, it will be
necessary to alter the PC’s Ethernet adapter configuration to operate correctly with the
MicroFlex e100.
i
NOTICE
You cannot connect an ordinary office PC to the MicroFlex e100 without first
altering the PC’s Ethernet adapter configuration. However, if you have installed a
second Ethernet adapter dedicated for use with the MicroFlex e100, then this
adapter’s configuration can be altered without affecting the PC’s office Ethernet
connection. If you are unsure about making changes to your PC’s Ethernet
adapter configuration, or are prevented by user permission levels, ask your I.T.
administrator to assist you.
The following explanation assumes the PC is connected directly to the MicroFlex e100, and
not across an intermediate Ethernet network. If you wish to attempt the connection through
an intermediate Ethernet network, then the network administrator must be consulted to
ensure that the necessary IP addresses will be allowed and are not already allocated on the
network. The MicroFlex e100 has a fixed IP address of the format 192.168.100.xxx. The last
number, xxx, is the decimal value defined by the MicroFlex e100’s node ID selector switches
(see section 5.7.1).
1. On the Windows Start menu, select Settings, Network Connections.
2. In the Network Connections Window, right-click the ‘Local Area Connection’ entry for the
required Ethernet adapter and choose Properties.
3. In the Local Area Connection Properties dialog, in the ‘This connection uses the
following items’ list, select the ‘Internet Protocol (TCP/IP)’ entry and click Properties.
4. In the Internet Protocol (TCP/IP) Properties dialog, on the General tab, make a note of
the existing settings. Click Advanced... and make a note of any existing settings. Click
the Alternate Configuration tab and make a note of any existing settings.
5. On the General tab, choose the ‘Use the following IP address’ option.
6. In the IP address box, enter the IP address 192.168.100.241. This is the IP address that
will be assigned to the Ethernet adapter. The value 241 is deliberately chosen as it is
outside the range that can be used by MicroFlex e100, so avoiding possible conflicts.
7. In the Subnet mask box, enter 255.255.255.0 and click OK.
Click OK to close the Local Area Connection Properties dialog.
8. On the Windows Start menu, select Command Prompt (often found under Accessories).
9. n the Command Prompt window, type PING 192.168.100.16, where the final value (16 in
this example) is the value selected by the MicroFlex e100’s node ID selector switches. In
this example, the MicroFlex e100’s switches would be set to HI=1 LO=0, which
represents hexadecimal 10, equivalent to decimal 16 (see section 5.7.1 for a list of
hexadecimal / decimal equivalents). A reply message should be returned.
10. It should now be possible to run Mint WorkBench and connect to the MicroFlex e100
using the Ethernet / TCP/IP connection.
6-4 Configuration
MN1942
6.3 Mint Machine Center
The Mint Machine Center (MMC) is installed as part of the Mint WorkBench software. It is
used to view the network of connected controllers in a system. Individual controllers and
drives are configured using Mint WorkBench.
Note: If you have only a single MicroFlex e100 connected to your PC, then MMC is
probably not required. Use Mint WorkBench (see section 6.4) to configure the
MicroFlex e100.
Toolbars
Menu system
Controller pane
Information pane
Figure 50: The Mint Machine Center software
The Mint Machine Center (MMC) provides an overview of the controller network currently
accessible by the PC. The MMC contains a controller pane on the left, and an information
pane on the right. In the controller pane select the Host item, then in the information pane
click Scan. This causes MMC to scan for all connected controllers. Clicking once on a
controller’s name causes various options to be displayed in the information pane. Doubleclicking on a controller’s name launches an instance of Mint WorkBench that is automatically
connected to the controller.
Application View allows the layout and organization of controllers in your machine to be
modelled and described on screen. Controllers can be dragged onto the Application View
icon, and renamed to give a more meaningful description, for example “Conveyor 1,
Packaging Controller”. Drives that are controlled by another product, such as a
NextMove e100, can be dragged onto the NextMove e100 icon itself, creating a visible
representation of the machine. A text description for the system and associated files can be
added, and the resulting layout saved as an “MMC Workspace”. When you next need to
administer the system, simply loading the workspace automatically connects to all the
required controllers. See the Mint help file for full details of MMC.
MN1942
Configuration 6-5
MintDriveII
Mint WorkBench
RS232
MintDriveII
Mint WorkBench
RS485/422
Host PC
Mint Machine Center
MicroFlex e100
Mint WorkBench
USB
MicroFlex e100
Mint WorkBench
Ethernet
MicroFlex e100
Mint WorkBench
USB
Figure 51: Typical network visibility provided by Mint Machine Center
6-6 Configuration
MN1942
6.3.1 Starting MMC
1. On the Windows Start menu, select Programs, Mint WorkBench, Mint Machine Center.
2. In the controller pane, ensure that Host is
selected. In the information pane, click
Scan.
3. When the search is complete, click once
on ‘MicroFlex e100’ in the controller pane
to select it, then double click to open an
instance of Mint WorkBench. The
MicroFlex e100 will be already connected
to the instance of Mint WorkBench, ready
to configure.
MN1942
Configuration 6-7
6.4 Mint WorkBench
Mint WorkBench is a fully featured application for commissioning the MicroFlex e100. The
main Mint WorkBench window contains a menu system, the Toolbox and other toolbars.
Many functions can be accessed from the menu or by clicking a button - use whichever you
prefer. Most buttons include a ‘tool-tip’; hold the mouse pointer over the button (don’t click)
and its description will appear.
Menu
system
Menu system
Toolbars
Toolbars
Control and test area
Toolbox
Figure 52: The Mint WorkBench software
6-8 Configuration
MN1942
6.4.1 Help file
Mint WorkBench includes a comprehensive help file that contains information about every
Mint keyword, how to use Mint WorkBench and background information on motion control
topics. The help file can be displayed at any time by pressing F1. On the left of the help
window, the Contents tab shows the tree structure of the help file. Each book
contains a
number of topics . The Index tab provides an alphabetic list of all topics in the file, and
allows you to search for them by name. The Search tab allows you to search for words or
phrases appearing anywhere in the help file. Many words and phrases are underlined and
highlighted with a color (normally blue) to show that they are links. Just click on the link to go
to an associated keyword. Most keyword topics begin with a list of relevant See Also links.
Figure 53: The Mint WorkBench help file
For help on using Mint WorkBench, click the Contents tab, then click the small plus sign
beside the Mint WorkBench & Mint Machine Center book icon. Double click a
topic
name to display it.
MN1942
Configuration 6-9
6.4.2 Starting Mint WorkBench
Note: If you have already used MMC to start an instance of Mint WorkBench then the
following steps are unnecessary. Go to section 6.4.3 to continue configuration.
1. On the Windows Start menu, select Programs, Mint WorkBench, Mint WorkBench.
2. In the opening dialog box, click Start New Project... .
6-10 Configuration
MN1942
3. In the Select Controller dialog, click Scan to search for the MicroFlex e100. Mint
WorkBench will scan the PC’s ports for the MicroFlex e100.
When the search is complete, click ‘MicroFlex e100’ in the list to select it, then click
Select.
This check box is already selected for you. When you click
Select, it means that the Commissioning Wizard will start
automatically.
Note: If the MicroFlex e100 is not listed, check the USB or Ethernet cable between the
MicroFlex e100 and the PC. Check that the MicroFlex e100 is powered correctly.
Click Scan to re-scan the ports.
MN1942
Configuration 6-11
6.4.3 Commissioning Wizard
Each type of motor and drive combination has different performance characteristics. Before
the MicroFlex e100 can be used to control the motor accurately, the MicroFlex e100 must be
‘tuned’. This is the process where the MicroFlex e100 powers the motor in a series of tests.
By monitoring the drive’s output and the feedback from the motor’s encoder, the
MicroFlex e100 can make small adjustments to the way it controls the motor. This
information is stored in the MicroFlex e100 and can be uploaded to a file if necessary.
The Commissioning Wizard provides a simple way to tune the MicroFlex e100 and create the
necessary configuration information for your drive/motor combination, so this is the first tool
that should be used. If necessary, any of the parameters set by the Commissioning Wizard
can be adjusted manually after commissioning is complete.
6.4.3.1 Using the Commissioning Wizard
Each screen of the Commissioning Wizard requires you to enter information about the motor,
drive or application. Read each screen carefully and enter the required information. When
you have completed a screen, click Next > to display the next screen. If you need to change
something on a previous screen, click the < Back button. The Commissioning Wizard
remembers information that you have entered so you will not need to re-enter everything if
you go back to previous screens. If you need extra help, click Help or press F1.
Connectivity:
If you wish to change a node ID or baud rate then click in the appropriate cell and select an
alternative value. When multiple controllers are to be connected on the same bus they must
each have a unique node ID. For example, if two MicroFlex e100s and a NextMove e100 are
connected to the PC using individual USB connections, they must each be assigned a
unique USB nodeID.
Select your Motor Type:
Select the type of motor that you are using (rotary or linear).
6-12 Configuration
MN1942
Select your Motor:
Carefully enter the details of your motor. If you are using a Baldor Motor, the catalog number
or spec. number can be found stamped on the motor’s nameplate. If you are using a motor
with EnDat feedback, are not using a Baldor motor, or need to enter the specification
manually, select the I would like to define a custom motor option.
Confirm Motor and Drive information:
If you entered the catalog or spec. number on the previous page, it is not necessary to
change anything on this screen; all the required data will be entered already. However, if you
selected the I would like to define a custom motor option, it will be necessary to enter the
required information before continuing.
Motor Feedback:
If you entered the catalog or spec. number on the previous page, it is not necessary to
change anything on this screen; the feedback resolution will be entered already. However, if
you selected the I would like to define a custom motor option, it will be necessary to enter the
feedback resolution before continuing.
Drive Setup complete:
This screen confirms that drive setup is complete.
Select Operating Mode and Source:
In the Operating Mode section, choose the required operating mode. In the Reference
Source section, it is important to select ‘Host/Mint’ as the Control Ref. Source. This will allow
the Autotune Wizard to operate correctly, and allow further initial testing to be performed
using Mint WorkBench. Although the MicroFlex e100 may eventually be controlled over
Ethernet POWERLINK (EPL), the ‘EPL’ reference source should only be selected after the
MicroFlex e100 has been commissioned and is ready to add to the EPL network. This can be
selected by choosing the Operating Mode tool in the Toolbox.
Application Limits:
It is not necessary to change anything on this screen. However, if you wish to adjust the
application peak current (App. Peak Current) and/or application maximum speed (App. Max.
Speed), then click in the appropriate box and enter a value.
Scale Factor:
It is not necessary to change anything on this screen. However, it is recommended to select
a user unit for position, velocity and acceleration. This allows Mint WorkBench to display
distances, speeds and accelerations using meaningful units, instead of encoder counts. For
example, selecting a Position User Unit of Revs (r) will mean that all position values entered
or displayed in Mint WorkBench will represent revolutions. The Position Scale Factor value
will change automatically to represent the required scale factor (the number of quadrature
counts per revolution). If you need to use an alternative unit, for example degrees, type
“Degrees” in the Position User Unit box and enter a suitable value in the Position Scale
Factor box. Separate velocity and acceleration units can also be defined. See the Mint help
file for more information about scale factors.
Profile Parameters:
It is not necessary to change anything on this screen. However, if you wish to adjust the
parameters for any control method, click in the appropriate box and enter a value.
MN1942
Configuration 6-13
Operation setup complete:
This screen confirms that operation setup is complete.
During commissioning, changed parameters are stored in the MicroFlex e100’s temporary
(volatile) memory. For this reason, the Commissioning Wizard will occasionally prompt you to
save the parameters. Selecting Yes will cause the parameters to be saved in the
MicroFlex e100’s non-volatile flash memory, to be retained when power is removed. If you
select No, you must remember to use the Save Drive Parameters function before removing
power from the MicroFlex e100; this function is available on the Tools menu, or by clicking
the
button on the Mode toolbar. Saving parameters into flash memory will cause the
MicroFlex e100 to be reset.
6.4.3.2 Autotune Wizard
The Autotune Wizard tunes the MicroFlex e100 for optimal performance with the attached
motor. This removes the need for manual fine-tuning of the system, although in some critical
applications this still may be required.
Click Options... to configure optional autotuning parameters. These include Triggered
Autotune which allows the autotuning process to be delayed until the drive is enabled.
CAUTION
The motor will move during autotuning. For safety it is advisable to disconnect
any load from the motor during initial autotuning. The motor can be tuned with
the load connected after the Commissioning Wizard has finished.
Autotune
Click START to begin the auto-tuning process. Mint WorkBench will take measurements
from the motor and then perform small test moves.
For further information about tuning with the load attached, see section 6.4.5.
6-14 Configuration
MN1942
6.4.4 Further tuning - no load attached
The Autotune Wizard calculates many parameters that allow the MicroFlex e100 to provide
good control of the motor. In some applications, these parameters may need to be fine-tuned
to provide the exact response that you require.
1. Click the Fine-tuning icon in the Toolbox on the left of the screen.
The Fine-tuning window is displayed at the right of the screen.
This already shows some of the parameters that have been
calculated by the Commissioning Wizard.
The main area of the Mint WorkBench window displays the
capture window. When further tuning tests are performed, this will
display a graph representing the response.
2. The Fine-tuning window has a number
of tabs the bottom.
Click on the Velocity tab.
Note: Some tabs may not be available depending on the configuration mode you
selected in the Commissioning Wizard.
3. In the Test Parameters area at the
bottom of the tab, click in the Move Type
drop down box and select Forward.
In the Velocity and Distance boxes,
enter values to create a short move.
The values you enter depend on the
velocity scaling factor that was selected
in the Commissioning Wizard. This example assumes the velocity scaling factor was
selected as Revs Per Minute (rpm), so entering a value of 1000 here will create a move
with a velocity of 1000 rpm. Similarly, assuming the position scaling factor had been set
to Revolutions (r), the value 10 will create a move lasting for 10 revolutions of the motor.
4. Click Go to start the test move. Mint
WorkBench will perform the test move
and display a graph of the result.
5. Click on the graph labels to turn off
unwanted traces. Leave just Demand
Velocity and Measured Velocity turned
on.
Note: The graph that you see will not look exactly the same as the following graph!
Remember that each motor has a different response.
MN1942
Configuration 6-15
Measured
velocity
Data 1
Demand velocity
Time(ms)
Figure 54: Typical autotuned response (no load)
Figure 54 shows that the response reaches the demand quickly and only overshoots the
demand by a small amount. This can be considered an ideal response for most systems.
For further information about tuning with the load attached, see section 6.4.5.
6-16 Configuration
MN1942
6.4.5 Further tuning - with load attached
To allow Mint WorkBench to adjust the basic tuning to compensate for the intended load, it is
necessary to attach the load to the motor and then perform the autotune procedure again.
1. Attach the load to the motor.
2. Click the Autotune icon in the Toolbox on the left of the screen.
3. Click the Autotune on load check box.
4. Click START to begin the auto-tuning process. Mint WorkBench
will take measurements from the motor and then perform small
test moves.
5. Click the Fine-tuning icon in the Toolbox on the left of the screen.
6. In the Velocity tab’s Test Parameters
area,
ensure
the
same
move
parameters are entered and then click
Go to start the test move.
Mint WorkBench will perform the test
move and display a graph of the result.
MN1942
Configuration 6-17
6.4.6 Optimizing the velocity response
It may be desirable to optimize the default autotuned response to better suit your application.
The following sections describe the two main tuning issues and how to correct them.
6.4.6.1 Correcting overshoot
Figure 55 shows a response where the measured velocity overshoots the demand by a
significant amount.
1. Go to the Fine-tuning window’s Velocity
tab.
To reduce the amount of overshoot,
click Calculate... and increase the
bandwidth using the slider control.
Alternatively, type a larger value in the
Bandwidth box.
Click OK to close the Bandwidth dialog.
2. Click Go to start the test move. Mint
WorkBench will perform the test move
and display a graph of the result.
Measured
velocity
Data 1
Demand velocity
Time(ms)
Figure 55: Velocity overshoots demand
6-18 Configuration
MN1942
6.4.6.2 Correcting zero-speed noise in the velocity response
Figure 56 shows a response where there is very little overshoot but a significant amount of
zero-speed noise. This can cause undesirable humming or ringing in the motor.
1. Go to the Fine-tuning window’s Velocity
tab.
To reduce the amount of noise, click
Calculate...
and
decrease
the
bandwidth using the slider control.
Alternatively, type a smaller value in the
Bandwidth box.
Click OK to close the Bandwidth dialog.
2. Click Go to start the test move. Mint
WorkBench will perform the test move
and display a graph of the result.
Data 1
Demand velocity
Noise in
measured
velocity at
zero-speed
Time(ms)
Figure 56: Zero-speed noise
MN1942
Configuration 6-19
6.4.6.3 Ideal velocity response
Repeat the tests described in sections 6.4.6.1 and 6.4.6.2 until the optimal response is
achieved. Figure 57 shows an ideal velocity response. There is only a small amount of
overshoot and very little zero-speed noise.
Measured
velocity
Data 1
Demand velocity
Time(ms)
Figure 57: Ideal velocity response
6-20 Configuration
MN1942
6.4.7 Performing test moves - continuous jog
This section tests the basic operation of the drive and motor by performing a continuous jog.
Note: To stop a move in progress, click the red stop button or the drive enable button
on the toolbar. Alternatively, use the Mint WorkBench ‘Red Stop Button’ feature.
1. Check that the Drive enable button is
pressed (down).
2. In the Toolbox, click the Edit & Debug icon.
3. Click in the Command window.
4. Type:
JOG(0)=10
This will cause the motor to move
continuously at 10 units per second. In Mint
WorkBench, look at the Spy window located
on the right of the screen. Check that the
axis tab is selected. The Spy window’s
Velocity display should show 10 (approximately). If there seems to be very little motor
movement, it is probably due to the scale factor. In the Commissioning Wizard, on the
Select Scale Factor page, if you did not adjust the scale factor then the current unit of
movement is feedback counts per second. Depending on the motor’s feedback device,
10 feedback counts per second could equate to a very small velocity. Issue another JOG
command using a larger value, or use the Operating Mode Wizard to select a suitable
scale factor (e.g. 4000 if the motor has a 1000 line encoder, or 10,000 for a 2500 line
encoder).
5. To stop the test, type:
STOP(0)
6. If you have finished testing click the Drive
Enable button to disable the drive.
MN1942
Configuration 6-21
6.4.8 Performing test moves - relative positional move
This section tests the basic operation of the drive and motor by performing a positional move.
Note: To stop a move in progress, click the red stop button or the drive enable button
on the toolbar. Alternatively, use the Mint WorkBench ‘Red Stop Button’ feature.
1. Check that the Drive enable button is pressed
(down).
2. In the Toolbox, click the Edit & Debug icon.
3. Click in the Command window.
4. Type:
MOVER(0)=10
GO(0)
This will cause the motor to move to a
position 10 units from its current position.
The move will stop when completed.
5. If you have finished testing click the Drive
Enable button to disable the drive.
6-22 Configuration
MN1942
6.5 Further configuration
Mint WorkBench provides a number of other tools for testing and configuring the MicroFlex
e100. Every tool is explained fully in the help file. Press F1 to display the help file, then
navigate to the Mint WorkBench book. Inside this is the Toolbox book.
6.5.1 Fine-tuning tool
The Commissioning Wizard calculates many parameters that allow the MicroFlex e100 to
provide basic control of the motor. These parameters may need to be fine-tuned to provide
the exact response that you require. The Fine-tuning screen allows you to do this.
1. Click the Fine-tuning icon in the Toolbox on the left of the screen.
The Fine-tuning window is displayed at the right of the screen.
This already shows some of the parameters that have been
calculated by the Commissioning Wizard.
The main area of the Mint WorkBench window displays the capture window. When
further tuning tests are performed, this will display a graph representing the response.
2. The Fine-tuning window has several
tabs at the bottom - Position, Velocity,
Current, SRamp etc. Click on a tab to
select it.
Click the tab for the type of tests you wish to perform.
Note: Some tabs may not be available depending on the configuration mode you
selected in the Commissioning Wizard.
6.5.1.1 Fine-tuning - Position tab
The Position tab allows you to adjust position loop settings and perform test moves. The
Commissioning Wizard may have already set some of these values, depending on the type
of system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab.
Enter test values and then click Go to perform the test move. If you need help, just press F1
to display the help file.
6.5.1.2 Fine-tuning - Velocity tab
The Velocity tab allows you to set velocity loop gains and perform test moves. The
Commissioning Wizard may have already set some of these values, depending on the type
of system selected on the mode screen.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab.
Enter test values and then click Go to perform the test move. If you need help, just press F1
to display the help file.
MN1942
Configuration 6-23
6.5.1.3 Fine-tuning - Current tab
The Current tab allows you to set current loop gains and perform test moves. The
Commissioning Wizard may have already set some of these values, depending on the type
of system selected on the mode screen. Normally, it should not be necessary to alter these
values.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Test Parameters area at the bottom of the tab.
Enter test values and then click Go to perform the test move. If you need help, just press F1
to display the help file.
The additional Measure and Feedback alignment buttons can be used to repeat the same
measurement and alignment tests that are used by the Commissioning Wizard.
6.5.1.4 Fine-tuning - SRamp / Simple SRamp tabs
The SRamp and Simple SRamp tabs allow you to set parameters and perform test moves
using S-ramped profiles. These profiles cause the normal trapezoidal move profile to be
modified to create smoother acceleration and decleration.
Enter new values in the required boxes and then click Preview to see an example of the
intended move profile. Click Go to perform the test move. If you need help, just press F1 to
display the help file.
6.5.1.5 Fine-tuning - Filter tab
The Filter tab allows you to set the properties of the MicroFlex e100’s two torque filters. It
should only be necessary to use the torque filters if there is a particular problem with
resonant frequencies in the load.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. To perform tests, go to the Frequency Response Params area at the bottom
of the tab. Enter test values and then click Go to perform the test move. If you need help, just
press F1 to display the help file.
6.5.1.6 Fine-tuning - Flux tab
The Flux tab allows you to set gains and perform test moves when using induction motors.
Enter new values in the required boxes and then click Apply to download the values to the
MicroFlex e100. Click Go to perform the test move. If you need help, just press F1 to display
the help file.
6-24 Configuration
MN1942
6.5.2 Parameters tool
The Parameters tool can be used to view or change most of the drive’s parameters.
1. Click the Parameters icon in the Toolbox on
the left of the screen.
The main area of the Mint WorkBench
window displays the Parameters editor
screen.
Items listed with a grey
Items listed with a green
icon are Read Only so cannot be changed.
icon are currently set to their Factory Default value.
Items listed with a yellow
icon have been altered from their factory default value,
either during the commissioning process or by the user.
2. In the parameters tree, scroll to the required
item. Click on the small + sign beside the
item’s name.
The list will expand to show all items in the
category.
Click on the item you wish to edit.
3. The adjacent table will list the chosen item.
Click in the Active Table cell and enter a
value. This immediately sets the parameter,
which will remain in the MicroFlex e100 until
another value is defined. The icon to the left
of the item will become yellow to indicate that
the value has been changed.
Many of the MicroFlex e100’s parameters are set automatically by the Commissioning
Wizard, or when tests are performed in the fine-tuning window.
MN1942
Configuration 6-25
6.5.3 Spy window
The Spy window can be used to monitor and capture parameters in real-time. If you tried the
test moves in section 6.4.7 or 6.4.8 then you have already seen the Spy window, as it is
displayed in conjunction with Edit & Debug mode. See the Mint help file for full details of each
tab.
1. Click the Edit & Debug icon in the Toolbox on
the left of the screen.
The Spy Window is displayed on the right of
the screen. Click on the tabs at the bottom of
the window to select the required function.
2. The Axis tab displays the five most commonly
monitored parameters, together with the state of
special purpose inputs and outputs.
3. The I/O tab displays the state of all the digital inputs
and outputs.
Clicking on an output LED will toggle the output on/
off.
4. The Monitor tab allows up to six parameters to be
selected for monitoring.
Click in a drop down box to select a parameter.
At the bottom of the Monitor tab, real-time data
capture can be configured.
6-26 Configuration
MN1942
6.5.4 Other tools and windows
Remember, for help on each tool just press F1 to display the help file, then navigate to the
Mint WorkBench book. Inside this is the Toolbox book.

Edit & Debug Tool
This tool provides a work area
including the Command window and
Output window. The Command
window can be used to send
immediate Mint commands to the
MicroFlex e100. If you tried the test
moves in section 6.4.7 or 6.4.8, then
you have already used Edit & Debug
mode. Press Ctrl+N to open a new
Mint program editing window.

Scope Tool
Displays the capture screen. This screen is also shown when the Fine-tuning tool is
selected.

Digital I/O
Allows you to configure the active states
and special assignments for all the digital
inputs and outputs.
See section 5.2.2.1 or 5.2.3.1 for
important details about using a digital
input as a home input.
MN1942
Configuration 6-27
6-28 Configuration
MN1942
Troubleshooting
7 Troubleshooting
7
7.1 Introduction
This section explains common problems that may be encountered, together with possible
solutions. If you want to know the meaning of the LED indicators, see section 7.2.
7.1.1 Problem diagnosis
If you have followed all the instructions in this manual in sequence, you should have few
problems installing the MicroFlex e100. If you do have a problem, read this section first.
In Mint WorkBench, use the Error Log tool to view recent errors and then check the help file.
If you cannot solve the problem or the problem persists, the SupportMe feature can be used.
7.1.2 SupportMe feature
The SupportMe feature is available from the Help menu or by clicking the
button on the
motion toolbar. SupportMe can be used to gather information which can then be e-mailed,
saved as a text file, or copied to another application. The PC must have e-mail facilities to
use the e-mail feature. If you prefer to contact technical support by telephone or fax, contact
details are provided at the front of this manual. Please have the following information ready:

The serial number of your MicroFlex e100 (if known).

Use the Help, SupportMe menu item in Mint WorkBench to view details about your
system.

The catalog and specification numbers of the motor that you are using.

A clear description of what you are trying to do, for example trying to establish
communications with Mint WorkBench or trying to perform fine-tuning.

A clear description of the symptoms that you can observe, for example the Status LED,
error messages displayed in Mint WorkBench, or errors reported by the Mint error
keywords ERRORREADCODE or ERRORREADNEXT.

The type of motion generated in the motor shaft.

Give a list of any parameters that you have setup, for example the motor data you
entered/selected in the Commissioning Wizard, the gain settings generated during the
tuning process and any gain settings you have entered yourself.
7.1.3 Power-cycling the MicroFlex e100
The term “Power-cycle the MicroFlex e100” is used in the Troubleshooting sections. Remove
the 24 V supply, wait for the MicroFlex e100 to power down completely (the Status LED will
turn off), then re-apply the 24 V supply.
MN1942
Troubleshooting 7-1
7.2 MicroFlex e100 indicators
7.2.1 STATUS LED
The Status LED indicates general MicroFlex e100 status information.
Solid green:
Drive enabled (normal operation).
Flickering / blinking green:
Firmware download / update in progress.
Solid red:
Drive disabled, but no errors are latched.
Flashing red:
Powerbase fault or error(s) present. The number of flashes indicates which
error has occurred. For example, to display error 3 (overcurrent trip), the LED
flashes 3 times at 0.1 second intervals, followed by a 0.5 second pause. The
sequence is repeated continuously.
Error code
(no. of flashes)
Meaning
1 ..............
2 ..............
3 ..............
4 ..............
5 ..............
6 ..............
7 ..............
8 ..............
9 ..............
10 . . . . . . . . . . . . .
11. . . . . . . . . . . . . .
12 . . . . . . . . . . . . .
DC bus overvoltage trip.
IPM (integrated power module) trip.
Overcurrent trip.
Overspeed trip.
Feedback trip.
Motor overload (I2t) trip.
Overtemperature trip.
Drive overload (It) trip.
Following error trip.
Error input triggered.
Phase search error.
All other errors, including: Internal supply error, encoder
supply error, parameter restore failure, power base not
recognized.
If multiple errors occur at the same time, the lowest numbered error code will
be flashed. For example, a MicroFlex e100 which has tripped on both feedback
error (code 5) and over-current error (code 3) will flash error code 3. If the drive
is already displaying an error code when a new error with a lower code occurs,
the drive will start flashing the new code. Note that undervoltage trip does not
appear in the table because it is already indicated by the green/red flashing
state. If an undervoltage trip occurs in conjunction with another error, the drive
will flash the code of the additional error.
Further details about error codes can be found in the Mint WorkBench help file.
Press F1 and locate the Error Handling book.
Alternate red/green flashing:
Undervoltage warning (no AC power), but no errors are latched.
The DC-bus voltage has dropped below the powerbase undervoltage level (see
DRIVEBUSUNDERVOLTS). This error will only be generated if the drive is in the
enabled state. Check the AC power is connected.
7-2 Troubleshooting
MN1942
7.2.2 CAN LEDs
The CAN LEDs display the overall condition of the CANopen interface,
once the startup sequence has completed. The LED codes conform to
the CAN in Automation (CiA) DR303_3 indicator standard. The green
LED indicates the state of the node’s internal CANopen ‘state
machine’. The red LED indicates the state of the physical CANopen
bus.
Green (run)
Off: Node initializing or not powered.
1 flash: Node in STOPPED state.
3 flashes: Software is being downloaded to the node.
Continuous flashing: Node in PRE-OPERATIONAL state.
Flickering (very fast flashing): Auto-baudrate detection or LSS services in
progress; flickers alternately with red LED.
Continuously illuminated, not flashing: Node in OPERATIONAL state.
Red (error)
Off: No errors or not powered.
1 flash: Warning - too many error frames.
2 flashes: Guard event or heartbeat event has occurred.
3 flashes: The SYNC message has not been received within the timeout period.
Flickering (very fast flashing): Auto-baudrate detection or LSS services in
progress; flickers alternately with green LED.
Continuously illuminated, not flashing: The node’s CAN controller is in the BUS
OFF state, preventing it from taking part in any CANopen communication.
MN1942
Troubleshooting 7-3
7.2.3 ETHERNET LEDs
The ETHERNET LEDs display the overall condition of the Ethernet
interface once the startup sequence has completed. The LED codes
conform to the Ethernet POWERLINK Standardization Group
(EPSG) standard at the time of production.
Green (status)
Off: Node in NOT ACTIVE state. The controlled node is waiting to be triggered by
the manager node.
1 flash: Node in PRE-OPERATIONAL1 state. EPL mode is starting.
2 flashes: Node in PRE-OPERATIONAL2 state. EPL mode is starting.
3 flashes: Node in READY TO OPERATE state. The node is signalling its
readiness to operate.
Blinking (continuous flashing): Node in STOPPED state. The controlled node has
been deactivated.
Flickering (very fast flashing): Node in BASIC ETHERNET state (EPL is not
operating, but other Ethernet protocols may be used).
Continuously illuminated, not flashing: Node in OPERATIONAL state. EPL is
operating normally.
Red (error)
Off: EPL is working correctly.
Continuously illuminated: An error has occurred.
7-4 Troubleshooting
MN1942
7.2.4 Communication
Status LED is off:

Check that the 24 V DC control circuit supply is connected correctly to connector X2 and
is switched on.
ETHERNET LEDs blinking green and red simultaneously:

Does the MicroFlex e100 have firmware in it? If you tried to download new firmware and
the download failed, the controller may not have firmware. Download new firmware.
Mint WorkBench fails to detect the MicroFlex e100:

Ensure that the MicroFlex e100 is powered and the Status LED is illuminated (see
section 7.2.1).

Check that the Ethernet or USB cable is connected between the PC and MicroFlex e100.

Try an alternative cable or different port on the PC.

In the “Search up to Nodexx” option in Mint WorkBench’s Select Controller dialog, check
that the MicroFlex e100’s node ID is not higher than the selected value, or search up to a
greater node ID.

For USB connections, check that the cable is properly connected. Check the USB
connector socket pins for damage or sticking. Check that the USB device driver has
been installed; a ‘USB Motion Controller’ device should be listed in Windows Device
Manager.

Check that the PC’s Ethernet port has been correctly configured for TCP/IP operation
(see section 6.2.4).
7.2.5 Power on
The Status LED is flashing red:

The MicroFlex e100 has detected a motion error. Click the Error button on the motion
toolbar to view a description of the error. Alternatively, select the Error Log tool to view a
list of errors.
Click the Clear Errors button on the motion toolbar.
7.2.6 Mint WorkBench
The Spy window does not update:

The system refresh has been disabled. Go to the Tools, Options menu item, select the
System tab and then choose a System Refresh Rate (500 ms is recommended).
Cannot communicate with the controller after downloading firmware:

After firmware download, always power cycle the MicroFlex e100 (remove 24 V power
and then reconnect).
Mint WorkBench loses contact with MicroFlex e100 while connected using USB:

Check that the MicroFlex e100 is powered.

Check that a ‘USB Motion Controller’ device is listed in Windows Device Manager. If not,
there could be a problem with the PC’s USB interface.
MN1942
Troubleshooting 7-5
7.2.7 Tuning
Cannot enable the MicroFlex e100 because there is an error 10010:

Check the drive enable input on connector X3 pins 9 and 19 is connected and powered
correctly.
When the MicroFlex is enabled the motor is unstable:

Check that the load is firmly coupled to the motor.

Use the Mint WorkBench Drive Setup Wizard to confirm that the correct motor data has
been entered.

Use the Mint WorkBench Autotune Wizard to retune the motor.

If the motor is still unstable, select the Mint WorkBench Autotune Wizard once more.
Click Options.... On the Bandwidth tab, move the Current and/or Position and Speed
Control sliders to a slower position to select to a lower bandwidth. Click OK to exit and
then start the Autotune Wizard again.
7.2.8 Ethernet
Cannot connect to the drive over TCP/IP:

Check that there is not an EPL manager node (for example NextMove e100 with node ID
240) on the network. If there is a manager node on the network, then an EPL compatible
router must be used to allow TCP/IP communication on the EPL network.

Check that the PC’s Ethernet adapter has been correctly configured, as described in
section 6.2.4.
The Ethernet POWERLINK network does not seem to be operating correctly:

Confirm that only one device on the newtork is set to be the Ethernet POWERLINK
manager node (node ID 240, selector switches LO = F, HI = 0).

Confirm that the reference source on all controlled nodes has been set to EPL in the Mint
WorkBench Operating Mode Wizard, and that the manager node has been configured
correctly. For a NextMove e100 manager node, this requires the System Config Wizard
to be used in Mint WorkBench.

Confirm that each device on the network has a different node ID.

Confirm that there are no more than 10 ‘daisy-chained’ devices on each branch of the
network.
7.2.9 CANopen
The CANopen bus is ‘passive’:
This means that the internal CAN controller in the MicroFlex e100 is experiencing a number
of Tx and/or Rx errors, greater than the passive threshold of 127. Check:

12-24 V is being applied between pin 9 (+24 V) and pin 6 or 3 (0 V) of the OPT 1
connector, to power the opto-isolators.

There is at least one other CANopen node in the network.

The network is terminated only at the ends, not at intermediate nodes.

All nodes on the network are running at the same baud rate.

All nodes have been assigned a unique node ID.

The integrity of the CAN cables.
7-6 Troubleshooting
MN1942
The MicroFlex e100 should recover from the ‘passive’ state once the problem has been
rectified (this may take several seconds).
The CANopen bus is ‘off’:
This means that the internal CAN controller in the MicroFlex e100 has experienced a fatal
number of Tx and/or Rx errors, greater than the off threshold of 255. At this point the node
will have switched itself to a state whereby it cannot influence the bus. Check:

12-24 V is being applied between pin 9 (+24 V) and pin 6 or 3 (0 V) of the OPT 1
connector, to power the opto-isolators.

There is at least one other CANopen node in the network.

The network is terminated only at the ends, not at intermediate nodes.

All nodes on the network are running at the same baud rate.

All nodes have been assigned a unique node ID.

The integrity of the CAN cables.
To recover from the ‘off’ state, the source of the errors must be removed and bus then reset.
This can be done using the Mint BUSRESET keyword, or by resetting the MicroFlex e100.
The Manager node cannot scan/recognize a node on the network using the Mint
NODESCAN keyword:
Assuming that the network is working correctly (see previous symptoms) and the bus is in an
‘Operational’ state, check:

Only nodes that conform to DS401, DS403 and other ABB CANopen nodes are
recognized by the Mint NODESCAN keyword. Other types of node will be identified with a
type “unknown” (255) when using the Mint NODETYPE keyword.

Check that the node in question has been assigned a unique node ID.

The node must support the node guarding process. MicroFlex e100 does not support the
Heartbeat process.

Try power-cycling the node in question.
If the node in question does not conform to DS401 or DS403 and is not an ABB CANopen
node, communication is still possible using a set of general purpose Mint keywords. See the
Mint help file for further details.
The node has been successfully scanned / recognized by the Manager node, but
communication is still not possible:
For communication to be allowed, a connection must be made to a node after it has been
scanned:

Controller nodes are automatically connected to after being scanned.

Nodes that conform to DS401, DS403 must have the connections made manually using
the Mint CONNECT keyword.
If a connection attempt using CONNECT fails then it may be because the node being
connected to does not support an object which needs to be accessed in order to setup the
connection.
MN1942
Troubleshooting 7-7
7-8 Troubleshooting
MN1942
Specifications
8 Specifications
8
8.1 Introduction
This section provides technical specifications for the MicroFlex e100.
8.1.1 AC input power and DC bus voltage (X1)
All models
AC input
Unit
1Φ
Nominal input voltage
3Φ
115 or 230
Minimum input voltage
V AC
105*
Maximum input voltage
Nominal DC-bus voltage
@230 V AC input
250
305
V DC
Nominal input current
@ maximum rated output current
A
321
3A
6A
9A
3A
6A
9A
7.5
15
22
4
8
12
* The MicroFlex e100 will operate at lower input voltages, although the drive will trip if the
DC-bus voltage falls below 50 V or 60% of the no-load voltage, whichever occurs first.
DC-bus voltage (V DC)
8.1.1.1 Effect of AC power supply voltage on DC-bus voltage
Three-phase AC supply
Single-phase AC supply
AC supply voltage (rms)
MN1942
Specifications 8-1
DC-bus ripple (% of DC-bus voltage)
8.1.1.2 Effect of AC power supply voltage on DC-bus ripple
Single-phase AC supply
Three-phase AC supply
AC supply voltage (rms)
DC-bus ripple voltage (Vpk-pk)
8.1.1.3 Effect of output current on DC-bus ripple voltage
Single-phase AC supply
Three-phase AC supply
% of Drive Rated Current
8-2 Specifications
MN1942
8.1.2 24 V control circuit supply input (X2)
Unit
3A
Nominal input voltage
Minimum input voltage
6A
9A
24
V DC
20
Maximum ripple
%
±10
Maximum continuous current @24 V DC
A
0.6
Power on surge current (typical)
@24 V DC, 100 ms
A
4
Maximum input voltage
30
8.1.3 Motor output power (X1)
Unit
Nominal phase current
Peak phase current
for 3 s
Nominal output
@ 230 V, 3Φ
Output voltage range (line-line)
@VDC-bus=320 V
Output frequency
ARMS
ARMS
VA
3A
6A
3
6
9A
9
6
12
18
1195
2390
3585
0 - 230
VRMS
Hz
0 - 2000
Output dv/dt
at drive, phase-phase
at drive, phase-ground
at motor (using 20 m cable), phase-phase
at motor (using 20 m cable), phase-ground
Nominal switching frequency
kHz
Minimum motor inductance (per winding)
mH
Efficiency
2
1.1
1.9
1.8
kV/μs
8.0
1
%
>95
8.1.4 Braking (X1)
Unit
Nominal switching threshold (typical)
V DC
Nominal power
(10% power cycle, R=57Ω)
kW
Peak power
(10% power cycle, R=57Ω)
kW
Maximum switching current
APK
3A
6A
on: 388, off: 376
0.25
2.7
10
Minimum load resistance
Ω
39
Maximum load inductance
μH
100
MN1942
9A
Specifications 8-3
8.1.5 Digital inputs - drive enable and DIN0 general purpose (X3)
Unit
Type
All models
Opto-isolated inputs
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
V DC
24
12
30
> 12
<2
Input current (maximum, per input)
mA
50
Sampling interval
ms
1
Minimum pulse width
μs
5
8.1.6 Digital inputs DIN1, DIN2 - high speed general purpose (X3)
Unit
Type
All models
Opto-isolated inputs
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
V DC
24
12
30
> 12
<2
Input current (maximum, per input)
mA
20
Maximum input frequency
ms
1
Minimum pulse width
μs
250
8.1.7 Digital outputs DOUT0, DOUT1 - status and general purpose (X3)
Unit
User supply (maximum)
Output current (max. continuous)
All models
V
28
mA
100
mA
s
200
<20
ms
1
Fuse
Approximate trip current
Reset time
Update interval
8-4 Specifications
MN1942
8.1.8 Incremental encoder feedback option (X8)
Unit
Encoder input
Maximum input frequency
(quadrature)
All models
RS422 A/B Differential, Z index
MHz
Hall inputs
8
RS422 A/B Differential
Output power supply to encoder
5 V (±7%), 200 mA max.
Maximum recommended cable length
30.5 m (100 ft)
8.1.9 BiSS interface (X8)
Unit
BiSS encoder interface
All models
Differential Data and Clock
Single or multi-turn.
A wide range of devices can be
supported. Contact ABB
technical support before
selecting a device.
Operating mode
Output power supply to encoder
5 V (±7%), 200 mA max.
Maximum recommended cable length
30.5 m (100 ft)
8.1.10 SSI encoder feedback option (X8)
Unit
All models
SSI encoder inputs
Differential Data and Clock
Operating mode
(Baldor motors)
Single turn.
Positioning resolution up to
262144 counts/rev (18-bit)
Output power supply to encoder
Maximum recommended cable length
MN1942
5 V (±7%), 200 mA max.
30.5 m (100 ft)
Specifications 8-5
8.1.11 SinCos / EnDat encoder feedback option (X8)
Unit
All models
EnDat / SinCos differential
inputs and data input
Absolute encoder input
Single or multi-turn.
512 or 2048 Sin/Cos cycles per
turn, with absolute positioning
resolution of up to
65536 steps.
Operating mode
(Baldor motors)
(Many other encoder
specifications are supported contact ABB.)
Output power supply to encoder
5 V (±7%), 200 mA max.
Maximum recommended cable length
30.5 m (100 ft)
8.1.12 Ethernet interface (E1 / E2)
Description
Unit
Signal
Ethernet POWERLINK
& TCP/IP
Protocols
Bit rates
Value
2 twisted pairs,
magnetically isolated
Mbit/s
100
8.1.13 CAN interface (OPT 1)
Description
Unit
Signal
Value
2-wire, isolated
Channels
1
Protocol
CANopen
Bit rates
Kbit/s
10, 20, 50, 100, 125,
250, 500, 1000
8.1.14 RS485 interface
Description
Unit
Signal
Bit rates
8-6 Specifications
Value
RS485, 2-wire, non-isolated
Baud
9600, 19200, 38400,
57600 (default), 115200
MN1942
8.1.15 Environmental
Unit
All models
All models
Operating temperature range*
Minimum
Maximum
Derate
Storage temperature range*
Humidity (maximum)*
Forced air cooling flow
(vertical, from bottom to top)
Maximum installation altitude
(above m.s.l.)
°C
°F
+0
+45
See sections
3.2.2 to 3.2.6
+32
+113
See sections
3.2.2 to 3.2.6
-40 to +85
%
m/s
-40 to +185
93
3A
6A
9A
None required
1
2.5
m
1000
Derate 1.1% / 100 m over 1000 m
ft
3300
Derate 1.1% / 330 ft over 3300 ft
Shock*
10 G
Vibration*
1 G, 10-150 Hz
IP rating
IP20**
* MicroFlex e100 complies with the following environmental test standards:
BS EN60068-2-1:1993 low temperature operational 0°C.
BS EN60068-2-2:1993 high temperature operational 45°C.
BS EN60068-2-1:1993 low temperature storage/transportation -40°C.
BS EN60068-2-2:1993 high temperature storage/transportation +85°C.
BS 2011:part2.1 Cb: 1990: 45°C 93%RH humidity/high temperature operational.
DIN IEC 68-2-6/29
** MicroFlex e100 complies with EN61800-5-1:2003 part 5.2.2.5.3 (Impact test), provided all
front panel connectors are inserted.
8.1.16 Weights and dimensions
Description
Weight
Nominal overall dimensions
MN1942
3A
6A
9A
1.45 kg
(3.2 lb)
1.5 kg
(3.3 lb)
1.55 kg
(3.4 lb)
180 mm x 80 mm x 157 mm
(7.1 in x 3.2 in x 6.2 in)
Specifications 8-7
8-8 Specifications
MN1942
Accessories
A Accessories
A
A.1 Introduction
This section describes accessories and options that you may need to use with your
MicroFlex e100. Shielded (screened) cables provide EMI / RFI shielding and are required for
compliance with CE regulations. All connectors and other components must be compatible
with the shielded cable.
MN1942
Accessories A-1
A.1.1 Fan tray
The fan tray (part FAN001-024) provides sufficient cooling for the 3 A, 6 A or 9 A
MicroFlex e100. It requires 23 - 27.5 V DC at 325 mA, which may be sourced from the same
filtered control circuit supply used for the MicroFlex e100. The MicroFlex e100 is UL listed
(file NMMS.E128059) when used in conjunction with the fan tray, mounted exactly as shown
in Figure 58.
94 (3.7)
84 (3.3)
21.5
(0.85)
Fan tray
Fan tray
dimensions
142.5 (5.6)
Assembled MicroFlex e100
and fan tray
66 (2.6)
Position of fan tray mounting holes
relative to MicroFlex e100
17.3
(0.68)
Bottom of MicroFlex
e100
Fan tray
16
(0.63)
4.5
(0.18)
It is important that the fan tray is mounted in
close proximity to the MicroFlex e100 as
shown above. Failure to do so will result in
decreased cooling efficiency.
Figure 58: Fan tray
A-2 Accessories
MN1942
A.1.2 Footprint filter (single-phase only)
The single-phase footprint AC power filter (part FI0029A00) provides mounting holes for the
MicroFlex e100 and fan tray. This allows the filter, fan tray and MicroFlex e100 to use
minimal panel mounting space. See section A.1.4 for details of filter FI0029A00.
Footprint filter
FI0029A00
MicroFlex e100
MFE230A00x
Fan tray
FAN001-024
Figure 59: Assembled footprint filter, fan tray and MicroFlex e100
A.1.3 24 V power supplies
A range of compact 24 V DIN rail mounting power supplies are available. The supplies
include short circuit, overload, over-voltage and thermal protection.
Part
Input voltage
Output voltage
DR-75-24
DR-120-24
Output rating
75 W (3.2 A)
110-230 V AC
24 V DC
DRP-240-24
120 W (5 A)
240 W (10 A)
Table 9: 24 V power supplies
MN1942
Accessories A-3
A.1.4 EMC filters
AC filters remove high frequency noise from the AC power supply, protecting the
MicroFlex e100. These filters also prevent high frequency signals from being transmitted
back onto the power lines and help meet EMC requirements. To select the correct filter, see
sections 3.4.8 and 3.4.9.
A.1.4.1 Part numbers
Part
Rated volts
Rated amps
@ 40°C
Leakage current
(mA)
Weight
kg (lbs)
FI0014A00
250
3
0.4
0.27 (0.6)
FI0015A00
250
6
0.4
0.45 (0.99)
FI0015A01
250
10
0.4
0.73 (1.61)
FI0015A02
250
12
0.4
0.73 (1.61)
FI0018A00
480
7
33
0.5 (1.1)
FI0018A03
480
16
33
0.8 (1.76)
FI0029A00
250
22
33
3.0 (6.6)
B
F
M5
A
D
G
E
C
Dimensions mm (inches)
Dimension
FI0018A00
FI0018A03
A
190 (7.48)
250 (9.84)
B
160 (6.30)
220 (8.66)
C
180 (7.09)
235 (9.25)
D
20 (0.79)
25 (0.98)
E
4.5 (0.18)
5.4 (0.21)
F
71 (2.80)
70 (2.76)
G
40 (1.57)
45 (1.77)
Figure 60: Filter dimensions, types FI0018A00 and FI0018A03
A-4 Accessories
MN1942
L
H
D
E
A
C
G
F
K
J
B
Dimensions mm (inches)
Dimension
FI0015A01
FI0015A02
FI0014A00
FI0015A00
A
85 (3.35)
113.5 (4.47)
B
54 (2.13)
C
40 (1.57)
D
65 (2.56)
94 (3.70)
E
75 (2.95)
103 (4.06)
F
27 (1.06)
25 (0.98)
G
12 (0.47)
12.4 (0.49)
H
29.5 (1.16)
J
5.3 (0.21)
156 (6.14)
57.5 (2.26)
46.6 (1.83)
130.5 (5.14)
143 (5.63)
32.4 (1.28)
4.4 (0.17)
5.3 (0.21)
K
6.3 (0.25)
6 (0.24)
L
13.5 (0.53)
15.5 (0.61)
Figure 61: Filter dimensions, types FI0014A00, FI0015A00, FI0015A01, FI0015A02
MN1942
Accessories A-5
B
E
D
F
Mounting hole and slot detail
G
H
C
A
C
A
J
G
G
H
J
K
K
5.5 mm
11 mm
10 mm
5 mm
Dimensions shown as: mm (inches).
Dimensions mm (inches)
Dimension
FI0029A00
A
255 (10.04)
B
100 (3.94)
C
244.5 (9.63)
D
70 (2.76)
E
40 (1.57)
F
20 (0.79)
Figure 62: Filter dimensions, type FI0029A00
A-6 Accessories
MN1942
A.1.5 Brake resistors
Depending on the application, MicroFlex e100 might require an external brake resistor to be
connected to pins R1 and R2 of connector X1. The brake resistor dissipates energy during
braking to prevent an over–voltage error occurring. See sections 3.6 and 3.7 for details about
choosing the correct resistor.
WARNING
Electrical shock hazard. DC bus voltages may be present at these
terminals. Use a suitable heatsink (with fan if necessary) to cool the brake
resistor. The brake resistor and heatsink (if present) can reach
temperatures in excess of 80 °C (176 °F).
B
A
C
F
E
G
D
Resistor
RGJ139
RGJ160
RGJ260
RGJ360
Dimensions mm (inches)
Power
W
Res.
Ω
A
B
C
D
E
F
G
100
39
165
(6.49)
41
(1.61)
22
(0.87)
152
(5.98)
12
(0.47)
10
(0.39)
4.3
(0.17)
100
60
165
(6.49)
41
(1.61)
22
(0.87)
152
(5.98)
12
(0.47)
10
(0.39)
4.3
(0.17)
200
60
165
(6.49)
60
(2.36)
30
(1.18)
146
(5.75)
17
(0.67)
13
(0.51)
5.3
(0.21)
300
60
215
(8.46)
60
(2.36)
30
(1.18)
196
(7.72)
17
(0.67)
13
(0.51)
5.3
(0.21)
Figure 63: Brake resistor dimensions
MN1942
Accessories A-7
A.2 Cables
A wide range of motor and feedback cables are available from ABB.
A.2.1 Motor power cables
For easier installation, it is recommended that a color-coded motor power cable is used.
A description of a BSM rotary motor power cable part number is shown here, using the
example number CBL025SP-12:
Meaning
Alternatives
CBL The item is a cable
-
025
Indicates the length, in this example 2.5 meters Various lengths are available.
SP
The cable is a Servo motor Power cable
-
12
Current rating of 12 A
20=20 A; 35=35 A
Motor power cables include the motor power connector. Larger motors requiring 35 A cable
normally use terminal box connections, so a motor power connector is not required.
A.2.1.1 Cables available in North and South America
Cable
rated current
Cable assembly
description
12 Amps
Power cable:
no connectors
CBL050-501
Power cable
assembly:
CE style threaded
motor connector
(motor end only)
CBL015SP-12
CBL030SP-12
CBL061SP-12
CBL091SP-12
CBL152SP-12
CBL229SP-12
Power cable:
no connector
CBL051-501
Power cable
assembly:
CE style threaded
motor connector
(motor end only)
CBL015SP-20
CBL030SP-20
CBL061SP-20
CBL091SP-20
CBL152SP-20
CBL229SP-20
Power cable:
no connector
CBL052-501
20 Amps
35 Amps
A-8 Accessories
Part
Length
m
ft
Available by the foot or on
100 m (328 ft) drum.
1.5
3.0
6.1
9.1
15.2
22.9
5
10
20
30
50
75
Available by the foot or on
100 m (328 ft) drum
1.5
3.0
6.1
9.1
15.2
22.9
5
10
20
30
50
75
Available by the foot or on
100 m (328 ft) drum.
MN1942
A.2.1.2 Cables available in the rest of the world
Cable
rated current
Cable assembly
description
12 Amps
Power cable:
no connectors
CBL050-501
Power cable
assembly:
CE style threaded
motor connector
(motor end only)
CBL025SP-12
CBL050SP-12
CBL075SP-12
CBL100SP-12
CBL150SP-12
CBL200SP-12
Power cable:
no connector
CBL051-501
Power cable
assembly:
CE style threaded
motor connector
(motor end only)
CBL025SP-20
CBL050SP-20
CBL075SP-20
CBL100SP-20
CBL150SP-20
CBL200SP-20
Power cable:
no connector
CBL052-501
20 Amps
35 Amps
MN1942
Part
Length
m
ft
Available by the meter or on
100 m drum.
2.5
5.0
7.5
10
15
20
8.2
16.4
24.6
32.8
49.2
65.6
Available by the meter or on
100 m drum.
2.5
5
7.5
10
15
20
8.2
16.4
24.6
32.8
49.2
65.6
Available by the meter or on
100 m drum.
Accessories A-9
A.2.2 Feedback cable part numbers
A description of a feedback cable part number is shown here, using the example number
CBL025SF-E2:
Meaning
Alternatives
CBL
The item is a cable
-
025
Indicates the length, in this example 2.5 meters
Various lengths are available.
SF
The cable is a Servo motor Feedback cable
-
Encoder feedback cable with motor connector
S=SSI feedback cable
D=BiSS/EnDat/SinCos feedback
cable
E
2
Drive connector included:
15-pin D-type connector for all feedback types
-
Note: Feedback cables have the outer shield tied to the connector housing(s).
If you are not using an ABB cable with your chosen feedback device, be sure to obtain a
cable that is a shielded twisted pair 0.34 mm2 (22 AWG) wire minimum, with an overall
shield. Ideally, the cable should not exceed 30.5 m (100 ft) in length. Maximum wire-to-wire
or wire-to-shield capacitance is 50 pF per 300 mm (1 ft) length, to a maximum of 5000 pF for
30.5 m (100 ft).
A.2.3 SSI feedback cables
A.2.3.1 Cables available in North and South America
Cable assembly description
Part
SSI feedback cable:
no connectors
CBL044-501
Feedback cable assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
CBL015SF-S2
CBL030SF-S2
CBL061SF-S2
CBL091SF-S2
CBL152SF-S2
CBL229SF-S2
Length
m
ft
Available by the foot or
on 100 m (328 ft) drum.
5
10
20
30
50
75
1.5
3.0
6.1
9.1
15.2
22.9
A.2.3.2 Cables available in the rest of the world
Cable assembly description
Part
SSI feedback cable:
no connectors
CBL044-501
Feedback cable assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
CBL025SF-S2
CBL050SF-S2
CBL075SF-S2
CBL100SF-S2
CBL150SF-S2
CBL200SF-S2
A-10 Accessories
Length
m
ft
Available by the meter
or on 100 m drum.
2.5
5.0
7.5
10
15
20
8.2
16.4
24.6
32.8
49.2
65.6
MN1942
A.2.4 Encoder / Hall feedback cables
A.2.4.1 Cables available in North and South America
Length
Cable assembly description
Part
Encoder feedback cable:
no connectors
CBL043-501
Feedback cable assembly:
CE style threaded motor connector
(motor end only)
CBL025SF-E
2.5
8.2
Feedback cable assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
CBL015SF-E2
CBL030SF-E2
CBL061SF-E2
CBL091SF-E2
CBL152SF-E2
CBL229SF-E2
1.5
3.0
6.1
9.1
15.2
22.9
5
10
20
30
50
75
m
ft
Available by the foot or
on 100 m (328 ft) drum.
A.2.4.2 Cables available in the rest of the world
MN1942
Length
Cable assembly description
Part
Encoder feedback cable:
no connectors
CBL043-501
Feedback cable assembly:
CE style threaded motor connector
(motor end only)
CBL025SF-E
2.5
8.2
Feedback cable assembly:
CE style threaded motor connector
and low density 15-pin D-type drive
connector
CBL025SF-E2
CBL050SF-E2
CBL075SF-E2
CBL100SF-E2
CBL150SF-E2
CBL200SF-E2
2.5
5
7.5
10
15
20
8.2
16.4
24.6
32.8
49.2
65.6
m
ft
Available by the meter
or on 100 m drum.
Accessories A-11
A.2.5 BiSS, EnDat and SinCos feedback cables
A.2.5.1 Cables available in North and South America
Cable assembly description
Part
Absolute encoder feedback cable:
no connectors
CBL045-501
Absolute encoder
feedback cable assembly:
CE style threaded motor connector
and high density 15-pin D-type drive
connector
CBL015SF-D2
CBL030SF-D2
CBL061SF-D2
CBL091SF-D2
CBL152SF-D2
CBL229SF-D2
Length
m
ft
Available by the foot or
on 100 m (328 ft) drum.
5
10
20
30
50
75
1.5
3.0
6.1
9.1
15.2
22.9
A.2.5.2 Cables available in the rest of the world
Cable assembly description
Part
Absolute encoder feedback cable:
no connectors
CBL045-501
Absolute encoder
feedback cable assembly:
CE style threaded motor connector
and high density 15-pin D-type drive
connector
CBL025SF-D2
CBL050SF-D2
CBL075SF-D2
CBL100SF-D2
CBL150SF-D2
CBL200SF-D2
Length
m
ft
Available by the meter
or on 100 m drum.
8.2
16.4
24.6
32.8
49.2
65.6
2.5
5
7.5
10
15
20
A.2.6 Ethernet cables
The cables listed in this table connect MicroFlex e100 to other EPL nodes such as
NextMove e100, additional MicroFlex e100s, or other EPL compatible hardware. The cables
are standard CAT5e shielded twisted pair (S/UTP) ‘crossover’ Ethernet cables:
Cable assembly description
Part
CAT5e Ethernet cable
CBL002CM-EXS
CBL005CM-EXS
CBL010CM-EXS
CBL020CM-EXS
CBL050CM-EXS
CBL100CM-EXS
A-12 Accessories
Length
m
ft
0.2
0.5
1.0
2.0
5.0
10.0
0.65
1.6
3.3
6.6
16.4
32.8
MN1942
Control System
B Control System
B
B.1 Introduction
The MicroFlex e100 can use two main control configurations:

Servo (Position).

Torque Servo (Current).
Each configuration supports different control modes, selected by using the Tools, Control
Mode menu item or by using the CONTROLMODE keyword in the Command window (see the
Mint help file). The control configurations are described in the following sections.
MN1942
Control System B-1
B.1.1 Servo configuration
The servo configuration is the default configuration for the drive, allowing the motor control
system to operate as a torque controller, a velocity controller or a position controller. This
configuration comprises 3 nested control loops; a current control loop, a velocity control loop
and a position control loop, as shown in Figure 64.
The universal encoder interface reads rotor position from the encoder and estimates velocity.
The commutation block uses the position to calculate the electrical angle of the rotor. The
current sensor system measures U and V phase currents. These are fed into a current
conversion block that converts them into quantities representing torque producing and
magnetizing currents (the ’vector’ currents which are locked to the rotor).
In the current control loop, a current demand and the final measured current values form the
inputs to a PI (Proportional, Integral) control system. This control system generates a set of
voltage demands that are fed into a PWM (pulse-width modulation) block. The PWM block
uses the space-vector modulation method to convert these voltage demands into a
sequence of U, V and W phase switching signals, which are applied to the output bridge of
the drive. The PWM block uses the measured DC bus voltage to compensate for variations
in supply voltage.
The torque controller converts a torque demand into a current demand and compensates for
various load non-linearities. A 2-stage notch or low-pass filter allows the effects of load
compliance to be reduced. To avoid motor damage, a user-defined application current limit is
also applied, as well as individual positive and negative torque limits.
In the velocity control loop, a velocity demand and measured velocity form the inputs to a PI
control system. The output of the control system is a torque demand which, when the drive
is operating as a velocity controller, forms the input to the current control loop.
Finally, in the position control loop, a position demand and measured position form the inputs
to a PID (Proportional, Integral, Differential) control system incorporating velocity feedback,
velocity feed-forward and acceleration feed-forward. The output of the position control
system is a velocity demand which, when the drive is operating as a position controller, forms
the input to the velocity control loop.
B-2 Control System
MN1942
MN1942
Control System B-3
POSDEMAND
+
--
FOLERROR
VELDEMAND
ACCELDEMAND
TORQUEDEMAND
Position controller
PID
KPROP
KINT
KINTMODE
KINTLIMIT
KDERIV
+
--
+
KVELFF
KVEL
Control mode
switch
P
V
+
--
VELERROR
+
+
T
TORQUELIMITPOS
TORQUELIMITNEG
CURRENTLIMIT
Limiting
+
--
Current
Conv
PVM
Universal
Encoder
Interface
Offset
Comp
EFFORT
Current controllers
PI + TF
KIPROP
KIINT
KITRACK
DRIVEBUSVOLTS
Temperature drift
compensation
CURRENTMEAS
Measured torque and
magnetising currents
TORQUEFILTERTYPE
TORQUEFILTERFREQ
TORQUEFILTERBAND
TORQUEFILTERDEPTH
Commutation
Electrical angle
Control mode
switch
P,V
Torque filters
Figure 64: Servo configuration control structure
POS
VEL
Velocity controller
PI + TF
KVPROP
KVINT
KVTRACK
KACCEL
Torque control
V
U
Encoder
E
Current
Sensors
Motor
Bus Voltage
Measurement
B.1.2 Torque servo configuration
Figure 65 shows the torque-servo control configuration. Here, the velocity loop has been
removed and the output of the position controller is fed into the current loop via the torque
filters.
The torque servo configuration is useful when the drive is operating as a closed-loop position
controller and settling time must be minimized. Although the servo configuration tends to
give better velocity tracking when operating in position mode, settling times can be longer.
The control mode switch allows the drive to operate in either torque or position modes, but
not velocity mode.
B-4 Control System
MN1942
MN1942
Control System B-5
POSDEMAND
VELDEMAND
+
-
FOLERROR
ACCELDEMAND
TORQUEDEMAND
Position controller
PID
KPROP
KINT
KINTMODE
KINTLIMIT
KDERIV
+
-
+
+
POS
VEL
KACCEL
+
-
CURRENTMEAS
TORQUELIMITPOS
TORQUELIMITNEG
CURRENTLIMIT
Limiting
Measured torque and
magnetising currents
TORQUEFILTERTYPE
TORQUEFILTERFREQ
TORQUEFILTERBAND
TORQUEFILTERDEPTH
Commutation
Electrical angle
Control mode
switch
P
T
Torque filters
Torque control
Figure 65: Torque Servo configuration control structure
KVEL
Control mode
switch
+
+
KVELFF
EFFORT
Temperature drift
compensation
Current
Conv
Offset
Comp
PVM
Universal
Encoder
Interface
Current controllers
PI + TF
KIPROP
KIINT
KITRACK
DRIVEBUSVOLTS
V
U
Encoder
E
Current
Sensors
Motor
Bus Voltage
Measurement
B-6 Control System
MN1942
Mint Keyword Summary
C Mint Keyword Summary
C
C.1 Introduction
The following table summarizes the Mint keywords supported by the MicroFlex e100. Note
that due to continuous developments of the MicroFlex e100 and the Mint language, this list is
subject to change. Check the latest Mint help file for full details of new or changed keywords.
C.1.1 Keyword listing
Keyword
Description
ABORT
To abort motion on all axes.
ABORTMODE
To control the default action taken in the event of an abort.
ABSENCODER
To read the current EnDat encoder position.
ABSENCODERTURNS
To set or read the number of turns of unique information
available on an absolute encoder.
ACCEL
To define the acceleration rate of an axis.
ACCELDEMAND
To read the instantaneous demand acceleration.
ACCELJERK
To define the jerk rate to be used during periods of
acceleration.
ACCELJERKTIME
To define the jerk rate to be used during periods of
acceleration.
ACCELSCALEFACTOR
To scale axis encoder counts, or steps, into user defined
acceleration units.
ACCELSCALEUNITS
To define a text description for the acceleration scale
factor.
ACCELTIME
To define the acceleration rate of an axis.
ACCELTIMEMAX
To define the acceleration rate of an axis.
AXISMODE
To return the current mode of motion.
AXISPOSENCODER
To select the source of the position signal used in dual
encoder feedback systems.
AXISVELENCODER
To select the source of the velocity signal used in dual
encoder feedback systems.
BUSBAUD
To specify the bus baud rate.
BUSENABLE
To enable or disable the operation of a fieldbus.
MN1942
Mint Keyword Summary C-1
Keyword
Description
BUSEVENT
Returns the next event in the bus event queue of a
specific bus.
BUSEVENTINFO
Returns the additional information associated with a bus
event.
BUSNODE
To set or read the node ID used by this node for the
specified bus.
BUSPROTOCOL
To read the protocol currently supported on a particular
fieldbus.
BUSRESET
Resets the bus controller.
BUSSTATE
Returns the status of the bus controller.
CANCEL
To stop motion and clear errors on an axis.
CANCELALL
To stop motion and clear errors on all axes.
CAPTUREBUFFERSIZE
To read the total size of the capture buffer.
CAPTURECOMMAND
Controls the operation of capture.
CAPTUREDURATION
To define the total duration of the data capture.
CAPTUREMODE
To set or read the mode on a capture channel.
CAPTUREMODEPARAMETER
To specify a parameter associated with CAPTUREMODE.
CAPTURENUMPOINTS
To read the number of captured points per channel.
CAPTUREPERIOD
To define the interval between data captures.
CAPTUREPRETRIGGERDURATION
To set the duration of the pre-trigger phase.
CAPTUREPROGRESS
To return the progress of the pre-trigger or post-trigger
capture phase.
CAPTURESTATUS
To return the progress of the capture.
CAPTURETRIGGER
To generate a capture trigger.
CAPTURETRIGGERABSOLUTE
To ignore the sign of the trigger value when triggering from
a capture channel source.
CAPTURETRIGGERCHANNEL
To set the channel to be used as the reference source for
triggering.
CAPTURETRIGGERMODE
To set the method used to evaluate the trigger source.
CAPTURETRIGGERSOURCE
To set the reference source to be used for triggering.
CAPTURETRIGGERVALUE
To set the trigger value when triggering from a capture
channel source.
COMMS
Accesses the reserved comms array.
C-2 Mint Keyword Summary
MN1942
Keyword
Description
COMMSINTEGER
Accesses the reserved comms array, storing values as
integers.
COMPAREENABLE
To enable/disable the position compare control of a
specific digital output.
COMPAREOUTPUT
To specify the digital output used for position compare.
COMPAREPOS
To write to the position compare registers.
CONFIG
To set the configuration of an axis for different control
types.
CONNECT
To enable a connection between two remote nodes to be
made or broken.
CONNECTSTATUS
Returns the status of the connection between this node
and another node.
CONTROLMODE
To set or read the control mode.
CONTROLMODESTARTUP
To set or read the control mode used when the drive is
turned on.
CONTROLRATE
To set the control loop and profiler sampling rates.
CONTROLREFCHANNEL
To specify a channel for the source of the control
reference command.
CONTROLREFSOURCE
To specify the source of the control reference command.
CONTROLREFSOURCESTARTUP To set or read the source of the control reference
command used when the drive is turned on.
CONTROLTYPE
To set or read the motor control type.
CURRENTDEMAND
To read the demands to the current controllers.
CURRENTLIMIT
To restrict the current output to a defined range.
CURRENTMEAS
Reads the measured current.
CURRENTSENSORMODE
To enable a current sensor temperature drift
compensation scheme.
DECEL
To set the deceleration rate on the axis.
DECELJERK
To define the jerk rate to be used during periods of
deceleration.
DECELJERKTIME
To define the jerk rate to be used during periods of
deceleration.
DECELTIME
To set the deceleration rate on the axis.
DECELTIMEMAX
To define the deceleration rate of an axis.
MN1942
Mint Keyword Summary C-3
Keyword
Description
DRIVEBUSNOMINALVOLTS
To return the nominal value of the DC bus voltage for the
drive.
DRIVEBUSOVERVOLTS
To set or return the overvoltage trip level for the drive.
DRIVEBUSUNDERVOLTS
To set or return the undervoltage trip level for the drive.
DRIVEBUSVOLTS
To return the current level of the DC bus.
DRIVEENABLE
To enable or disable the drive for the specified axis.
DRIVEENABLEINPUTMODE
To control the action taken in the event of the drive being
disabled from the drive enable input.
DRIVEENABLEOUTPUT
To specify an output as a drive enable.
DRIVEENABLEREADY
To read if the drive is ready to be enabled.
DRIVEENABLESWITCH
To read the state of the drive enable input.
DRIVEID
To define a text description for the drive.
DRIVEOVERLOADAREA
Reads the extent of a drive overload condition.
DRIVEOVERLOADMODE
Sets or reads the action taken in the event of a drive
overload condition.
DRIVEPEAKCURRENT
Reads the peak current rating of the drive.
DRIVEPEAKDURATION
Reads the duration for which peak drive current can be
sustained.
DRIVERATEDCURRENT
Reads the continuous current rating for the drive.
DRIVESPEEDFATAL
To define the overspeed trip level.
DRIVESPEEDMAX
To set or read the maximum motor speed to be used.
EFFORT
To read the instantaneous effort applied by the current
controllers.
ENCODER
To set or read the axis encoder value.
ENCODERCYCLESIZE
To set or read the size of a sin/cos cycle on an encoder.
ENCODERMODE
To make miscellaneous changes to the encoders.
ENCODEROFFSET
To set or read the offset used to calculate encoder
position for absolute encoders.
ENCODERPRESCALE
To scale down the encoder input.
ENCODERRESOLUTION
To set or read the number of encoder lines (prequadrature) for the motor.
ENCODERSCALE
To set or read the scale factor for the encoder channel.
ENCODERTYPE
To set or read the feedback type of the motor.
C-4 Mint Keyword Summary
MN1942
Keyword
Description
ENCODERVEL
To read the velocity from an encoder channel.
ENCODERWRAP
To set or read the encoder wrap range for the encoder
channel.
ENCODERZLATCH
To get and reset the state of an axis’ encoder Z latch.
ERRCODE
To return the last error code read from the error list.
ERRDATA
To return data associated with the last error read from the
error list.
ERRLINE
To return the line number of the last error read from the
error list.
ERRORCLEAR
To clear all errors in the specified group.
ERRORDECEL
To set the deceleration rate on the axis for powered stops,
in the event of an error or stop input.
ERRORINPUT
To set or return the digital input to be used as the error
input for the specified axis.
ERRORINPUTMODE
To control the default action taken in the event of an
external error input.
ERRORPRESENT
To determine if errors in a particular group are present in
the error list.
ERRORREADCODE
To determine if a particular error is present in the error list.
ERRORREADNEXT
Returns the next entry in the specified group from the
error list.
ERRORSWITCH
To return the state of the error input.
ERRSTRING
To return the error string for the last error code read from
the error list.
ERRTIME
To return the time stamp for the last error code read from
the error list.
EVENTACTIVE
To indicate whether an event is currently active.
EVENTDISABLE
To selectively enable and disable Mint events.
EVENTPEND
To manually cause an event to occur.
EVENTPENDING
To indicate whether an event is currently pending.
FACTORYDEFAULTS
To reset parameter table entries to their default values.
FIRMWARERELEASE
To read the release number of the firmware.
FOLERROR
To return the instantaneous following error value.
MN1942
Mint Keyword Summary C-5
Keyword
Description
FOLERRORFATAL
To set the maximum permissible following error before an
error is generated.
FOLERRORMODE
To determine the action taken on the axis in the event of a
following error.
FOLLOW
To enable encoder following with a specified gear ratio.
FOLLOWMODE
To define the mode of operation of the FOLLOW keyword.
FOLLOWNUMERATOR
To set or read the follow ratio’s numerator.
GLOBALERROROUTPUT
Allows the user to specify a global error output which will
be deactivated in the event of an error.
GO
To begin synchronized motion.
HALL
To read the current Hall state on feedback devices which
use Hall sensors.
HALLFORWARDANGLE
To define the electrical angles at which Hall states
change, when the motor is running in the forward
direction, for feedback devices which use Hall sensors.
HALLREVERSEANGLE
To define the electrical angles at which Hall states
change, when the motor is running in the reverse
direction, for feedback devices which use Hall sensors.
HALLTABLE
To define the Hall table for an encoder motor.
HOME
To find the home position on an axis.
HOMEACCEL
To set the acceleration rate for the homing profile.
HOMEBACKOFF
To set the home back-off speed factor.
HOMECREEPSPEED
To set the creep speed for homing moves.
HOMEDECEL
To set the deceleration rate for the homing profile.
HOMEINPUT
To set a digital input to be the home switch input for the
specified axis.
HOMEPHASE
To find the phase of the homing sequence currently in
progress.
HOMEPOS
To read the axis position at the completion of the homing
sequence.
HOMEREFPOS
To define a reference position for homing moves.
HOMESPEED
To set the speed for the initial seek phase of the homing
sequence.
HOMESTATUS
To set or read the status of a homing sequence.
HOMESWITCH
To return the state of the home input.
C-6 Mint Keyword Summary
MN1942
Keyword
Description
HOMETYPE
To set the homing mode to be performed at start-up.
IDLE
Indicates if a move has finished executing and the axis
has finished moving.
IDLEMODE
To control the checks performed when determining if an
axis idle.
IDLEPOS
Reads or sets the idle following error limit.
IDLESETTLINGTIME
To read the time taken for an axis to become idle.
IDLETIME
To specify the period for which the axis must meet its idle
conditions before becoming idle.
IDLEVEL
Reads or sets the idle velocity limit.
IN
To read the state of all the inputs on an input bank.
INCA
To set up an incremental move to an absolute position.
INCR
To set up an incremental move to a relative position.
INPUTACTIVELEVEL
To set the active level on the digital inputs.
INPUTDEBOUNCE
To set or return the number of samples used to ’debounce’
a digital input bank.
INPUTMODE
To set or return the sum of a bit pattern describing which
of the user digital inputs should be edge or level triggered.
INPUTNEGTRIGGER
To set or return the user inputs that become active on
negative edges.
INPUTPOSTRIGGER
To set or return the user inputs that become active on
positive edges.
INSTATE
To read the state of all digital inputs.
INSTATEX
To read the state of an individual digital input.
INX
To read the state of an individual digital input.
JOG
To set an axis for speed control.
KACCEL
To set the servo loop acceleration feed forward gain.
KASINT
KASPROP
KDERIV
To set the servo loop derivative gain on the servo axes.
KFINT
To set or read the integral gain of the flux controller for
induction motor control.
KFPROP
To set or read the proportional gain of the flux controller
for induction motor control.
MN1942
Mint Keyword Summary C-7
Keyword
Description
KIINT
To set the integral gain used by the current controller.
KINT
To set the servo loop integral gain.
KINTLIMIT
To restrict the overall effect of the integral gain KINT.
KINTMODE
To control when integral action will be applied in the servo
loop.
KIPROP
To set the proportional gain used by the current controller.
KITRACK
To set the tracking factor used by the current controller.
KPROP
To set the proportional gain for the position controller.
KVEL
To set the servo loop velocity feedback gain term.
KVELFF
To set the velocity feedforward term for the position
controller.
KVINT
To set the integral gain used by the speed controller.
KVPROP
To set the proportional gain used by the speed controller.
KVTIME
To set the time constant of a low pass filter, applied to
measured speed.
KVTRACK
To set the tracking factor used by the speed controller.
LATCH
To read the state of a fast latch channel.
LATCHENABLE
Manually re-enables a fast latch channel.
LATCHINHIBITTIME
To specify a period during which further fast triggers will
be ignored.
LATCHINHIBITVALUE
To specify a range of values within which further fast
triggers will be ignored.
LATCHMODE
To set the default action to be taken to clear a fast latch.
LATCHSOURCE
To define the source of data to be latched by a fast latch
channel.
LATCHSOURCECHANNEL
To define the channel of the source of data to be latched
by a fast latch channel.
LATCHTRIGGERCHANNEL
To select which of the fast latch inputs (or outputs) will
trigger a fast latch channel.
LATCHTRIGGEREDGE
To define which edge polarity should cause the fast latch
to be triggered.
LATCHTRIGGERMODE
To select whether a fast latch is triggered by a digital input
or a digital output.
C-8 Mint Keyword Summary
MN1942
Keyword
Description
LATCHVALUE
To return the instantaneous latch value that was recorded
by a fast latch.
LIFETIME
Returns a lifetime counter for the drive.
LIMIT
To return the state of the forward and reverse limit switch
inputs for the given axis.
LIMITFORWARD
To return the state of the forward limit switch input for the
given axis.
LIMITFORWARDINPUT
To set the user digital input configured to be the forward
end of travel limit switch input for the specified axis.
LIMITMODE
To control the default action taken in the event of a
forward or reverse hardware limit switch input becoming
active.
LIMITREVERSE
To return the state of the reverse limit switch input for the
given axis.
LIMITREVERSEINPUT
To set the user digital input configured to be the reverse
end of travel limit switch input for the specified axis.
LOADDAMPING
To define the equivalent viscous damping coefficient for
the motor and load.
LOADINERTIA
To define the combined inertia of the motor and load.
MASTERCHANNEL
To set or read the channel of the input device used for
gearing.
MASTERSOURCE
To set or read the source of the input device used for
gearing.
MOTORBRAKEDELAY
To specify engage/disengage delays associated with
motor brake control.
MOTORBRAKEMODE
To activate or deactivate motor brake control.
MOTORBRAKEOUTPUT
To specify an output to be used as a control signal for a
braked motor.
MOTORBRAKESTATUS
To determine the state of the motor brake control.
MOTORCATALOGNUMBER
To return the catalog number of the motor.
MOTORDIRECTION
To set or read the electrical direction of the motor.
MOTORFEEDBACKANGLE
Reads the instantaneous value of commutation angle for
the motor.
MOTORFEEDBACKOFFSET
To set or read the electrical angle at which the absolute
position read from an EnDat, BiSS or SSI encoder is zero.
MN1942
Mint Keyword Summary C-9
Keyword
Description
MOTORFLUX
To set the motor’s magnetic flux level, to allow the drive to
accurately calculate motor torque and compensate for
back-EMF.
MOTORLINEARPOLEPITCH
To set or read the distance between north poles on a
linear motor.
MOTORLS
To set or read the motor leakage inductance.
MOTORMAGCURRENT
To set or read the magnetizing current (Im) of an induction
motor.
MOTORMAGIND
To set or read the magnetizing inductance (Lm) of an
induction motor.
MOTOROVERLOADAREA
Reads the extent of an overload condition.
MOTOROVERLOADMODE
To set or read the action taken in the event of a motor
overload condition.
MOTORPEAKCURRENT
To set or read the peak current rating of the motor.
MOTORPEAKDURATION
To set or read the duration for which peak motor current
can be sustained.
MOTORPOLES
To set or read the number of motor poles.
MOTORRATEDCURRENT
To set or read the rated current of the motor.
MOTORRATEDFREQ
To set or read the rated frequency of an induction motor.
MOTORRATEDSPEEDMMPS
To set or read the rated speed of a linear induction motor
in millimeters per second.
MOTORRATEDSPEEDRPM
To set or read the rated speed of an induction motor.
MOTORRATEDVOLTS
To set or read the rated voltage of an induction motor.
MOTORROTORLEAKAGEIND
To set or read the rotor leakage inductance of an induction
motor.
MOTORROTORRES
To set or read the rotor resistance of an induction motor.
MOTORRS
To set the motor stator resistance.
MOTORSLIP
To read the slip of an induction motor.
MOTORSPECNUMBER
To return the spec number of the motor.
MOTORSTATORLEAKAGEIND
To set or read the stator leakage inductance of an
induction motor.
MOTORSTATORRES
To set or read the stator resistance of an induction motor.
MOTORTEMPERATUREMODE
To set or read the action taken in the event of the motor
overtemperature trip input becoming active
C-10 Mint Keyword Summary
MN1942
Keyword
Description
MOTORTEMPERATURESWITCH
To read the state of the motor overtemperature trip input.
MOTORTYPE
To read or set the type of motor.
MOVEA
To set up a positional move to an absolute position.
MOVEBUFFERFREE
To return the number of free spaces in the move buffer for
the specified axis.
MOVEBUFFERLOW
To set or return the number of free spaces in the move
buffer before a move buffer low event is generated.
MOVEBUFFERSIZE
To set or return the size of the move buffer allocated on
the specified axis.
MOVER
To set up a positional move to a relative position.
NETFLOAT
To access a controller’s network data array, storing values
in floating-point format.
NETINTEGER
To access a controller’s network data array, storing values
as integers.
NODELIVE
To determine if a CAN node on the bus is currently live or
dead.
NODESCAN
To scan a specific CAN bus for the presence of a specific
node.
NODETYPE
To add or remove a CAN node to/from the CAN network.
Can also be read to determine the node type.
NUMBEROF
To return information about the abilities of the controller.
NVFLOAT
To read or write a floating-point value in non-volatile
memory.
NVLONG
To read or write a long integer value in non-volatile
memory.
NVRAMDEFAULT
To clear the contents of non-volatile RAM (NVRAM).
OUT
To set or read the state of all the outputs on an output
bank.
OUTPUTACTIVELEVEL
To set the active level on the digital outputs.
OUTX
To set or read an individual digital output.
PHASESEARCHBACKOFF
To select the back-off distance used to clear an end stop
during the phase search sequence.
PHASESEARCHBANDWIDTH
To define the bandwidth used to design the ’debounce’
controller used during the initial alignment stage of the
phase search sequence.
MN1942
Mint Keyword Summary C-11
Keyword
Description
PHASESEARCHCURRENT
To select amount of current applied to the motor during
the phase search sequence.
PHASESEARCHINPUT
To set or read the digital input to be used as the phase
search trigger input.
PHASESEARCHMODE
To turn on the ‘debounce’ controller used during the initial
alignment stage of the phase search sequence.
PHASESEARCHOUTPUT
To assign a digital output as the phase search output.
PHASESEARCHSPEED
To select the speed of travel during the search sections of
a phase search sequence.
PHASESEARCHSTATUS
To determine whether commutation is aligned on an axis.
PHASESEARCHSWITCH
To return the current state of the phase search input for
the axis.
PHASESEARCHTRAVEL
To select the amount of travel during the search sections
of a phase search sequence.
PLATFORM
To return the platform type.
POS
To set or read the current axis position.
POSDEMAND
To set or read the instantaneous position demand.
POSOFFSET
To set or read the offset used to calculate axis position for
absolute encoders.
POSREMAINING
To indicate the remaining move distance.
POSSCALEFACTOR
To scale axis encoder counts, or steps, into user defined
position units.
POSSCALEUNITS
To define a text description for the position scale factor.
POSTARGET
Reads the target position of the current positional move.
POSTARGETLAST
Reads the target position of the last move in the move
buffer.
PROFILEMODE
To select the type of velocity profiler to use.
REMOTEADC
To read the value of a remote analog input (ADC).
REMOTEADCDELTA
To control the rate of change on a remote analog input
before a REMOTEADC message is sent.
REMOTECOMMS
Accesses the reserved comms array on another
controller.
REMOTECOMMSINTEGER
Accesses the reserved comms array on another
controller, storing values as integers.
C-12 Mint Keyword Summary
MN1942
Keyword
Description
REMOTEDAC
To control the value of a remote analog output channel
(DAC). The value is a percentage (positive and negative)
of the full-scale output value.
REMOTEEMERGENCYMESSAGE
Returns the error code from the last emergency message
received from a particular CANopen node.
REMOTEENCODER
To read the value of a remote encoder channel.
REMOTEERROR
Reads the CANopen error register information reported
within the last emergency message received from a
specific node.
REMOTEIN
To read the state of all the digital inputs on a remote CAN
node.
REMOTEINBANK
To read the state of a bank of digital inputs on a remote
CAN node.
REMOTEINX
To read the state of individual digital inputs from a remote
CAN node.
REMOTEMODE
To control the update mode for a remote node.
REMOTEOBJECT
To access the Object Dictionary of any CANopen node
present on the network.
REMOTEOBJECTFLOAT
To access ‘floating-point’ entries in the Object Dictionary
of a remote node present on the network.
REMOTEOBJECTSTRING
To access ’Vis-String’ entries in the Object Dictionary of
any CANopen node present on the network.
REMOTEOUT
To control the state of digital outputs on a remote CAN
node.
REMOTEOUTBANK
To read the state of a bank of digital outputs on a remote
CAN node.
REMOTEOUTX
To control the state of individual digital outputs on a
remote CAN node.
REMOTEPDOIN
To request data from a node in the form of a PDO
message.
REMOTEPDOOUT
To force a controller node to transmit a variable length
PDO message with a specific COB-ID. The PDO will
contain up to 64 bits of data that can be passed in the
form of two 32-bit values.
REMOTESTATUS
To set or read the status register on a remote CAN node.
RESETINPUT
To define the reset input for an axis.
MN1942
Mint Keyword Summary C-13
Keyword
Description
SCALEFACTOR
To scale axis encoder counts, or steps, into user defined
units.
SENTINELACTION
To control the action of a sentinel channel.
SENTINELACTIONMODE
To control how the action of a sentinel channel is
performed.
SENTINELACTIONPARAMETER To specify a parameter to fully define the sentinel action.
SENTINELSOURCE
To set or read the primary source used by a sentinel
channel.
SENTINELSOURCE2
To set or read the secondary source used by a sentinel
channel.
SENTINELSOURCEPARAMETER To set or read the parameter used to qualify the primary
sentinel source.
SENTINELSOURCE2
-PARAMETER
To set or read the parameter used to qualify the
secondary sentinel source.
SENTINELSTATE
To read the current state of a sentinel channel.
SENTINELTRIGGERABSOLUTE To set or read the ’absolute’ parameter used by a sentinel
channel.
SENTINELTRIGGERMODE
To set or read the mode used by a sentinel channel.
SENTINELTRIGGERVALUEFLOAT
To specify the ’lowVal’ or ’highVal’ parameter, as a
floating-point number, to be used in a sentinel channel’s
trigger criteria.
SENTINELTRIGGERVALUEINTEGER
To specify the ’lowVal’ or ’highVal’ parameter, as an
integer number, to be used in a sentinel channel’s trigger
criteria.
SEXTANT
To read the current sextant value for a motor using Hall
sensors.
SOFTLIMITFORWARD
To set the forward software limit position on a specified
axis.
SOFTLIMITMODE
To set or read the default action taken if a forward or
reverse software limit position is exceeded.
SOFTLIMITREVERSE
To set or read the reverse software limit position on a
specified axis.
SPEED
To set or read the slew speed of positional moves loaded
in the move buffer.
STOP
To perform a controlled stop during motion.
STOPINPUT
To set or read the digital input to be used as the stop
switch input for the specified axis.
C-14 Mint Keyword Summary
MN1942
Keyword
Description
STOPMODE
To set or read the action taken when an axis is stopped.
STOPSWITCH
To read the current state of the stop input for the axis.
SUSPEND
To pause the current move.
SUSPENDINPUT
To set or read the digital input to be used as the suspend
switch input for the specified axis.
SUSPENDSWITCH
To return the current state of the suspend input for the
axis.
SYSTEMSECONDS
To set or read a programmable system lifetime counter for
the drive.
TEMPERATURE
To read the internal drive temperature.
TEMPERATURELIMITFATAL
To set or read the temperature fatal limit.
TERMINALADDRESS
To set or read the node ID for a CAN node associated with
a terminal.
TERMINALDEVICE
To set or read the device type associated with a given
terminal id.
TERMINALMODE
To set or read handshaking modes for a terminal.
TERMINALPORT
To set or read the communication port associated with a
given terminal.
TORQUEDEMAND
To read the instantaneous torque demand.
TORQUEFILTERBAND
Defines the band of operation for a torque filter stage.
TORQUEFILTERDEPTH
Defines the reduction in gain for a notch torque filter
stage.
TORQUEFILTERFREQ
Defines a characteristic frequency for a torque filter stage.
TORQUEFILTERTYPE
Defines the type of characteristic used for the given
torque filter stage.
TORQUELIMITNEG
To set or read the maximum negative torque limit.
TORQUELIMITPOS
To set or read the maximum positive torque limit.
TORQUEREF
To set or read a torque reference for torque (constant
current) mode on a servo axis.
TORQUEREFERRORFALLTIME
To set or read the ’deceleration ramp’ for a torque profile
in the event of an error.
TORQUEREFFALLTIME
To set or read the ’deceleration ramp’ for a torque profile.
TORQUEREFRISETIME
To set or read the ’acceleration ramp’ for a torque profile.
VEL
To return the instantaneous axis velocity.
MN1942
Mint Keyword Summary C-15
Keyword
Description
VELDEMAND
To read the current instantaneous demand velocity.
VELERROR
To report the velocity following error.
VELFATAL
To set or read the threshold for the maximum difference
between demand and actual velocity.
VELFATALMODE
To control the default action taken in the event of the
velocity threshold being exceeded.
VELREF
To set or read a fixed point speed reference.
VELSCALEFACTOR
To scale axis encoder counts, or steps, into user defined
velocity units.
VELSCALEUNITS
To define a text description for the velocity scale factor.
VFTHREEPOINTFREQ
To read and write the V/F three point intersection
frequency.
VFTHREEPOINTMODE
To read and write the V/F three point mode.
VFTHREEPOINTVOLTS
To read and write the V/F three point intersection voltage.
VOLTAGEBOOST
To read and write the extra voltage added to the voltage
demand at zero frequency.
VOLTAGEDEMAND
To read the voltage demand outputs from the current
controllers.
C-16 Mint Keyword Summary
MN1942
CE & UL
D CE & UL
D
D.1 Outline
This section provides general information regarding
recommended methods of installation for CE
compliance. It is not intended as an exhaustive guide
to good practice and wiring techniques. It is assumed
that the installer of the MicroFlex e100 is sufficiently
qualified to perform the task, and is aware of local
regulations and requirements. ABB products that meet
the EMC directive requirements are indicated with a
“CE” mark. A duly signed CE declaration of conformity
is available from ABB.
D.1.1 EMC Conformity and CE marking
The information contained herein is for your guidance only and does not guarantee that the
installation will meet the requirements of the council directive 89/336/EEC.
The purpose of the EEC directives is to state a minimum technical requirement common to
all the member states within the European Union. In turn, these minimum technical
requirements are intended to enhance the levels of safety both directly and indirectly.
Council directive 89/336/EEC relating to Electro Magnetic Compliance (EMC) indicates that it
is the responsibility of the system integrator to ensure that the entire system complies with all
relative directives at the time of installing into service.
Motors and controls are used as components of a system, per the EMC directive. Hence all
components, installation of the components, interconnection between components, and
shielding and grounding of the system as a whole determines EMC compliance.
The CE mark informs the purchaser that the equipment has been tested and complies with
the appropriate standards. It rests upon the manufacturer or his authorized representative to
ensure the item in question complies fully with all the relative directives in force at the time of
installing into service, in the same way as the system integrator previously mentioned.
Remember that it is the instructions of installation and the product that should comply with
the directive.
D.1.2 MicroFlex e100 compliance
When installed as directed in this manual, MicroFlex e100 units meet the emission limits for
an “industrial” environment, as defined by the EMC directives (EN61000-6-4: 2001). To meet
the more stringent emission limits of the “residential, commercial and light industrial”
environment (EN61000-6-3: 2001), the MicroFlex e100 must be mounted in a suitable metal
cabinet incorporating 360° screened cable glands.
MN1942
CE & UL D-1
D.1.3 Use of CE compliant components
The following points should be considered:

Using CE approved components will not guarantee a CE compliant system!

The components used in the drive, installation methods used, materials selected for
interconnection of components are important.

The installation methods, interconnection materials, shielding, filtering and earthing /
grounding of the system as a whole will determine CE compliance.

The responsibility of CE mark compliance rests entirely with the party who offers the end
system for sale (such as an OEM or system integrator).
D.1.4 EMC wiring technique
Cabinet
Using a typical electroplated zinc coated enclosure, connected to earth/ground, means that
all parts mounted on the back plane are connected to earth/ground and all outer shield
(screen) connections can be connected to earth/ground. Within the cabinet there should be a
spatial separation between power wiring (motor and AC power cables) and control wiring.
Shield (screen) connections
All connections between components must use shielded cables. The cable shields must be
connected to the enclosure. Use conductive clamps to ensure good earth/ground
connection. With this technique, a good earth/ground shield can be achieved.
EMC filters
The filter should be mounted next to the MicroFlex e100. The connections between the
MicroFlex e100 and the filter should use shielded (screened) cables. The cable shields
should be connected to shield clamps at both ends.
Earthing/grounding
For safety reasons (VDE0160), all components must be connected to earth/ground with a
separate wire. Earth/ground connections must be made from the central earth/ground (star
point) to the brake resistor enclosure and from the central earth/ground (star point) to the
power supply.
D-2 CE & UL
MN1942
D.1.5 EMC installation suggestions
To ensure electromagnetic compatibility (EMC), the following installation points should be
considered to help reduce interference:

Earthing/grounding of all system elements to a central earth/ground point (star point)

Shielding of all cables and signal wires

Filtering of power lines.
A proper enclosure should have the following characteristics:

All metal conducting parts of the enclosure must be electrically connected to the back
plane. These connections should be made with an earthing/grounding strap from each
element to a central earthing/grounding point (star point). *

Keep the power wiring (motor and power cable) and control wiring separated. If these
wires must cross, be sure they cross at 90 degrees to minimize noise due to induction.

The shield connections of the signal and power cables should be connected to the shield
rails or clamps. The shield rails or clamps should be conductive clamps fastened to the
cabinet. **

The cable to the brake resistor must be shielded. The shield must be connected to earth/
ground at both ends.

The location of the AC filter has to be situated close to the drive so the AC power wires
are as short as possible.

Wires inside the enclosure should be placed as close as possible to conducting metal,
cabinet walls and plates. It is advised to terminate unused wires to chassis ground.*

To reduce earth/ground current, use the largest suitable wire available for earth/ground
connections.
*
**
Earthing/grounding in general describes all metal parts which can be connected to a
protective conductor, e.g. housing of cabinet, motor housing, etc. to a central earth/
ground point (star point). This central earth/ground point (star point) is then connected to
the main plant (or building) earth/ground.
Or run as twisted pair at minimum.
MN1942
CE & UL D-3
D.1.6 Wiring of shielded (screened) cables
Remove the outer insulation
to expose the overall shield.
Clamp should provide 360°
contact with the cable.
Flat or p-type
conductive clamp
Figure 66: Earthing/grounding cable shields
MicroFlex e100
X8
CHA+
CHACHB+
CHBCHZ+
CHZ+5V
DGND
Encoder Connector
Housing
Cable
Twisted pairs
1
9
2
10
3
11
12
13
Connect overall shield
to connector backshell
Connect overall shield
to connector backshell
Figure 67: Encoder signal cable grounding
D-4 CE & UL
MN1942
D.2 UL file numbers
The following table lists UL file numbers for ABB products (formerly Baldor) and other
accessories. Note that UL file numbers for accessories that not manufactured by ABB are
beyond ABB’s control and therefore subject to change without notice.
UL file
number
Company
Description
E128059
Baldor Electric Co.
Drives
E46145
Baldor Electric Co.
Motors
E132956
Cabloswiss s.p.a.
Power cables (6A, 12A, 20A, 25A, 50A, 90A)
Encoder cables
Resolver/SSI cables
EnDat cables
E192076
Unika Special Cables s.p.a
Power cables (6A, 12A, 20A, 25A, 50A, 90A)
Encoder cables
Resolver/SSI cables
EnDat cables
E153698
Coninvers GmbH
Connectors
E64388
Schaffner EMV AG
AC filters
E70122
Epcos AG
AC filters
E212934
Frizlen GmbH & Co. KG
Brake resistors
E227820
RARA Electronics Corp.
Brake resistors
MN1942
CE & UL D-5
D-6 CE & UL
MN1942
Index
Index
A
CE Guidelines, C-1, D-1
Abbreviations See Units and Abbreviations
Circuit breakers, 3-17
Accessories, A-1
24 V power supplies, A-3
brake resistors, A-7
EMC filters, A-4
fan tray, A-2
feedback cables, A-10, A-11, A-12
footprint filter, A-3
motor power cables, A-8
Command window, 6-27
B
Basic Installation, 3-1
BiSS
cable, 4-8, A-12
interface, 4-7
specification, 8-5
Brake
capacity, 3-25
duty cycle, 3-30
energy, 3-27
power, 3-27
resistor, 3-25
resistor, duty cycle derating, 3-29
resistor, selection, 3-26
specification, 8-3
C
CAN interface
CANopen, 5-22
connector, 5-20
introduction, 5-20
LEDs, 7-3
opto-isolation, 5-21
specifications, 8-6
termination, 5-20
wiring, 5-20
Catalog number
identifying, 2-2
MN1942
Commissioning Wizard, 6-12
using, 6-12
Configuration, 6-23
Connections
See also Input / Output
feedback, 4-1
motor, 3-20
power, 3-12, 3-14
Connectors
CAN, 5-20
Ethernet, 5-17, 5-19
I/O, 5-3
locations, 3-10, 3-11
RS485, 5-15
USB, 5-15
Control system, B-1
servo configuration, B-2
torque servo configuration, B-4
Cooling, 3-5, 3-6, 3-7, 3-8, A-2
heat dissipation, 3-9
overtemperature trips, 3-8
D
Demand outputs, 6-21, 6-22
Derating, 3-6, 3-7, 3-8
Digital I/O, 5-2
digital input DIN0, 5-5, 8-4
digital inputs DIN1 & DIN2, 5-7, 8-4
digital output DOUT0, 5-11, 8-4
digital output DOUT1, 5-13, 8-4
drive enable input, 5-3, 8-4
fast position capture, 5-8
special functions on DIN1 & DIN2, 5-8
step & direction, 5-8
Dimensions, 3-4
Index
E
Earthing (grounding)
leakage, 3-13
protection class, 3-13
protective earth (PE), 3-12
Encoder
cable, 4-5
SinCos, 4-11
SSI, 4-9
Filters
24 V control circuit supply, 3-19
AC power (EMC), 3-18, A-4
part numbers, A-4
Footprint filter, A-3
Encoder, incremental
cable, 4-3, A-11
feedback, 4-2
specification, 8-5
without Halls, 4-4
Fuses, 3-17
EnDat
cable, A-12
H
EnDat (absolute) encoder
cable, 4-14
feedback, 4-13
specification, 8-6
Environmental
cooling, 3-3
location, 3-3
specification, 8-7
Ethernet connector, 5-19
Ethernet interface
cables, A-12
connector, 5-19
Ethernet POWERLINK, 5-18
introduction, 5-17
LEDs, 7-4
specifications, 8-6
TCP/IP, 5-17
F
Fast position capture, 5-8
Features, 2-1
Feedback
BiSS, 4-7
cable, A-10, A-11, A-12
connections, 4-1
encoder without Halls, 4-4
EnDat (absolute), 4-13
Halls-only feedback, 4-4
incremental encoder, 4-2
Index
G
General Information, 1-1
Grounding See Earthing (grounding)
Hardware requirements, 3-1
Heat dissipation, 3-9
Help file, 6-9
I
Incremental encoder
cable, 4-3, A-11
feedback, 4-2
specification, 8-5
without Halls, 4-4
Indicators
CAN LEDs, 7-3
ETHERNET LEDs, 7-4
STATUS LED, 7-2
Input / Output, 4-1, 5-1
CAN interface, 5-20
connection summary, 5-26
digital input DIN0, 5-5, 8-4
digital inputs DIN1 & DIN2, 5-7, 8-4
digital output DOUT0, 5-11, 8-4
digital output DOUT1, 5-13, 8-4
drive enable input, 5-3, 8-4
encoder interface, 4-1
Ethernet interface, 5-17
node ID selector switches, 5-23
RS485 port, 5-15
serial port, 5-15
USB port, 5-15
Installation
See also Basic Installation
MN1942
cooling, 3-5
dimensions, 3-4
mechanical, 3-3
Mint WorkBench, 6-1
mounting, 3-5
TCP/IP configuration, 6-4
USB driver, 6-3
K
Keyword summary, C-1
L
LED indicators
CAN LEDs, 7-3
ETHERNET LEDs, 7-4
STATUS LED, 7-2
LED status indicator, 7-2
Linear motor
cable configuration, 4-6
M
Mint keyword summary, C-1
Mint Machine Center (MMC), 6-5
starting, 6-7
Mint WorkBench, 6-8
Commissioning Wizard, 6-12
fine-tuning tool, 6-23
help file, 6-9
other tools and windows, 6-27
parameters tool, 6-25, 6-26
starting, 6-10
Motor
brake connection, 3-24
circuit contactors, 3-21
connections, 3-20
power cable, 3-21, A-8
sinusoidal filter, 3-22
thermal switch, 3-23
Mounting, 3-5
N
Node ID selector switches, 5-23
MN1942
O
Operation, 6-1
configuring the TCP/IP connection, 6-4
connecting to the PC, 6-1
installing Mint WorkBench, 6-1
installing the USB driver, 6-3
power on checks, 6-2
preliminary checks, 6-2
starting, 6-2
Overloads
drive, 3-17
motor, 3-20
overtemperature trips, 3-8
P
Parameters tool, 6-25, 6-26
Power
24 V control circuit supply, 3-19
24 V power supplies, A-3
connections, 3-12
discharge period, 3-15
disconnect and protection devices, 3-16
input conditioning, 3-15
input cycling, 3-15, 7-1
inrush, 3-15
sources, 3-1
supply filters, 3-18, A-4
using a variac, 3-16
Precautions, 1-2
Product Notice, 1-2
R
Receiving and Inspection, 2-2
Regeneration See Brake
RS485
port, 5-15
RS485 interface
specifications, 8-6
S
Safety Notice, 1-2
Servo axis
testing the demand output, 6-21, 6-22
Index
communication, 7-5
Ethernet, 7-6
ETHERNET LEDs, 7-4
Mint WorkBench, 7-5
power cycling, 7-1
power on, 7-5
problem diagnosis, 7-1
STATUS LED, 7-2
SupportMe, 7-1
tuning, 7-6
SinCos
cable, 4-12, A-12
feedback, 4-11
specification, 8-6
Specifications, 8-1
24 V control supply, 8-3
AC input power and bus voltage, 8-1
BiSS interface, 8-5
braking, 8-3
CAN interface, 8-6
digital input DIN0, 8-4
digital input DIN1, 8-4
digital input DIN2, 8-4
digital output DOUT0, 8-4
digital output DOUT1, 8-4
drive enable input, 8-4
EnDat feedback, 8-6
environmental, 8-7
Ethernet interface, 8-6
incremental encoder feedback, 8-5
motor output, 8-3
RS485 interface, 8-6
SinCos feedback, 8-6
SSI encoder feedback, 8-5
weights and dimensions, 8-7
U
UL file numbers, D-5
Units and abbreviations, 2-3
USB
installing the driver, 6-3
port, 5-15
W
Weights and dimensions, 8-7
Wires sizes, 3-17
WorkBench See Mint WorkBench
SSI
cable, 4-10, A-10
feedback, 4-9
specification, 8-5
Status LED, 7-2
Step & Direction
DIN1/2, 5-8
specification, 8-4
T
TCP/IP
configuring, 6-4
Testing
demand output, 6-21, 6-22
Thermal switch connection, 3-23
Tools, 3-2
Troubleshooting, 6-1, 7-1
CAN LEDs, 7-3
CANopen, 7-6
Index
MN1942
Comments
If you have any suggestions for improvements to this manual, please let us know. Write your
comments in the space provided below, remove this page from the manual and mail it to:
Manuals
ABB Ltd
Motion Control
6 Bristol Distribution Park
Hawkley Drive
Bristol
BS32 0BF
United Kingdom.
Alternatively, you can e-mail your comments to:
[email protected]

Comment:
continued...
MN1942
Comments
Thank you for taking the time to help us.
Comments
MN1942
Contact us
ABB Oy
Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone +358 10 22 11
Fax
+358 10 22 22681
www.abb.com/drives
ABB Ltd
Motion Control
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
United Kingdom
Telephone +44 (0) 1454 850000
Fax
+44 (0) 1454 859001
www.abb.com/drives
ABB Inc.
Automation Technologies
Drives & Motors
16250 West Glendale Drive
New Berlin, WI 53151
USA
Telephone 262 785-3200
1-800-HELP-365
Fax
262 780-5135
www.abb.com/drives
ABB Beijing Drive Systems Co. Ltd.
No. 1, Block D, A-10 Jiuxianqiao Beilu
Chaoyang District
Beijing, P.R. China, 100015
Telephone +86 10 5821 7788
Fax
+86 10 5821 7618
www.abb.com/drives
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