ABB MicroFlex e150 servo drive User’s manual

ABB motion control
User’s manual
MicroFlex e150 servo drive
MN1961WEN
List of related manuals
Drive hardware manuals and guides
MicroFlex e150 Quick Installation Guide
Safety Manual: Safe Torque Off (STO) function for
MicroFlex e150 drives
MicroFlex e150 wall chart
MicroFlex e150 flyer
Code (English)
LT0307
LT0313
LT0296
3AUA0000097609
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User’s manual
MicroFlex e150
Table of contents
1. Safety
4. Mechanical installation
6. Electrical installation:
AC input, motor and
9. Start-up
 2012 ABB Oy. All Rights Reserved.
LT0291A01
EN
EFFECTIVE: 2012-06-28
Table of contents 5
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Safety
Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Introduction to the manual
11
11
13
14
14
Safety
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick installation and start-up flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
15
16
16
17
18
18
19
3. Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections - front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections - top panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
22
23
23
24
25
4. Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effects of mounting surface and proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
27
28
28
29
30
31
5. Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Table of contents
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Implementing the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting the contacts of relay outputs and attenuating inductive loads . . . . . . . . . . . . . . . .
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
34
34
35
36
36
38
39
39
39
40
6. Electrical installation: AC input, motor and brake
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Earthing / grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input power conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplying input power from a variac (variable transformer) . . . . . . . . . . . . . . . . . . . . . . .
Power supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harmonic suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reversing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power disconnect and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 V control circuit supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor power cable shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor circuit contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sinusoidal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal switch connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake resistor (regeneration resistor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
44
45
45
47
47
48
48
48
49
50
51
52
53
55
55
55
57
58
7. Electrical installation: input / output
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog inputs AIN0, AIN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog output AOUT0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a digital input as a drive enable input (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a digital input as a home switch input (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs - Safe Torque Off (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs - general purpose DIN0, DIN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs - general purpose DIN1, DIN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special functions on inputs DIN1, DIN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs - general purpose DIN4 - DIN9 (models ...EIOA only) . . . . . . . . . . . . . . . .
Status output (DOUT0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital outputs DOUT1, DOUT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
60
60
61
62
63
63
64
65
66
67
68
69
70
Table of contents 7
Digital outputs DOUT3 - DOUT6 (models ...EIOA only) . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder output (models ...EEOA only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EtherCAT® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EtherCAT configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incremental encoder interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BiSS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SSI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SinCos interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EnDat interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extra incremental encoder interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
73
74
74
76
76
77
78
79
80
81
82
84
85
85
86
86
8. Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Safe Torque Off (STO) connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9. Start-up
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connecting the MicroFlex e150 to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installing Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Starting the MicroFlex e150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Power on checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Configuring the TCP/IP connection (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Configuring the network adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Configuring the MicroFlex e150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Mint Machine Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Starting MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Commissioning Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Further tuning - no load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Further tuning - with load attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Optimizing the velocity response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Performing test moves - continuous jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Performing test moves - relative positional move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Further configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Configuration tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Parameters tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Spy window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8 Table of contents
Other tools and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Safe Torque Off (STO) acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10. Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-cycling the MicroFlex e150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MicroFlex e150 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
117
118
118
119
119
120
122
122
123
123
11. Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimension drawing (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effect of AC power supply voltage on DC-bus voltage . . . . . . . . . . . . . . . . . . . . . . . . .
Effect of AC power supply voltage on DC-bus ripple voltage . . . . . . . . . . . . . . . . . . . . .
Effect of output current on DC-bus ripple voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating characteristic for 3 A models (E152A03...): . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating characteristic for 6 A models (E152A06...): . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating characteristic for 9 A models (E152A09...): . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overtemperature trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended fuses, circuit breakers and wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input power-cycling and inrush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 V control circuit supply (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor output power (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking power and average power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input / output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog inputs AIN0, AIN1 (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog output AOUT0 (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs STO1, STO2 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs DIN0, DIN3 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital inputs DIN1, DIN2 - high speed (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125
126
127
128
128
129
130
130
131
132
132
133
134
135
135
136
136
137
138
138
138
140
140
141
142
142
143
143
143
143
144
144
Table of contents 9
Digital inputs DIN4 - DIN9 (OPT1, models ...EIOA only) . . . . . . . . . . . . . . . . . . . . . . . .
Digital outputs DOUT0 (Status), DOUT1, DOUT2 (X3) . . . . . . . . . . . . . . . . . . . . . . . . .
Digital outputs DOUT3 - DOUT6 (OPT1, models ...EIOA only) . . . . . . . . . . . . . . . . . . .
Encoder output (OPT1, models ...EEOA only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incremental encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SSI encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BiSS encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SinCos / EnDat encoder interface (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet interface (E1, E2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design and test standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental test standards: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional safety standards: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with the EN 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Validating the operation of the Safe Torque Off function . . . . . . . . . . . . . . . . . . . . . . . .
CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque servo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
144
145
145
145
145
146
146
146
147
147
148
148
148
148
148
150
150
150
150
151
151
151
151
152
152
153
154
154
155
155
157
12. Accessories
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot-mount filter (single phase only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 V power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
159
160
161
161
162
165
166
166
167
167
13. Appendix: Safe Torque Off (STO)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation of the STO function and diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
169
169
171
172
10 Table of contents
Validating the operation of the Safe Torque Off function . . . . . . . . . . . . . . . . . . . . . . . .
Technical data: Digital inputs STO1, STO2 (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STO function: data related to safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STO function: TüV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
172
173
173
174
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
175
175
175
175
Safety 11
1
Safety
Safety in installation and maintenance
These warnings are intended for all who work on the drive, motor cable or motor.
 Electrical safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
Only qualified electricians are allowed to install and maintain the drive!
•
Be sure the system is properly earthed/grounded before applying power. Do not
apply AC power before earths/grounds are connected.
•
Never work on the drive, motor cable or motor when input power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable. Always ensure by measuring with a multimeter (impedance at least
1 Mohm) that there is no voltage between the drive input phases L1, L2 and L3
and the ground.
•
Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits can carry dangerous
voltage even when the input power of the drive is switched off.
•
Do not make any insulation or voltage withstand tests on the drive.
•
All ELV (extra low voltage) circuits connected to the drive must be used within a
zone of equipotential bonding, i.e. within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. This is accomplished by proper factory
grounding.
12 Safety
•
Even when the motor is stopped, dangerous voltage is present at the power
circuit terminals L1, L2, L3, U, V, W, R1, R2 (connector X1).
•
If a motor is driven mechanically, it can generate hazardous voltages that are
conducted to its power terminals. The enclosure must be earthed/grounded to
prevent possible shock hazard.
•
To prevent equipment damage, be certain that the input power has correctly sized
protective devices installed.
•
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 drive are shielded correctly.
•
Do not tin (solder) exposed wires. Solder contracts over time and can cause loose
connections. Use crimp connections where possible.
•
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.
•
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.
•
To comply with CE directive 2004/108/EC an appropriate AC filter must be
installed.
•
Both the AC supply and the 24 V DC supply must be fused.
•
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, or
by using basic insulation with a protective earth.
•
The input of the control circuit must be limited to Safety Extra Low Voltage circuits.
Permanent magnet motor drives
These are additional warnings concerning permanent magnet motor drives. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
WARNING! Do not work on the drive when the permanent magnet motor is
rotating. Also, when the supply power is switched off and the inverter is
stopped, a rotating permanent magnet motor feeds power to the intermediate circuit
of the drive and the supply connections become live.
Before installation and maintenance work on the drive:
•
Stop the motor.
•
Ensure that there is no voltage on the drive power terminals according to step 1 or
2, or if possible, according to the both of the following steps:
Safety 13
1. Disconnect the motor from the drive with a safety switch or by other means.
Measure that there is no voltage present on the drive input (L1, L2, L3), motor
output (U, V, W), or brake terminals (R1, R2).
2. Ensure that the motor cannot rotate during work. Make sure that no other
system, like a hydraulic crawling drive, is able to rotate the motor directly or
through any mechanical connection like felt, nip, rope, etc. Measure that there
is no voltage present on the drive input (L1, L2, L3), output (U, V, W), or brake
/ regeneration terminals (R1, R2). Ground the drive output terminals
temporarily by connecting them together as well as to the PE.
 General safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
•
The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Center for
replacement.
•
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.
•
Operating the MicroFlex e150 in torque mode with no load attached to the motor
can cause the motor to accelerate rapidly to excessive speed.
•
Make sure that dust from drilling does not enter the drive during the installation.
Electrically conductive dust inside the drive can cause damage or lead to
malfunction.
•
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 with the drive. If not installed in an electrical cabinet,
barriers around the equipment are required.
•
Avoid locating the drive immediately above or beside heat generating equipment,
directly below water or steam pipes, or in the vicinity of corrosive substances or
vapors, metal particles and dust.
•
Ensure sufficient cooling. Failure to meet cooling air flow requirements will result
in reduced product lifetime and/or drive overtemperature trips.
•
The metal heat sink on the left side of the MicroFlex e150 can become very hot
during normal operation.
14 Safety
Safe start-up and operation
These warnings are intended for all who plan to start-up or operate the drive.
 General safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
•
Before adjusting the drive and putting it into service, make sure that the motor and
all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at speeds
above and below the speed provided by connecting the motor directly to the
power line.
•
Improper operation or programming of the drive can 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.
•
Do not activate automatic fault reset functions if dangerous situations can occur.
When activated, these functions will reset the drive and resume operation after a
fault.
•
Do not control the motor with an AC contactor or disconnecting device
(disconnecting means); use instead external commands (I/O or fieldbus).
•
If a drive enable signal is already present when power is applied to the
MicroFlex e150, the motor could begin to move immediately.
•
The metal heat sink on the left side of the MicroFlex e150 can become very hot
during normal operation.
•
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.
•
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 can generate enough heat to ignite combustible materials. To
avoid fire hazard, keep all combustible materials and flammable vapors away
from brake resistors.
Introduction to the manual 15
2
Introduction to the manual
What this chapter contains
The chapter describes applicability, target audience and purpose of this manual. It
describes the contents of this manual and refers to a list of related manuals for more
information. The chapter also contains a flowchart of steps for checking the delivery
and installing and commissioning the drive. The flowchart refers to chapters/sections
in this manual.
Applicability
The manual is applicable to the MicroFlex e150 drive.
Target audience
The reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols. The manual is written for readers
worldwide. Both SI and imperial units are shown.
Purpose of the manual
This manual provides information needed for planning the installation, installing,
commissioning, using and servicing the drive.
16 Introduction to the manual
Contents of this manual
The manual consists of the following chapters:
•
Safety (page 11) gives safety instructions you must follow when installing,
commissioning, operating and servicing the drive.
•
Introduction to the manual (this chapter, page 15) describes applicability, target
audience, purpose and contents of this manual. It also contains a quick
installation and commissioning flowchart.
•
Hardware description (page 21) describes the operation principle, connector
layout, type designation label and type designation information in short.
•
Mechanical installation (page 27) describes how to check the installation site,
unpack, check the delivery and install the drive mechanically.
•
Planning the electrical installation (page 33) describes the requirements for the
AC supply, cabling and RCDs.
•
Electrical installation: AC input, motor and brake (page 43) describes the
installation of high power connections including the AC supply, motor output, and
brake resistor.
•
Electrical installation: input / output (page 59) describes the installation of low
power connections, including analog and digital input/outputs (including Safe
Torque Off), motor feedback and Ethernet.
•
Installation checklist (page 87) provides a list of checks to confirm that the
physical installation has been completed correctly.
•
Start-up (page 89) describes the steps for applying power to the drive, installing
the Mint Machine Center software, and tuning and optimizing the motor/drive
combination.
•
Fault tracing (page 117) describes the drive’s LED indicators and provides
solution to common problems encountered during installation.
•
Technical data (page 125) contains the technical specifications of the drive, e.g.
the dimensions, ratings, technical specifications, and provisions for fulfilling the
requirements for CE and other markings.
•
Appendix: Safe Torque Off (STO) (page 169) describes STO features, installation,
and technical data.
•
Accessories (page 159) describes optional accessories.
Related documents
See List of related manuals on page 2 (inside the front cover).
Introduction to the manual 17
Quick installation and start-up flowchart
Task
See
Plan the electrical installation and acquire
the accessories needed (cables, fuses,
etc.).
Check the ratings, required cooling air
flow, input power connection,
compatibility of the motor, motor
connection, and other technical data.
Planning the electrical installation
(page 43)
Technical data (page 119)
Check the installation site.
Requirements for the installation site
(page 27)
Unpack and check the units (only intact
units may be started up).
Check that all necessary optional
modules and equipment are present and
correct.
Mount the drive.
Checking the delivery (page 28).
Mounting and cooling (page 29).
Route the cables.
Routing the cables (page 39)
Check the insulation of the supply cable,
the motor and the motor cable.
Checking the insulation of the assembly
(page 44)
Connect the power cable.
Connect the motor cable.
Connect the control cables.
Connecting the power cables (page 45).
Motor connections (page 52).
Electrical installation: input / output
(page 59).
Check the installation.
Installation checklist (page 87).
Start the drive.
Start-up (page 89)
18 Introduction to the manual
Terms and abbreviations
The following units and abbreviations might appear in this manual.
 General terms
Unit / term /
abbreviation
Description
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
cu.ft
feet
cubic 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
CDROM
CiA
CTRL+E
DAC
DS402
American Wire Gauge
Compact Disc Read Only Memory
CAN in Automation International Users and Manufacturers Group e.V.
on the PC keyboard, press Ctrl and E at the same time.
Digital to Analog Converter
CiA Device Profile for Drives and Motion Control
EDS
Electronic Data Sheet
EMC
Electromagnetic Compatibility
HMI
Human Machine Interface
ISO
International Standards Organization
Kbit/s
kilobits per second
LCD
Liquid Crystal Display
Mbit/s
MB
MMC
megabits per second
megabytes
Mint Machine Center
Introduction to the manual 19
Unit / term /
abbreviation
(NC)
Description
Not Connected
RF
Radio Frequency
SSI
Synchronous Serial Interface
TCP/IP
UDP
Transmission Control Protocol / Internet Protocol
User Datagram Protocol
See also page 173 for safety related abbreviations.
 Trademarks
EtherCAT® is a registered trademark and patented technology,
licensed by Beckhoff Automation GmbH, Germany.
Windows XP, Windows Vista and Windows 7 are registered trademarks of the
Microsoft Corporation.
20 Introduction to the manual
Hardware description 21
3
Hardware description
What this chapter contains
The chapter briefly describes the operation principle, layout, type designation label
and type designation information. It also shows a general diagram of power
connections and control interfaces.
22 Hardware description
Features
The MicroFlex e150 is a versatile servo drive, providing a flexible and powerful
motion control solution for rotary and linear motors. Standard features include:
•
Single axis drive for AC brushless servo motors. Can also control induction
motors.
•
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 single-phase, or 230 V AC threephase supplies.
•
Universal feedback interface supporting incremental encoder, BiSS, SSI, EnDat
or SinCos feedback.
•
Position, velocity and current control.
•
3 optically isolated general purpose digital inputs. Two inputs have ‘fast input'
capability, providing real-time position capture.
•
2 dedicated Safe Torque Off (STO) digital inputs.
•
3 optically isolated general purpose digital outputs.
•
2 analog inputs (±10 V) and 1 analog output (±10 V).
•
I/O option provides an additional 6 digital inputs and 4 digital outputs.
•
Encoder Out option provides an encoder output.
•
USB serial port (compatible with USB 2.0 and USB 3.0).
•
EtherCAT support.
•
Programmable in Mint.
 Operating principle
The figure below shows the simplified main circuit diagram of the drive. The rectifier
converts three-phase AC voltage to DC voltage. The capacitor bank of the
intermediate circuit stabilizes the DC voltage. The inverter converts the DC voltage
back to AC voltage for the AC motor. The brake chopper connects the external brake
resistor to the intermediate DC circuit when the voltage in the circuit exceeds its
maximum limit.
Rectifier
L1
Capacitor
bank
Inverter
U
AC supply L2
V
L3
W
AC motor
Brake chopper
R1 R2
Hardware description 23
Product overview
 Connections - front panel
X1 Power
LEDs
The seven-segment display and the two EtherCAT
LEDs are described in MicroFlex e150 indicators on
page 119.
Earth/Ground
Earth/Ground
(NC)
L1
AC Phase 1/L
L2
AC Phase 2 / N
L3
AC Phase 3
U
Motor U
V
Motor V
W
Motor W
R1
Brake
R2
Brake
DIP switches
These switches select the Ethernet mode and
RS485 settings. See DIP switches on page 80.
X6 RS485 serial port
U1 USB
1
2
3
4
+5 V
DataData+
GND
1
2
3
4
5
6
2-wire
TXA/RXA
TXB/RXB
GND
7 V out
(NC)
(NC)
4-wire
TXA
TXB
GND
7 V out
RXA
RXB
X3 Input / Output
1
2
3
4
5
6
7
8
9
10
StatusDOUT2DOUT1DIN2DIN3DIN1DIN0SREF
SREF
Shield
11
12
13
14
15
16
17
18
19
20
Status+
DOUT2+
DOUT1+
DIN2+
DIN3+
DIN1+
DIN0+
STO1
STO2
Shield
X4 Input / Output
1
2
3
4
AOUT0
AIN1+
AIN0+
Shield
5
6
7
8
AGND
AIN1AIN0Shield
X8 Feedback in
X2 Control circuit power
0V
+24V
(NC) = Not Connected. Do not
make a connection to this pin.
Pin
Incremental SinCos
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Shell
CHA+
CHB+
CHZ+
Sense
Hall UHall U+
Hall VHall V+
CHACHBCHZ+5 V out
DGND
Hall WHall W+
Shield
(NC)
(NC)
(NC)
Sense
SinSin+
CosCos+
(NC)
(NC)
(NC)
+5 V out
DGND
(NC)
(NC)
Shield
BiSS/SSI/
EnDat 2.2
Data+
Clock+
(NC)
Sense
(NC)
(NC)
(NC)
(NC)
DataClock(NC)
+5 V out
DGND
(NC)
(NC)
Shield
* EnDat v2.1 only. EnDat v2.2 does not use the Sin and Cos signals.
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 ferrules.
EnDat 2.1
Data+
Clock+
(NC)
Sense
Sin-*
Sin+*
Cos-*
Cos+*
DataClock(NC)
+5 V out
DGND
(NC)
(NC)
Shield
24 Hardware description
 Connections - top panel
OPT1: Input / Output option
14
13
12
11
10
9
8
Shield
CREF1
DIN8
DIN9
USRV+0
DOUT5
DOUT6
7
6
5
4
3
2
1
DIN4
DIN5
DIN6
DIN7
CREF0
DOUT3
DOUT4
OPT1: Encoder Output option
9
8
7
6
(NC)
CHZCHBCHA-
5
4
3
2
1
DGND
(NC)
CHZ+
CHB+
CHA+
E1 / E2 EtherCAT®
E2
EtherCAT
IN
E1
EtherCAT
OUT
E1 is also used for standard
Ethernet if DIP switch 4 is in the
ON position (see page 80).
1 TX+
2 TX3 RX+
4 (NC)
5 (NC)
6 RX7 (NC)
8 (NC)
Both connectors have
identical pinouts.
See chapter Electrical installation: AC input, motor and brake on page 43 for
installation in general.
Hardware description 25
Type designation label
A description of the product’s catalog numbering system is shown below:
F
CAT.
M
H 2
E152A09EIOA
S/No.
U0316010002
Desc.
MicroFlex e150 Drive 9A
INPUT
105-250 AC 50/60 Hz 1 Ø/3Ø
A 0
3
T
R
-
E
N 2
3
E152A09ENOA
OUTPUT 9A Cont/18A Pk 0-250V 3Ø, 3kW
Made in the UK
U0316010002
Typical label shown.
Actual appearance may differ.
E152A09EIOAxxx
E15
MicroFlex e150 with Mint Lite programming.
2A
115 - 230 V AC supply input.
09
Rated amps: 03 = 3 A, 06 = 6 A, 09 = 9 A.
E
Feedback: E = Universal Encoder (connector X8, see page 23).
IO
Build option: NO = No Option, EO = Encoder Out option, IO = Input / Output option.
A
Hardware revision.
xxx
(Optional) Custom variant.
26 Hardware description
Mechanical installation 27
4
Mechanical installation
What this chapter contains
The chapter describes the mechanical installation procedure of the drive.
 Requirements for the installation site
The safe operation of this equipment depends upon its use in the appropriate
environment. The following points must be considered:
•
The MicroFlex e150 must be installed indoors, permanently fixed and located so
that it can only be accessed by service personnel using tools. When installed in a
cabinet, the cabinet must have a volume of at least 0.19 m3 (6.84 cu.ft). If not
installed in a cabinet, barriers around the equipment are required.
•
The MicroFlex e150 must be secured by the slots in the flange. The protective
earth/ground (the threaded hole on the top of the MicroFlex e150) 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.
•
Avoid locating the MicroFlex e150 immediately above or beside heat generating
equipment, or directly below water steam pipes.
•
Avoid locating the MicroFlex e150 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.
•
The maximum suggested operating altitude is 1000 m (3300 ft).
•
The MicroFlex e150 must be installed where the pollution degree according to
EN 60664 shall not exceed 2.
•
The atmosphere must not contain flammable gases or vapors.
•
There must not be abnormal levels of nuclear radiation or X-rays.
28 Mechanical installation
•
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).
•
The D-type connectors on the front panel of the MicroFlex e150 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).
 Required tools
•
A small slot screwdriver(s) with a blade width of 3 mm or less for connector X1,
and 2 mm (1/10 in) or less for connectors X3 and X4.
•
A drill, and M5 screws or bolts for mounting the MicroFlex e150.
•
Wire stripper.
•
For UL installations, 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.
Checking the delivery
Check that there are no signs of damage. Notify the shipper immediately if damaged
components are found.
If MicroFlex e150 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 Ambient conditions on page 147.
Before attempting installation and operation, check the information on the type
designation label of the drive to verify that the drive is of the correct type. See section
Type designation label on page 25.
Mechanical installation 29
Mounting and cooling
Ensure you have read and understood Requirements for the installation site on page
27. Mount the MicroFlex e150 vertically on its rear side, the side opposite the front
panel. M5 bolts or screws should be used to mount the MicroFlex e150. Detailed
dimensions are shown in Dimension drawing (all models) on page 126.
For effective cooling, the MicroFlex e150 must be mounted upright on a smooth
vertical metal surface. The MicroFlex e150 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 e150 case, to allow full rated current at 45 °C
(113 °F).
Temperature derating characteristics are shown in Temperature derating on page
130.
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 Fan tray on page 160, ensures that correct cooling is provided and
allows the MicroFlex e150 to be UL listed.
30 Mechanical installation
 Effects of mounting surface and proximity
Warm
1 mm
15
If the MicroFlex e150 is mounted above or below
another MicroFlex e150 (or other obstruction),
there should be a minimum space of 90 mm
(3.5 in) to maintain effective cooling. Remember
that a MicroFlex e150 will be receiving air that has
been already heated if it is mounted above
another MicroFlex e150 or heat source. Multiple
MicroFlex e150 units mounted above each other
should be aligned, not offset, to promote air flow
across the heat sinks.
90 mm
15 mm
1
Forced air flow
It is recommended to allow approximately 60 mm
(2.4 in) at the front to accommodate wiring and
connectors.
Hot
Metal backplane
Cool
The proximity of the MicroFlex e150 to other
components could affect cooling efficiency. If the
MicroFlex e150 is mounted beside another
MicroFlex e150 (or other obstruction), there
should be a minimum space of 15 mm (0.6 in) to
maintain effective cooling.
Fan
Fan
Mechanical installation 31
Installing
1. Mark the hole locations. See
Dimension drawing (all models) on
page 126 for complete dimensions.
167.7 mm (6.6 in)
63.5 mm (2.5 in)
2. Position the drive and check the
hole positions are correct.
3. Drill the holes, mount the drive and
tighten all four screws until the
drive is secure.
32 Mechanical installation
Planning the electrical installation 33
5
Planning the electrical
installation
What this chapter contains
The chapter contains the instructions that you must follow when checking the
compatibility of the motor and drive, selecting cables, protective devices, and cable
routing.
Note: The installation must always be completed according to applicable local laws
and regulations. ABB does not assume any liability whatsoever for any installation
which breaches the local laws and/or other regulations. Furthermore, if the
recommendations given by ABB are not followed, the drive might experience
problems that are not covered by the warranty.
The installation methods described in this chapter will improve the reliability of the
system, reduce troubleshooting time, and optimize the EMC (electromagnetic
compatibility) behavior of the control system.
Checking the compatibility of the motor and drive
Check that the 3-phase AC motor and the drive are compatible according to the
Motor output power (X1) on page 137.
Selecting the supply disconnecting device
Install a hand-operated supply disconnecting device (disconnecting means) between
the AC power source and the drive. The disconnecting device must be of a type that
can be locked to the open position for installation and maintenance work.
34 Planning the electrical installation
 European Union
To meet the European Union Machinery Directive, according to standard
EN 60204-1, Safety of Machinery, the disconnecting device must be one of the
following types:
•
a switch-disconnector of utilization category AC-23B (EN 60947-3)
•
a disconnector having an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
•
a circuit breaker suitable for isolation in accordance with EN 60947-2.
 Other regions
The disconnecting device must conform to the applicable safety regulations.
Emergency stop devices
For safety reasons, install emergency stop devices at each operator control station
and at other operating stations where emergency stop might be needed.
Implementing the STO function
See Appendix: Safe Torque Off (STO) on page 169.
Planning the electrical installation 35
Thermal overload and short-circuit protection
Thermal overload protection
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal
overload switch or a circuit breaker must be used for protecting each cable and
motor. These devices might require a separate fuse to cut off the short-circuit current.
Protection against short-circuit in motor cable
The drive protects the motor and motor cable in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed. The motor outputs are fully short-circuit
proof according to EN 61800-5-1.
Protecting against short-circuit in the supply cable or drive
Protect the supply cable with fuses or circuit breakers. Size the fuses according to
instructions given in Technical data on page 134. The fuses protect the input cable in
short-circuit situations, restrict drive damage and prevent damage to adjoining
equipment in case of a short circuit inside the drive.
Fuses
Recommended fuses are listed in Recommended fuses, circuit breakers and wire
sizes on page 134. Alternative fuses must be compatible fast acting types.
Circuit breakers
It is highly recommended that fuses are used instead of circuit breakers. Circuit
breakers should only be used when absolutely necessary. Your local ABB
representative can help you in selecting the breaker type when the supply network
characteristics are known.
Motor thermal protection
According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive can be
configured to include a motor temperature input that protects the motor and switches
off the current when necessary. For more information about motor thermal protection,
see Thermal switch connection on page 57, and the Mint keyword
MOTORTEMPERATUREINPUT in the Mint WorkBench help file.
Brake output short-circuit protection
The brake resistor output is fully short-circuit proof according to EN 61800-5-1.
36 Planning the electrical installation
Selecting the power cables
 General rules
Dimension the input power and motor cables according to local regulations.
•
The input power and the motor cables must be able to carry the corresponding
load currents. See Electrical power network specification on page 127 and Motor
output power (X1) on page 137 for the rated currents.
•
The cable must be rated for at least 70 °C (US: 75 °C / 167 °F) maximum
permissible temperature of the conductor in continuous use.
•
The conductivity of the PE conductor must be equal to that of the phase
conductor (same cross-sectional area).
•
600 V AC cable is accepted for up to 500 V AC.
•
Refer to Technical data on page 151 for the EMC requirements.
A symmetrical shielded motor cable must be used to meet the EMC requirements of
the CE and C-Tick marks; see the following diagrams.
A four-conductor system is allowed for input cabling, but a shielded symmetrical
cable is recommended. Compared to a four-conductor system, the use of a
symmetrical shielded cable reduces electromagnetic emission of the whole drive
system as well as motor bearing currents and wear. The motor cable and its PE
pigtail (twisted shield) should be kept as short as possible in order to reduce
electromagnetic emission.
Planning the electrical installation 37
Alternative power cable types
Motor cables (also recommended for supply cabling):
Symmetrical shielded cable: three phase
conductors and a concentric or otherwise
constructed PE conductor, and a shield.
Check with local / state / country electrical
codes for allowance.
PE
conductor
Note: A separate PE conductor is required
if the conductivity of the cable shield is not
sufficient for the purpose.
Shield
Shield
PE
PE
Allowed for AC power cabling
A four-conductor system: three phase
conductors and a protective conductor.
Shield
PE
PE
Motor cable shield
To function as a protective conductor, the shield must have the same cross-sectional
area as the phase conductors when they are made of the same metal. To effectively
suppress radiated and conducted radio-frequency emissions, the shield conductivity
must be at least 1/10 of the phase conductor conductivity. The requirements are
easily met with a copper or aluminium shield. The minimum requirement of the motor
cable shield of the drive is shown below. It consists of a concentric layer of copper
wires. The better and tighter the shield, the lower the emission level and bearing
currents.
4
1
3
1
Insulation jacket
2
Copper wire screen
3
Helix of copper tape or copper wire
4
Inner insulation
5
Cable core
2
5
38 Planning the electrical installation
Protecting the contacts of relay outputs and attenuating
inductive loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
Equip inductive loads with noise attenuating circuits (varistors, RC filters [AC] or
diodes [DC]) in order to minimize the EMC emission at switch-off. If not suppressed,
the disturbances might connect capacitively or inductively to other conductors in the
control cable and form a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install protective components at the I/O terminal block.
1
2
230 V AC
3
230 V AC
4
24 V DC
1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode
Planning the electrical installation 39
Selecting the control cables
It is recommended that all control cables are shielded.
Double-shielded twisted pair cable is recommended for analog signals. For pulse
encoder cabling, follow the instructions given by the encoder manufacturer. Use one
individually-shielded pair for each signal. Do not use a common return for different
analog signals.
Double-shielded cable is best for low-voltage digital signals but single-shielded
twisted multi-pair cable (Figure b) may also be used.
a
b
Run the analog signal and digital signals in separate cables.
Relay-controlled signals, providing their voltage does not exceed 48 V, may be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals are run as twisted pairs.
Never mix 24 V DC and 115/230 V AC signals in the same cable.
Relay cable
The cable type with braided metallic screen (for example, ÖLFLEX by LAPPKABEL)
has been tested and approved by ABB.
Connection of a motor temperature sensor to the drive I/O
See Thermal switch connection on page 57.
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives
may be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables are installed on separate trays. Avoid
long parallel runs of motor cables with other cables to decrease electromagnetic
interference caused by the rapid changes in the drive output voltage.
Where control cables must cross power cables make sure that they are arranged at
an angle as near to 90 degrees as possible.
The cable trays must have good electrical bonding to each other and to the grounding
electrodes. Aluminium tray systems can be used to improve local equalizing of
potential.
40 Planning the electrical installation
A diagram of the cable routing is shown below:
Power cable
min. 300 mm
(12 in)
Motor cable
Drive
min. 500 mm
(20 in)
Control cables
 Separate control cable ducts
Route 24 V and 230 V cables in separate ducts unless the 24 V cable is insulated for
230 V or insulated with an insulation sleeving for 230 V.
24 V
230 V
24 V
230 V
Planning the electrical installation 41
Typical installation example
Installation cabinet ‘star point’
Drive earth wire
must be at least
10 mm2 (7 AWG)
AC power
from fuses
or reactor
Mount AC filter and
MicroFlex e150 on the
same metal panel.
AC power wires should be as short as
possible, typically less than 0.3 m (1 ft).
Longer wires must be shielded as shown.
Wire colors can vary according to region.
CAUTION
DO NOT TOUCH!
Brake resistors can
become extremely hot!
Locate away from
vulnerable components
and wiring.
Protective Earth
(PE)
Connect AC power
cable shield to metal
panel, using
conductive shield
earth/ground clamps.
On painted panels,
remove paint to
expose bare metal.
42 Planning the electrical installation
Electrical installation: AC input, motor and brake 43
6
Electrical installation:
AC input, motor and brake
What this chapter contains
The chapter describes how to connect input power cables, motor and brake resistor.
WARNING! The work described in this chapter may only be carried out by a
qualified electrician. Follow the instructions in chapter Safety on page 11.
Ignoring the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for 5
minutes after disconnecting the input power.
See the requirements in Electrical power network specification on page 127. Use a
fixed connection to the AC power line.
44 Electrical installation: AC input, motor and brake
Checking the insulation of the assembly
Drive
Every drive has been tested for insulation between the main circuit and the chassis at
the factory. If further high potential (‘hipot’) testing is performed, use only DC voltages
as AC voltage hipot tests could damage the drive. It is recommended to seek advice
from your ABB sales representative before performing hipot tests.
Input power cable
Check the insulation of the input power cable according to local regulations before
connecting to the drive.
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is connected to the motor and disconnected from the
drive output terminals U, V and W.
2. Measure the insulation resistance between each phase conductor and the
Protective Earth conductor using a measuring voltage of 500 V DC. The insulation
resistance of the motor must exceed 100 Mohm (reference value at 25 °C or
77 °F). Please consult the manufacturer’s instructions. Moisture inside the motor
casing reduces the insulation resistance. If moisture is suspected, dry the motor
and repeat the measurement.
Electrical installation: AC input, motor and brake 45
Connecting the power cables
Connection diagram: AC input
AC
Supply
Line (L1)
Route L1, L2, L3 and
earth/ground together
in conduit or cable
Circuit breaker
or fuses
AC filter
Connect
earth/ground
to protective
earth on top
of drive
Line (L2)
Line (L3)
Isolating switch
Incoming safety
earth/ground (PE)
STAR POINT
To earth/ground outer shield,
use 360° clamps connected
to enclosure backplane.
MicroFlex e150 is designed to be powered from standard single or three-phase lines
that are electrically symmetrical with respect to earth/ground. The power supply
module within the MicroFlex e150 provides rectification, smoothing and current surge
protection. Fuses or circuit breakers are required in the input lines for cable
protection.
For three phase supplies, connect the supply to L1, L2 and L3 as shown above. 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 e150. If local codes do not specify different regulations, use at
least the same gauge wire for earth/ground as used for L1, L2 and L3.
The X1 mating connector is a Phoenix COMBICON MSTB 2,5HC/11-ST-5,08.
Tightening torque is 0.5-0.6 N·m (4.4-5.3 lb-in). The threaded hole in the top or
bottom of the case may be used as an additional functional earth/ground connection
for signals on connector X3. The threaded holes 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).
 Earthing / grounding
A permanent earth/ground bonding point is provided on the heat sink, 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 Typical installation example on page 41.
46 Electrical installation: AC input, motor and brake
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.
Protection class
User protection has been achieved using Protective Class I (EN 61800-5-1), 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.
Earth leakage
Maximum earth leakage from the MicroFlex e150 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 EMC filters on page 162). If the MicroFlex e150 and filter
are mounted in an enclosure, it is recommended the enclosure is earthed using a
10 mm2 conductor.
Electrical installation: AC input, motor and brake 47
Input power conditioning
Certain power line conditions must be avoided; an AC line reactor, an isolation
transformer or a step up/step down transformer might be required for some power
conditions:
•
If the feeder or branch circuit that provides power to the MicroFlex e150 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 e150 to limit the maximum symmetrical
short circuit current to 5000 A.
•
If the feeder or branch circuit that provides power to the MicroFlex e150 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 e150.
 Supplying input power from a variac (variable transformer)
When AC power is supplied from a variac, the MicroFlex e150's pre-charge circuit
might 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.
48 Electrical installation: AC input, motor and brake
Power supply filters
To comply with EC directive 2004/108/EC, an AC power filter of the appropriate type
must be connected. This can be supplied by ABB and will ensure that the
MicroFlex e150 complies with the CE specifications for which it has been tested.
Ideally, one filter should be provided for each MicroFlex e150; filters should not be
shared between drives or other equipment.
 Harmonic suppression
When operating the 3 A MicroFlex e150 (part E152A03...) on a single-phase AC
supply, a 13 mH, 4 A rms (10 A peak) line reactor is required to ensure compliance
with EN 61000-3-2 class A limits, when the total equipment supply load is less than
1 kW.
 Reversing the filter
When using filters FI0015A00 or FI0015A02, they must be reversed to ensure that
the MicroFlex e150 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 e150 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.
Electrical installation: AC input, motor and brake 49
Power disconnect and protection devices
A power disconnect should be installed between the input power supply and the
MicroFlex e150 for a fail-safe method to disconnect power. The MicroFlex e150 will
remain in a powered condition until all input power is removed from the drive and the
internal bus voltage has depleted.
The MicroFlex e150 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 Recommended
fuses, circuit breakers and wire sizes on page 134. For CE compliance, see Technical
data on page 150.
From
supply
From
supply
Circuit breaker
Fuse
L
L
L
L
N
N
N
N
Circuit breaker and fuse, single-phase
From
supply
Circuit breaker
From
supply
Fuse
L1
L1
L1
L1
L2
L2
L2
L2
L3
L3
L3
L3
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.
Using 2 phases of a 3-phase supply
Power can 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 e150. A two pole breaker must be used to isolate both lines. Fuses must
be fitted in both lines.
50 Electrical installation: AC input, motor and brake
 Drive overload protection
The MicroFlex e150 will immediately trip and disable if there is an overload condition.
The parameters for managing drive overloads are configured automatically by the
Commissioning Wizard (page 101). If they need to be changed, use the Parameters
tool in Mint WorkBench (page 113).
Electrical installation: AC input, motor and brake 51
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 is 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 e150. If other
devices are powered from the same 24 V supply, a filter (part FI0014A00) should be
installed to isolate the MicroFlex e150 from the rest of the system. Alternatively, a
ferrite sleeve can be attached to the supply cable near connector X2.
Customer supplied
24 V DC
24 V filter
(optional)
Fuse *
Ferrite
sleeve**
+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.
X2
52 Electrical installation: AC input, motor and brake
Motor connections
MicroFlex e150 will operate with a large number of brushless servo motors. For
information on selecting servo motors please contact your local ABB representative.
The motor must be capable of being powered by an inverter PWM output. The motor
can be connected directly to the MicroFlex e150 or through a motor contactor (MContactor). 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 can be fitted in series with the motor.
When using a motor in the Mint WorkBench catalog, the parameters for managing
motor overloads are configured automatically by the Commissioning Wizard (page
101). If they need to be changed, or you are using an alternative motor, use the
Parameters tool (page 113).
WARNING! Hazardous voltages can exist on the motor output connections. Do
not touch the motor output connections before you first ensure there is no high
voltage present.
WARNING! The motor cables 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.
WARNING! Do not connect supply power to the MicroFlex e150 UVW outputs.
The MicroFlex e150 might be damaged.
For CE compliance, the motor earth/ground should be connected to the drive
earth/ground, and the motor power cable must be shielded; see Motor power cable
shielding on page 53. The connector or gland used at the motor must provide 360
degree shielding. The maximum recommended cable length is 30.5 m (100 ft). See
Recommended fuses, circuit breakers and wire sizes on page 134 for recommended
wire sizes.
Electrical installation: AC input, motor and brake 53
Connect motor
earth/ground
to protective
earth on top of
drive.
Motor
Earth
U
V
W
Optional motor
circuit contactors.
To earth/ground outer
shield, use 360° clamp
connected to backplane.
Unshielded
lengths should
be as short as
possible.
 Motor power cable shielding
It is essential that the motor cable shield is correctly bonded to a functional earth,
typically the same earthed metal backplane on which the MicroFlex e150 is mounted.
The motor power output cable carries a high frequency high current waveform to the
motor, so the cable’s shielding must be earthed to prevent the cable radiating
electromagnetic contamination into the surrounding area. Such contamination can
cause spurious errors in unrelated parts of the installation, such as low voltage
communication cables. To provide a low impedance path to earth and effective
shielding, the conductor must provide contact with a large proportion of the cable’s
circumference. The following diagram shows two possible methods.
Exposing the cable shield
1. Make a single circular cut in the cable’s outer sheath, ensuring that the cable’s
braided shield is not damaged.
2. Slide the section of outer sheath towards the end of the cable to expose an area
of braided shield. Carefully remove the excess sheath at the end of the cable.
3. Attach the metal P-clip or clamp to the exposed area of braided shield.
4. Ensure that the P-clip (or Motor Cable Management Bracket, OPT-CM-001) is
securely attached to an unpainted area of the metal backplane.
54 Electrical installation: AC input, motor and brake
On painted
panels, remove
paint to expose
bare metal.
1.
Make a single circular cut
in the cable’s outer
sheath, ensuring that the
cable’s braided shield is
not damaged.
2.
Slide the section of outer
sheath towards the end of
the cable to expose an
area of braided shield.
Carefully remove the
excess sheath at the end
of the cable.
from
MicroFlex e150
from
MicroFlex e150
Optional Motor Cable Management Bracket
OPT-CM-001 (recommended)
Metal P-clip
Continuation of motor power cable shielding
When using a motor contactor, or extending the motor cable through a terminal box,
ensure that the motor cable shielding is continued all the way to the motor.
M-Contactor
Terminal box
Motor
from
MicroFlex e150
Electrical installation: AC input, motor and brake 55
 Motor circuit contactors
If required by local codes or for safety reasons, an M-Contactor (motor circuit
contactor) can be installed to provide a physical disconnection of the motor windings
from the MicroFlex e150 (see Motor connections on page 52). Opening the MContactor ensures that the MicroFlex e150 cannot drive the motor, which might be
necessary during equipment maintenance or similar operations.
If an M-Contactor is installed, the MicroFlex e150 must be disabled at least 20 ms
before the M-Contactor is opened. If the M-Contactor is opened while the
MicroFlex e150 is supplying voltage and current to the motor, the MicroFlex e150 can
be damaged. Incorrect installation or failure of the M-Contactor or its wiring can result
in damage to the MicroFlex e150.
Ensure that shielding of the motor cable is continued on both sides of the MContactor, as shown in the previous diagram.
 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 30.5 m (100 ft) or more. ABB servo 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 can be beneficial.
 Motor brake connection
A rotary motor might require a brake. The brake prevents the uncontrolled release of
suspended or tensioned loads when power to the motor is removed or disconnected,
e.g. by a motor circuit contactor. Contact your local supplier for details of appropriate
brakes.
You can wire a motor's brake, via relays, to digital outputs on connector X3 or OPT1
(see Connections - front panel on page 23, and Connections - top panel on page 24).
This provides a way for the MicroFlex e150 to control the motor's brake. A typical
circuit is shown in the following diagram:
56 Electrical installation: AC input, motor and brake
User
supply
V+
X3
User
supply
GND
C
DOUT1+
from motor brake
connections
13
D
Relay
DOUT1-
3
The relay has normally open
contacts and is shown deactivated
(contacts open, brake engaged).
+24 V
0V
Separate
customer
supplied
24 V DC supply
The inner shield
surrounding the
brake wires should
be earthed/grounded
at one point only.
This circuit uses DOUT1 as a motor brake output. The output is configured using Mint
keyword 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;
•
The relay is deactivated, causing the brake to engage;
•
The drive is disabled, removing power from the motor.
To disengage the brake:
•
The drive is enabled;
•
The drive applies power to the motor to hold position under normal control;
•
The relay is activated, causing the brake to be disengaged.
It is sometimes necessary to include a small delay after the relay has been activated,
before starting motion. This delay allows time for the relay contacts to engage and the
brake to release. See the MOTORBRAKEDELAY keyword.
WARNING! The 24 V DC power supply used to power the brake must be a
separate supply as shown in the diagram. Do not use the supply that is
powering the MicroFlex e150 digital outputs. The brake wires often carry noise that
could cause erratic drive operation or damage. The brake contacts must never be
wired directly to the digital outputs. The relay should be fitted with a protective flyback
diode, as shown. The separate 24 V DC supply used for the motor brake can also be
used to power the relay in the thermal switch circuit.
Electrical installation: AC input, motor and brake 57
 Thermal switch connection
You can use the motor's thermal switch contacts (normally closed), to control a relay
connected to a digital input on connector X3 or OPT1 (see Connections - front panel
on page 23, and Connections - top panel on page 24). This allows the
MicroFlex e150 to respond to motor over-temperature conditions. Using the Mint
WorkBench Digital I/O tool, the input can be configured to be the motor temperature
input. The Mint keyword MOTORTEMPERATUREINPUT can also be used to configure a
digital input for this purpose. A typical circuit, using DIN0 as the input, is shown in the
following diagram.
The relay has normally open
contacts and is shown deactivated
(contacts open, motor overheated).
motor
thermal
switch
X1
DIN0+
17
A
B
DIN0+24 V
0V
Separate
customer
supplied
24 V DC supply
+24 V
7
0V
Customer
supplied
24 V DC
supply
WARNING! The 24 V DC power supply connected to the thermal switch must
be a separate supply as shown in the diagram. 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. The separate 24 V DC supply
used for the thermal switch can also be used for the motor brake circuit.
58 Electrical installation: AC input, motor and brake
Brake resistor (regeneration resistor)
An optional external brake resistor might 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 the Brake (X1) section starting on page 138. Suitable brake resistors are listed in
Resistor choice on page 141. The brake resistor output is conditionally short-circuit
proof.
WARNING! Electrical shock hazard. DC-bus voltages can be present at these
terminals. Use a suitable heat sink (with fan if necessary) to cool the brake
resistor. The brake resistor and heat sink (if present) can reach temperatures in
excess of 80 °C (176 °F).
Brake resistor
STAR
POINT
Earth/ground outer shield,
using 360° conductive
clamp connected to
enclosure backplane
Electrical installation: input / output 59
7
Electrical installation:
input / output
What this chapter contains
The chapter describes how to connect low voltage control signals.
The following conventions will be used to refer to the inputs and outputs:
I/O . . . . . . . . . . .
AIN . . . . . . . . . .
AOUT . . . . . . . .
DIN . . . . . . . . . .
DOUT . . . . . . . .
STO. . . . . . . . . .
Input / Output
Analog Input
Analog Output
Digital Input
Digital Output
Safe Torque Off
WARNING! The work described in this chapter may only be carried out by a
qualified electrician. Follow the instructions in chapter Safety on page 11.
Ignoring the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for 5
minutes after disconnecting the input power.
60 Electrical installation: input / output
Analog I/O
The MicroFlex e150 provides:
•
Two 12-bit resolution ±10 V analog inputs.
•
One 12-bit resolution ±10 V analog output.
An analog input receives the torque / velocity reference signal when operating as an
analog drive (see CONTROLREFSOURCE in the Mint help file), or it can be used as a
general purpose ADC input.
 Analog inputs AIN0, AIN1
Location: X4, pins 3 & 7 (AIN0), 2 & 6 (AIN1), 5 (AGND).
The analog inputs pass through a differential buffer and second order low-pass filter
with a cut-off frequency of approximately 1.2 kHz.
In Mint, analog inputs can be read using the ADC keyword. See the Mint help file for
full details of ADC, ADCMODE and other related ADC... keywords.
Input circuit:
MicroFlex e150
+15V
X4
AIN0AIN0+
-
-
7
3
+
+
Mint
ADC.0
-15V
AGND
5
For differential inputs connect input lines to AIN+ and AIN-. Leave AGND
unconnected:
X4
AIN0+
3
AIN0-
7
X4
AIN0+
AIN0
(ADC.0)
5
Differential connection
3
7
GND
AIN0
(ADC.0)
5
Single ended connection
Electrical installation: input / output 61
Typical input circuit to provide 0-10 V (approx.) input from a 24 V source
+24VDC
Nȍ:
X4
Nȍ:
potentiometer
3
7
0V
AIN0
(ADC.0)
5
 Analog output AOUT0
Location: X4, pin 1 (AOUT0), 5 (AGND)
The analog output can be used to drive loads of 4 kΩ or greater. Shielded twisted pair
cable should be used. The shield connection should be made at one end only.
In Mint, the analog output can be controlled using the DAC keyword. See the Mint help
file for full details of DAC and other related DAC... keywords.
Output circuit:
MicroFlex e150
+15V
X4
Demand
±100%
AD5530BRUZ
1
AOUT0
5
AGND
-15V
62 Electrical installation: input / output
Digital I/O
The MicroFlex e150 provides:
•
10 general purpose digital inputs.
•
2 dedicated Safe Torque Off (STO) inputs.
•
6 general purpose digital outputs.
•
1 dedicated status output.
Connector
X3
Digital input /
output
STO1
STO2
X3
OPT 1
(top panel,
models
...EIOA
only)
Common
connection
SREF
Purpose
To enable the drive and provide the Safe
Torque Off (STO) function (page 64).
DIN0
(Separate)
DIN1
(Separate)
DIN2
(Separate)
DIN3
(Separate)
General purpose input (page 65).
CREF1
General purpose inputs (page 68).
CREF0
General purpose inputs (page 68).
DIN4
DIN5
General purpose input (page 65).
General purpose 'fast' inputs (page 66).
DIN6
DIN7
DIN8
DIN9
X3
Status out
(DOUT0)
(Separate)
X3
DOUT1
(Separate)
DOUT2
(Separate)
OPT 1
(top panel,
models
...EIOA
only)
Status output (page 69).
Can also be used as a general purpose output
General purpose outputs (page 70).
DOUT3
DOUT4
DOUT5
DOUT6
USRV+0
General purpose outputs (page 71).
Electrical installation: input / output 63
 Using a digital input as a drive enable input (optional)
A general purpose digital input can be configured as a ‘drive enable input’. This input
must be activated to allow the drive to operate. This provides an additional method for
stopping the drive using a hardware switch or external PLC/controller (e.g.
NextMove e100), although it does not provide any of the formal safety features of the
Safe Torque Off inputs (page 64). The optional drive enable input is configured using
the Digital I/O tool in Mint WorkBench.
 Using a digital input as a home switch input (optional)
If homing is being handled locally by the MicroFlex e150, the axis home switch (if
present) must be wired directly to the home input on the MicroFlex e150, otherwise it
will not be able to complete its internal homing routines. The home switch input is
configured using the Digital I/O tool in Mint WorkBench, or by using the Mint
HOMEINPUT keyword within a program. Other HOME… keywords define the homing
sequence.
If homing is being handled by an EtherCAT master over Ethernet, and the master is
profiling the motion, there are two options. The choice depends on the accuracy
required for the homing and the EtherCAT cycle-time:
•
The axis home switch can be wired to an input on the MicroFlex e150, and then
mapped back to the master over EtherCAT;
•
The home switch can be wired directly to the EtherCAT master.
64 Electrical installation: input / output
 Digital inputs - Safe Torque Off (STO)
Location: X3, pin 18 (STO1), 8 (SREF), 19 (STO2), 9 (SREF)
The two safe torque off (STO) inputs are identical. Each input directly enables part of
the motor output control circuit. Both inputs must be powered to allow the
MicroFlex e150 to supply power to the motor. If an additional hardware drive enable
input is used to control the MicroFlex e150, it must not be wired with the STO input
circuit. The state of the STO inputs can be viewed using the Mint WorkBench Spy
window's Axis tab. See the Mint help file for details.
See Appendix: Safe Torque Off (STO) on page 169.
Safe Torque Off digital input - STO1:
MicroFlex e150
Vcc
X3
33R
STO1
18
SREF
9
Shield
20
STO
circuit
6k8
TLP281
33R
DGND
Safe Torque Off digital input - STO2:
MicroFlex e150
Vcc
X3
33R
STO2
19
SREF
9
Shield
20
33R
STO
circuit
6k8
TLP281
DGND
Electrical installation: input / output 65
 Digital inputs - general purpose DIN0, DIN3
Location: X3, pins 17 & 7 (DIN0), 15 & 5 (DIN3)
These general purpose digital inputs are buffered by a TLP280 opto-isolator, allowing
the input signals to be connected with either polarity. The inputs do not share a
common reference. When the MicroFlex e150 is connected to Mint WorkBench, the
digital inputs can be configured using the Digital I/O tool. Alternatively, Mint keywords
including DRIVEENABLEINPUT, RESETINPUT, ERRORINPUT and STOPINPUT can be
used. The state of the digital inputs can be viewed using the Mint WorkBench Spy
window's Axis tab. See the Mint help file for details.
General purpose digital input - DIN0 shown:
MicroFlex e150
Vcc
X3
33R
DIN0+
17
DIN0-
7
3k3
Mint
33R
TLP280
DGND
Digital input - typical connections from an ABB NextMove e100:
NextMove e100 / controller
X11
User
supply
24 V
UDN2982
Mint
DRIVEENABLEOUTPUT
9
1
MicroFlex e150
X3
USR V+
DIN0+
DOUT0
DIN0-
10k
10
17
7
TLP280
USR GND
User
supply
GND
66 Electrical installation: input / output
 Digital inputs - general purpose DIN1, DIN2
Location: X3, pins 16 & 6 (DIN1), 14 & 4 (DIN2)
These general purpose fast digital inputs are buffered by a TLP115 opto-isolator,
allowing the input signals to be connected with either polarity. The inputs do not share
a common reference. When the MicroFlex e150 is connected to Mint WorkBench, the
digital inputs can be configured using the Digital I/O tool. Alternatively, Mint keywords
including DRIVEENABLEINPUT, RESETINPUT, ERRORINPUT and STOPINPUT can be
used. The state of the digital inputs can be viewed using the Mint WorkBench Spy
window's Axis tab. See the Mint help file for details.
General purpose fast digital input - DIN1 shown:
MicroFlex e150
X3
Vcc
33R
DIN1+
3k3
16
Mint
33R
DIN1-
6
TLP115
DGND
Digital input - typical connections from an ABB NextMove e100:
NextMove e100 / controller
X11
UDN2982
Mint
OUTX(0)
9
1
USR V+
DOUT0
User
supply
24 V
MicroFlex e150
X3
DIN1+
DIN1-
10k
10
USR
GND
User
supply
GND
16
6
TLP115
Shield
20
Electrical installation: input / output 67
 Special functions on inputs DIN1, DIN2
DIN1 and DIN2 can be configured to perform special functions.
Step (pulse) and direction inputs
DIN1 and DIN2 can be configured using the statement ENCODERMODE(1)=4 to
become 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.
Encoder input
DIN1 and DIN2 can be configured using the statement ENCODERMODE(1)=0 to form
an additional encoder input. The two channels are read as a quadrature (CHA, CHB)
encoder input.
In Mint, the encoder input formed by digital inputs DIN1 and DIN2 is encoder 1. The
primary motor feedback encoder source on connector X8 is encoder 0, and the extra
incremental encoder on connector X8 is encoder 2; see pages 81 and 86.
Fast latch input
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 realtime and read using the Mint keyword LATCHVALUE. The input can be 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 can 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. The captured value is latched in software to prevent subsequent
inputs causing the captured value to be overwritten.
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.
68 Electrical installation: input / output
 Digital inputs - general purpose DIN4 - DIN9 (models ...EIOA only)
Location: OPT1, pin 3 (CREF0), pin 4 (DIN7), 5 (DIN6), 6 (DIN5), 7 (DIN4), 11 (DIN9),
12 (DIN8), 13 (CREF1)
These general purpose digital inputs are buffered by a TLP280 opto-isolator, allowing
the input signals to be connected with either polarity. Inputs DIN4 and DIN5 share a
common reference, CREF1. Inputs DIN6 - DIN9 share a common reference, CREF0.
When the MicroFlex e150 is connected to Mint WorkBench, the digital inputs can be
configured using the Digital I/O tool. Alternatively, Mint keywords including
DRIVEENABLEINPUT, RESETINPUT, ERRORINPUT and STOPINPUT can be used.
The state of the digital inputs can be viewed using the Mint WorkBench Spy window's
Axis tab. See the Mint help file for details.
General purpose digital input - DIN4 shown:
MicroFlex e150
Vcc
OPT1
33R
DIN4
7
CREF1
13
3k3
33R
TLP280
DGND
Digital input - typical connections from an ABB NextMove e100:
NextMove e100 / controller
X11
User
supply
24 V
UDN2982
9
Mint
OUTX(0)
1
MicroFlex e150
OPT1
USR V+
DIN4
DOUT0
CREF1
10k
10
7
13
TLP280
USR GND
User
supply
GND
Electrical installation: input / output 69
 Status output (DOUT0)
Location: X3, pins 1 (Status+), 11 (Status-)
The optically isolated status output is designed to source current from the user
supply. The TLP127 has a maximum power dissipation of 200 mW at 25 °C. The
output includes a self-resetting fuse that operates at approximately 200 mA. The fuse
can 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.
Status output circuit:
User supply
V+
MicroFlex e150
X3
Fuse
1
Status+
200 mA
[Error]
TLP127
11
Status-
Load
(relay with
diode shown)
User supply
GND
The status output becomes active in the event of an error, or when the STO function
is activated. When the MicroFlex e150 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. The output’s state is displayed in the
Spy window. See the Mint help file for details.
General purpose output DOUT0
The status function must be disabled before the output can be used for other
purposes. To disable the status function, the command GLOBALERROROUTPUT=-1
must be issued from a Mint WorkBench command window, or included in a Mint
program. The command GLOBALERROROUTPUT=0 enables the status function. See
the Mint help file for details.
70 Electrical installation: input / output
Status output - typical connections to an ABB NextMove e100:
MicroFlex e150
X3
1
11
User
supply
24 V
NextMove e100 / controller
X9
Status+
DIN4
Status-
8
TLP127
CREF1
9
TLP280
User
supply
GND
 Digital outputs DOUT1, DOUT2
Location: X3, pins 13 & 3 (DOUT1), 12 & 2 (DOUT2)
The optically isolated general purpose outputs are designed to source current from
an individual user supply connection. The TLP127 has a maximum power dissipation
of 200 mW at 25 °C. Each output includes a self-resetting fuse that operates at
approximately 200 mA. The fuse can 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.
Digital output circuit - DOUT1 shown:
User supply
V+
MicroFlex e150
X3
Fuse
13
DOUT1+
200 mA
Mint
OUTX(1)
TLP127
3
DOUT1-
Load
(relay with
diode shown)
User supply
GND
When the MicroFlex e150 is connected to Mint WorkBench, the active level of the
outputs can be configured using the Digital I/O tool. Alternatively, the Mint keyword
OUTPUTACTIVELEVEL can be used. The state of the outputs is displayed in the Spy
window. See the Mint help file for details.
Electrical installation: input / output 71
DOUT1 - typical connections to an ABB NextMove e100:
MicroFlex e150
X3
13
3
User
supply
24 V
NextMove e100 / controller
X9
DOUT1+
DIN4
DOUT1-
8
TLP127
CREF1
9
TLP280
User
supply
GND
 Digital outputs DOUT3 - DOUT6 (models ...EIOA only)
Location: OPT1, pin 2 (DOUT3), 1 (DOUT4), 9 (DOUT5), 8 (DOUT6), 10 (USRV+0)
The optically isolated general purpose outputs are designed to source current from a
common user supply (USRV+0). The TLP127 has a maximum power dissipation of
200 mW at 25 °C. Each output includes a self-resetting fuse that operates at
approximately 200 mA. The fuse can 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.
Digital output circuit - DOUT3 shown:
User supply
V+
MicroFlex e150
OPT1
Fuse
10
USRV+0
200 mA
Mint
OUTX(3)
TLP127
2
DOUT3
Load
(relay with
diode shown)
User supply
GND
72 Electrical installation: input / output
When the MicroFlex e150 is connected to Mint WorkBench, the active level of the
outputs can be configured using the Digital I/O tool. Alternatively, the Mint keyword
OUTPUTACTIVELEVEL can be used. The state of the outputs is displayed in the Spy
window. See the Mint help file for details.
DOUT3 - typical connections to an ABB NextMove e100:
MicroFlex e150
OPT1
10
2
User
supply
24 V
NextMove e100 / controller
X9
USRV+0
DIN4
DOUT3
8
TLP127
CREF1
9
TLP280
User
supply
GND
Electrical installation: input / output 73
 Encoder output (models ...EEOA only)
Location: OPT1
The encoder output can be used for position feedback to a host controller, or in
master/slave situations where the axis movement can be transmitted to another
controller or drive. It is recommended that this output drives only one output circuit
load. The encoder output signals are driven by a DS26LS31 differential line driver
and conform to the RS422 electrical specification. Shielded twisted pair cable is
recommended.
The encoder output consists of an A and B quadrature pulse train (A and B are
square waves with a duty cycle of 50% out of phase by 90°) with a Z pulse if required.
The frequency of the pulse train is updated at 62.5 µs intervals and varied to match
the source encoder. Due to this update interval, the position of the encoder output
lags the source encoder by 125 µs. See the keyword ENCODEROUTRESOLUTION in
the Mint help file.
Encoder output - typical connections to an ABB NextMove e100:
MicroFlex e150
encoder output
Twisted
pairs
NextMove e100
encoder input
CHA+
1
1
CHA-
6
6
CHA-
CHB+
2
2
CHB+
CHA+
CHB-
7
7
CHB-
CHZ+
3
3
CHZ+
CHZ-
8
8
CHZ-
DGND
5
5
DGND
Connect internal
shields to AGND
Connect overall shield
to connector backshells
Baldor cable parts CBL0xxMF-E3B are recommended
(where xx represents a choice of available lengths).
74 Electrical installation: input / output
USB interface
Location: U1
The USB connector is used to connect the MicroFlex e150 to a PC running Mint
WorkBench. The MicroFlex e150 is a self-powered, USB 2.0 (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 ‘high-speed’ (480 Mbps) or USB 3.0 (5 Gbps) host PC or hub,
communication speed will remain at the USB 2.0 specification of the MicroFlex e150.
Ideally, the MicroFlex e150 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).
RS485 interface
Location: X6
The RS485 interface is used to connect third-party serial devices such as operator
panels and PLCs. The interface can operate in 2-wire or 4-wire RS485 mode, which
is selected using the Configuration tool in Mint WorkBench. The default mode is 2wire RS485, 57600 Baud, 8 data bits, 1 stop bit with no parity. MicroFlex e150
supports various protocols over the RS485 interface, such as Modbus RTU and HCP
(Host Comms Protocol), as well as simple ASCII character handling.
The 7 V supply on pin 4 is provided for future 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.
Connections to a 2-wire RS485 device - ABB AC500-eCo PLC shown:
ABB AC500-eCo PLC
MicroFlex e150
COM1
3
RxD/TxD-P
5
SGND
8
RxD/TxD-N
X6
TXA/RXA
1
GND
3
TXB/RXB
2
Electrical installation: input / output 75
Connections to a 4-wire RS485 device - ABB Keypad KPD202-501 shown:
ABB Keypad KPD202-501
MicroFlex e150
Serial
X6
TXA
RXA
8
RXA
TXA
1
5
GND
GND
3
3
TXB
RXB
6
RXB
TXB
7
2
5
2
76 Electrical installation: input / output
Ethernet interface
The Ethernet interface supports EtherCAT® (CoE and EoE) and standard Ethernet.
 Standard Ethernet
The standard Ethernet connection supports several protocols, including EtherNet/IP,
Modbus TCP, HTTP and ICMP. See the application notes at www.abbmotion.com for
details.
Ethernet port E2 is fixed in EtherCAT mode, so port E1 must be used for other
Ethernet connections. To set port E1 (OUT) to standard Ethernet mode, front panel
DIP switch 4 (page 80) must be in the ON position.
Connecting Mint WorkBench using standard Ethernet
TCP/IP allows the MicroFlex e150 to support standard Ethernet communication with
a host PC running Mint WorkBench. The connection uses a high level ‘Immediate
Command Mode’ (ICM) protocol to allow Mint commands, Mint programs and even
firmware to be sent to the controller over the Ethernet network.
The host PC must be connected to the controller either directly or via a switch, as
shown in the following diagram:
Connecting to drives using TCP/IP in standard Ethernet mode:
Host PC
MicroFlex e150 drives
External switch
E1
E1
E1
E1
Electrical installation: input / output 77
 EtherCAT®
MicroFlex e150 supports the EtherCAT protocol. This protocol provides deterministic
communication over a standard 100 Mbit/s (100Base-TX) Fast Ethernet (IEEE
802.3u) connection. This makes it suitable for the transmission of control and
feedback signals between the MicroFlex e150 and other EtherCAT enabled
controllers. EtherCAT's ‘CAN application layer over EtherCAT’ (CoE) capability allows
Mint to implement a drive protocol based on the CANopen DS402 Device Profile for
Drives and Motion Control.
MicroFlex e150 incorporates a built-in multi-port EtherCAT slave controller, providing
two ports for connection to other equipment. This allows nodes to be connected in
many configurations such as a ring, star, or tree, with EtherCAT's self-terminating
technology automatically detecting breaks or an intended end of line.
If only one port is used for EtherCAT operation, it must be the E2 (IN) port.
Straight line topology EtherCAT network:
Machine 1:
MicroFlex e150 drives 1-9
EtherCAT master
IN
IN
IN
IN
IN
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
1
2
3
4
5
6
7
8
9
Ring topology EtherCAT network:
Machine 1:
MicroFlex e150 drives 1-9
EtherCAT master
IN
IN
IN
IN
IN
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
1
2
3
4
5
6
7
8
9
78 Electrical installation: input / output
Multi-branch EtherCAT network:
Machine 1:
MicroFlex e150 drives 1-9
EtherCAT master
IN
External
switch
IN
IN
IN
IN
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
1
2
3
4
5
6
7
8
9
Machine 2:
MicroFlex e150 drives 10-20
IN
OUT
10
IN
OUT
11
IN
OUT
12
IN
OUT
13
IN
OUT
14
IN
OUT
15
IN
OUT
16
IN
OUT
17
IN
OUT
18
IN
OUT
19
IN
OUT
20
 EtherCAT configuration
EtherCAT configuration is usually performed from the EtherCAT manager. To assist
with configuration, the MicroFlex e150 provides an EtherCAT Slave Information (ESI)
file. This .xml file describes the drive’s capabilities to the EtherCAT manager. The ESI
file can be uploaded from the MicroFlex e150 using the Configuration tool in Mint
WorkBench.
Electrical installation: input / output 79
 Ethernet connectors
Location: E1 & E2
Ethernet port E2 (IN) is fixed in EtherCAT mode. To set port E1 (OUT) to EtherCAT
mode, front panel DIP switch 4 (page 80) must be in the off position. If only one port is
used for EtherCAT operation, it must be the E2 (IN) port.
To connect the MicroFlex e150 to other EtherCAT devices use CAT5e Ethernet
cables - either S/UTP (unshielded screened/foiled twisted pairs) or preferably S/FTP
(fully shielded screened/foiled twisted pairs). To ensure CE compliance, Ethernet
cables longer than 3 m should be S/FTP cables bonded to the metal backplane at
both ends using conductive clamps. Cables can 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.
Recommended cables are listed in Ethernet cables on page 167. Crossover or
straight cables can be used. Many Ethernet devices, including hubs and ABB e100 /
e150 products, incorporate Auto-MDIX switching technology which automatically
compensates for the wiring of straight cables.
The MicroFlex e150 Ethernet interface is galvanically isolated from the rest of the
MicroFlex e150 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 e150. Termination
components are incorporated in each of the Ethernet connectors, so no further
termination is required.
The EtherCAT interface supports the 100Base-TX (100 Mbit/s) speed.
80 Electrical installation: input / output
DIP switches
Location: SW1
The MicroFlex e150 has four DIP switches which allow special settings to be selected
on power up. Changing the switch positions after power up has no effect.
DIP switch settings:
Switch
Description
< OFF
ON >
4
E1 (OUT) port: EtherCAT mode
E1 (OUT) port: Standard Ethernet mode
3
Normal operation
Firmware recovery mode
2
X6 port: 2-wire TX/RX (or 4-wire TX):
disconnect 120 Ω termination resistor
X6 port: 2-wire TX/RX (or 4-wire TX):
connect 120 Ω termination resistor
1
X6 port: 4-wire RX:
disconnect 120 Ω termination resistor
X6 port: 4-wire RX:
connect 120 Ω termination resistor
Electrical installation: input / output 81
Motor feedback
Location: X8
MicroFlex e150 supports incremental encoder, encoder with BiSS (Bi-directional
Synchronous Serial Interface), encoder with SSI (Synchronous Serial Interface),
EnDat absolute encoder or SinCos encoder feedback, for use with linear and rotary
motors. When using BiSS, SSI or EnDat 2.2, an extra incremental encoder is also
available. There are some important considerations when wiring the feedback device:
•
The inputs are not isolated.
•
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.
Connection summary
Pin
1
9
10
15
Incremental BiSS, SSI, or
Extra
encoder
EnDat 2.2
incremental
encoder
EnDat 2.1
SinCos
1
CHA+
Data+
-
Data+
(NC)
2
CHB+
Clock+
-
Clock+
(NC)
3
CHZ+
(NC)
-
(NC)
(NC)
4
Sense
Sense
Sense
Sense
Sense
5
Hall U-
(NC)
CHA-
Sin-
Sin-
6
Hall U+
(NC)
CHA+
Sin+
Sin+
7
Hall V-
(NC)
CHB-
Cos-
Cos-
8
Hall V+
(NC)
CHB+
Cos+
Cos+
(NC)
9
CHA-
Data-
-
Data-
10
CHB-
Clock-
-
Clock-
(NC)
11
CHZ-
(NC)
-
(NC)
(NC)
12
+5 V out
+5 V out
+5 V out
+5 V out
+5 V out
13
DGND
DGND
DGND
DGND
DGND
14
Hall W-
(NC)
CHZ-
(NC)
(NC)
15
Hall W+
(NC)
CHZ+
(NC)
(NC)
Simultaneous inputs
82 Electrical installation: input / output
Twisted pairs must be used for each complementary signal pair e.g. CHA+ and CHAor Data+ and Data-.
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 e150 to increase the
encoder supply voltage on pin 12 to maintain a 5 V supply at the encoder (250 mA
max).
 Incremental encoder interface
See Connection summary on page 81 for pin configuration.
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. The Hall inputs can 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.
Encoder channel input circuit - channel A shown:
MicroFlex e150
X8
CHA+
to encoder signal loss detection
1
120R
CHA-
9
13
DGND
MAX3096
Differential
line receiver
to CPU
Electrical installation: input / output 83
Hall input circuit - U phase shown:
MicroFlex e150
X8
Hall U+
+5V
6
MAX3096
Differential
line receiver
Hall U-
to CPU
5
13
DGND
Encoders without Halls
Incremental encoders without Hall feedback connections can be connected to the
MicroFlex e150. However, if Hall connections are not present, it will be necessary for
the MicroFlex e150 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.
Encoder cable connections without Halls - rotary motors:
Motor
Twisted pairs
Encoder
Feedback
Connect overall shield to
connector backshells
X8
1
9
2
10
3
11
CHA+
CHACHB+
CHBCHZ+ (INDEX)
CHZ- (INDEX)
12
13
4
+5 V out
DGND
Sense
84 Electrical installation: input / output
Halls-only feedback devices
Feedback devices using only Hall sensors can be connected to the MicroFlex e150.
However, since there are no encoder connections, the MicroFlex e150 will not be
able to perform smooth speed control or accurate positioning control.
Halls-only feedback cable connections - rotary motors:
Motor
Twisted pairs
Hall
Feedback
X8
4
12
13
Sense
+5 V out
DGND
6
5
15
14
8
7
Hall U+
Hall UHall W+
Hall WHall V+
Hall V-
Connect overall shield to
connector backshells
 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.
BiSS interface cable connections:
Motor
Twisted pairs
X8
1
9
2
10
12
13
4
BiSS
Interface
Absolute
Encoder
Connect overall shield to
connector backshells
Data+
DataClock+
Clock+5V out
DGND
Sense
Chassis
Electrical installation: input / output 85
 SSI interface
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.
SSI interface cable connections:
Motor
1
9
2
10
12
13
4
SSI
Interface
Absolute
Encoder
X8
Twisted pairs
Data+
DataClock+
Clock+5V out
DGND
Sense
Connect
internal
shields to
pin 13.
Chassis
Connect overall shield to
connector backshells
 SinCos interface
The SinCos connections (Sin and Cos incremental channels only) are made using
the 15-pin D-type female connector X8.
SSI cable connections:
Motor
Twisted pairs
X8
5
6
7
8
12
13
4
SinCos
Feedback
Connect overall shield to
connector backshells
SinSin+
CosCos+
+5V out
DGND
Sense
Chassis
Connect
internal
shields to
pin 13.
86 Electrical installation: input / output
 EnDat interface
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. Version 2.2 EnDat encoders do not use the Sin
and Cos channels.
EnDat 2.1 interface cable connections:
Motor
1
9
5
6
7
8
2
10
12
13
4
EnDat
Interface
Absolute
Encoder
X8
Twisted pairs
Data+
DataSinSin+
CosCos+
Clock+
Clock+5V out
DGND
Sense
Connect
internal
shields to
pin 13.
Connect overall shield to
connector backshells
 Extra incremental encoder interface
The extra incremental encoder becomes available when using a digital encoder type
that does not require the Sin / Cos inputs (BiSS, SSI, EnDat 2.2). In Mint, the main
digital encoder source remains as encoder 0, and the extra incremental encoder is
encoder 2. Note that encoder 1 is the input formed by digital inputs DIN1 and DIN2;
see Special functions on inputs DIN1, DIN2 on page 67.
The 5 V encoder inputs (CHA, CHB and CHZ) can be used as differential inputs
(recommended for improved noise immunity) or single ended inputs. When used as
single ended inputs, leave the CHA-, CHB- and CHZ- pins unconnected.
Extra encoder input circuit - channel A shown:
MicroFlex e150
+5V
CHA+
6
MAX3096
Differential
line receiver
CHA-
5
13
DGND
to CPU
Installation checklist 87
8
Installation checklist
This chapter contains a list for checking the mechanical and electrical installation of
the drive.
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist together with another person.
WARNING! Only qualified electricians are allowed to carry out the work
described below. Follow the complete safety instructions of the drive. Ignoring
the safety instructions can cause injury or death. Open the main disconnector of the
drive and lock it to open position. Measure to ensure that the drive is not powered.
Check that …
The ambient operating conditions meet the specification in chapter Technical data.
There is an adequately sized protective earth (ground) conductor between the drive
and the metal mounting surface.
There is an adequately sized protective earth (ground) conductor between the motor
and the drive.
All protective earth (ground) conductors have been connected to the appropriate
terminals and the terminals have been tightened (pull conductors to check).
The supply voltage matches the nominal input voltage of the drive. Check the type
designation label.
The input power cable has been connected to appropriate terminals, the phase order
is correct, and the terminals have been tightened (pull conductors to check).
88 Installation checklist
Check that …
Appropriate supply fuses and disconnector have been installed.
The motor cable has been connected to appropriate terminals, the phase order is
correct, and the terminals have been tightened (pull conductors to check).
The brake resistor cable (if present) has been connected to appropriate terminals, and
the terminals have been tightened (pull conductors to check).
The motor cable (and brake resistor cable, if present) has been routed away from other
cables.
No power factor compensation capacitors have been connected to the motor cable.
All low voltage control cables have been correctly connected.
If a drive bypass connection will be used (for induction motors): The direct-on-line
contactor of the motor and the drive output contactor are either mechanically or
electrically interlocked (cannot be closed simultaneously).
There are no foreign objects or dust inside the drive.
Drive and motor connection box covers are in place.
Verify that all wiring conforms to applicable codes.
The motor and the driven equipment are ready for start-up.
Disconnect the load from the motor until instructed to apply a load. If this is not
possible, disconnect the motor wires at connector X1.
Check no physical damage is present.
Check all instruments have been properly calibrated.
 Safe Torque Off (STO) connections
The STO inputs are an intrinsic part of a safe drive installation.
The acceptance test of the safety function must be carried out by an authorized
person with expertise and knowledge of the safety function. The test must be
documented and signed by the authorized person.
The MicroFlex e150 will operate only when the STO inputs are powered.
See Appendix: Safe Torque Off (STO) on page 169.
Start-up 89
9
Start-up
What this chapter contains
This chapter describes software installation and the start-up procedure of the drive.
Introduction
Before powering the MicroFlex e150 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 e150. Mint WorkBench and other utilities can be found on the Mint Motion
Toolkit CD (OPT-SW-001), or downloaded from www.abbmotion.com.
The PC must have the following minimum specification:
Minimum specification
Processor
RAM
Hard disk space
CD-ROM
Serial port
1 GHz
512 MB
2 GB
A CD-ROM drive
USB port
or
Ethernet* 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
90 Start-up
 Connecting the MicroFlex e150 to the PC
The MicroFlex e150 can be connected to the PC using either USB or TCP/IP.
To use USB, connect a USB cable between a PC USB port and the MicroFlex e150
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 the
MicroFlex e150 E1 Ethernet port, and set DIP switch 4 to the ON position.
WARNING! You cannot connect an ordinary office PC to the MicroFlex e150
without first altering the PC's Ethernet adapter configuration. However, if you
have installed a second Ethernet adapter dedicated for use with the MicroFlex e150,
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.
 Installing Mint WorkBench
The Windows user account requires administrative user rights to install Mint
WorkBench.
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.
3. Follow the on-screen instructions to install Mint WorkBench.
To install Mint WorkBench from the website
To install Mint WorkBench from www.abbmotion.com, download the application and
run it.
Start-up 91
Starting the MicroFlex e150
If you have followed the instructions in the previous sections, you should have now
connected the power sources, your choice of inputs and outputs, and the USB cable
or Ethernet cable linking the PC to the MicroFlex e150.
 Preliminary checks
Before you apply power for the first time, check all items in Installation checklist,
starting on page 87.
 Power on checks
See section MicroFlex e150 indicators on page 119 for symbols that show if the drive
has detected a fault.
1. Turn on the 24 V DC supply.
2. Turn on the AC supply.
3. The drive status display shows the following test sequence, which normally takes
(in sequence),
(in sequence). The
approximately 15-20 seconds: ,
sequence ends with the symbol, or
if an STO input is not powered. Startup
can take more than 1 minute after downloading new firmware.
4. If the motor wires were disconnected in Preliminary checks on page 91, turn off
the AC supply and reconnect the motor wires. Turn on the AC supply.
5. To allow the Commissioning Wizard to function, the Safe Torque Off inputs (page
169) need to be powered to allow the MicroFlex e150 to be enabled.
6. If you do not wish to enable the MicroFlex e150 yet, the Commissioning Wizard
will inform you when this step is necessary.
 USB driver
The USB driver for the MicroFlex e150 is installed with Mint WorkBench.
•
If you are using Windows Vista or a newer operating system, no USB driver
configuration should be necessary.
•
If you are using Windows XP, it will prompt for the driver. Click Next >, choose
‘Install the software automatically’, and click Next > again. Windows will locate
and install the driver. The MicroFlex e150 is now ready to be configured using
Mint WorkBench. If the MicroFlex e150 is later connected to a different USB port
on the host computer, Windows might report that it has found new hardware.
Either install the driver files again for the new USB port, or connect the
MicroFlex e150 to the original USB port.
92 Start-up
To confirm that the USB driver is installed, check that a Motion Control category is
listed in Windows Device Manager:
Start-up 93
Configuring the TCP/IP connection (optional)
If you have connected the MicroFlex e150 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 e150.
 Configuring the network adapter
WARNING! You cannot connect an ordinary office PC to the MicroFlex e150
without first altering the PC's Ethernet adapter configuration. However, if you
have installed a second Ethernet adapter dedicated for use with the MicroFlex e150,
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 e150, 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 address will be
allowed and is not already allocated on the network.
1. On the Windows 7 Start menu, choose Control Panel, then Network and Sharing
Center. (Windows XP: Choose Start, Settings, Control Panel, then Network
Connections).
2. Click Local Area Connection, then click Properties. (Windows XP: Right-click the
‘Local Area Connection' entry for the required Ethernet adapter and choose
Properties).
3. Select the ‘Internet Protocol Version 4 (TCP/IPv4)' entry (Windows XP: ‘Internet
Protocol Version (TCP/IP’)) and click Properties.
4. On the General tab, make a note of the existing settings. Click Advanced... and
make a note of any existing settings. Click Cancel and then 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 an IP address, e.g. 192.168.100.241. This is the IP
address that will be assigned to the Ethernet adapter.
7. In the Subnet mask box, enter 255.255.255.0 and click OK.
8. Click Close to close the Local Area Connection Properties dialog.
 Configuring the MicroFlex e150
The MicroFlex e150 is supplied as a DHCP (Dynamic Host Configuration Protocol)
client. This means that when the MicroFlex e150 is connected to an Ethernet
94 Start-up
network, it broadcasts a request to be assigned an IP address. A DHCP server, in this
case a software service installed with Mint WorkBench, assigns an IP address (and
other IP parameters) to the MicroFlex e150.
When Mint WorkBench is started, it should be able to automatically find the
MicroFlex e150 using the Ethernet TCP/IP connection.
Static configuration
In unusual cases it might be necessary to manually assign a specific IP address to
the MicroFlex e150. This can be performed using the Mint WorkBench Configuration
Wizard.
Start-up 95
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.
If you have only a single MicroFlex e150 connected to your PC, then MMC is
probably not required. See Starting Mint WorkBench on page 99 to configure the
MicroFlex e150.
Toolbars
Menu system
Controller pane
Information pane
MMC provides an overview of the controller network currently accessible by the PC.
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. Double-clicking
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 MicroFlex e150, can be dragged onto the MicroFlex e150 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.
96 Start-up
 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 e150' in the controller
pane to select it, then double click to
open an instance of Mint WorkBench.
The MicroFlex e150 will be already
connected to the instance of Mint
WorkBench, ready to configure.
Go straight to Commissioning Wizard on
page 101 to continue the configuration
in Mint WorkBench.
Start-up 97
Mint WorkBench
Mint WorkBench is a fully featured application for programming and controlling the
MicroFlex e150. 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
Toolbars
Toolbox
Control and
test area
98 Start-up
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. Click on the link to go to an associated keyword. Most
keyword topics begin with a list of relevant See Also links.
For help on using Mint WorkBench, click the Contents tab, then click the small
beside the Mint WorkBench & Mint Machine Center book icon. Double click a
name to display it.
sign
topic
Start-up 99
 Starting Mint WorkBench
Note: If you have already used MMC to install firmware and start an instance of Mint
WorkBench, go straight 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...
100 Start-up
3. Click Scan to search for the MicroFlex e150.
When the search is complete, click MicroFlex e150 in the list, then click Select.
Note: If the MicroFlex e150 is not listed, check the USB or serial cable between
the MicroFlex e150 and the PC. Check that the MicroFlex e150 is powered
correctly. Click Scan to re-scan the ports. It can take up to 5 seconds for Mint
WorkBench to detect the MicroFlex e150.
When detection is complete, the Commissioning Wizard is displayed.
If Launch Commissioning Wizard was not checked, Edit & Debug mode is displayed.
Start-up 101
 Commissioning Wizard
Each type of motor and drive combination has different performance characteristics.
Before the MicroFlex e150 can be used to control the motor accurately, the
MicroFlex e150 must be ‘tuned'. Tuning is the process where the MicroFlex e150
powers the motor in a series of tests. By monitoring the drive's output and the
feedback from the motor's encoder, the MicroFlex e150 can make small adjustments
to the way it controls the motor. This information is stored in the MicroFlex e150 and
can be uploaded to a file if necessary.
The Commissioning Wizard provides a simple way to tune the MicroFlex e150 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.
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.
102 Start-up
Select your Motor Type:
Select the type of motor that you are using; rotary or linear, brushless or induction.
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 using a different manufacturer’s 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 ‘Direct (Host/Mint') as the
Reference Source. This will allow the Autotune Wizard to operate correctly, and allow
further initial testing to be performed using Mint WorkBench. Although the
MicroFlex e150 might eventually be controlled over EtherCAT, the ‘RT Ethernet'
reference source should only be selected after the MicroFlex e150 has been
commissioned and is ready to add to the EtherCAT 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.
Select 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 distance, speed and acceleration 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
Start-up 103
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.
Analog input parameters:
It is not necessary to change anything on this screen. However, if you wish to adjust
the analog inputs, click Common Settings to select the input range. The Tune Offset
button automatically adjusts the input to compensate for any DC offset.
Operation setup complete:
This screen confirms that operation setup is complete.
Autotune Wizard
The Autotune Wizard tunes the MicroFlex e150 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 might 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.
WARNING! 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 Further tuning - with
load attached on page 106.
NOTE: Even if you do not perform any further tuning or configuration, the STO
function must be tested; see Appendix: Safe Torque Off (STO) on page 169.
104 Start-up
 Further tuning - no load attached
The Autotune Wizard calculates many parameters that allow the MicroFlex e150 to
provide good control of the motor. In some applications, these parameters might 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.
Some tabs might 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.
Enter values in the Velocity and
Distance boxes 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
Start-up 105
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.
Typical autotuned response (no load):
Measured
velocity
Demand
velocity
Note: The graph that you see will not look exactly the same as this one! Each motor
has a different response.
The graph 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 Further tuning - with
load attached on page 106.
106 Start-up
 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.
Start-up 107
 Optimizing the velocity response
It might be desirable to optimize the default autotuned response to better suit your
application. The following sections describe the two main tuning factors and how to
correct them.
Correcting overshoot
The following graph 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.
Velocity overshoots demand:
Measured
velocity
Demand
velocity
108 Start-up
Correcting zero-speed noise in the velocity response
The following graph 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.
Zero-speed noise:
Demand
velocity
Noise in
measured
velocity at
zero speed
Start-up 109
Ideal velocity response
Repeat the tests described in Correcting overshoot and Correcting zero-speed noise
in the velocity response until the optimal response is achieved. The following graph
shows an ideal velocity response. There is only a small amount of overshoot and very
little zero-speed noise.
Ideal velocity response:
Measured
velocity
Demand
velocity
110 Start-up
 Performing test moves - continuous jog
This section tests the basic operation of the drive and motor by performing a
continuous jog. 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.
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).
4. To stop the test, type:
STOP(0)
5. If you have finished testing click the
Drive Enable button to disable the
drive.
Start-up 111
 Performing test moves - relative positional move
This section tests the basic operation of the drive and motor by performing a
positional move. 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.
Type:
MOVER(0)=10
GO(0)=10
This will cause the motor to move to a
position 10 units from its current position.
The move will stop when completed.
4. If you have finished testing click the
Drive Enable button to disable the
drive.
112 Start-up
Further configuration
Mint WorkBench provides a number of other tools for testing and configuring the
MicroFlex e150. 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.
 Configuration tool
The Configuration tool shows the MicroFlex e150’s integrated configuration interface.
1. Click the Configuration tool icon in the Toolbox on the left of
the screen.
The main area of the Mint WorkBench window displays the
MicroFlex e150 web interface.
2. Select Load configuration
from the controller or Start
new configuration and click
the green arrow.
3. Enter a descriptive name for
the controller and click the
green arrow.
4. Continue through the screens
making the required changes.
Click Finish at any time to go
to the last screen and save
the changes.
5. On the final screen, click
Finish to complete the
configuration.
Start-up 113
 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
icon are read only so cannot be changed.
Items listed with a green
icon are currently set to their factory default value.
Items listed with a yellow
icon have been changed 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 e150 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 e150's parameters are set automatically by the
Commissioning Wizard, or when tests are performed in the fine-tuning window.
114 Start-up
 Spy window
The Spy window can be used to monitor and capture parameters in real-time. If you
tried the test moves in Performing test moves - continuous jog on page 110 or
Performing test moves - relative positional move on page 111 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, realtime data capture can be configured.
Start-up 115
 Other tools and windows
Remember, for help on each tool 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 e150. If you tried the
test moves in Performing test moves continuous jog on page 110 or Performing test moves - relative positional move
on page 111, then you have already used Edit & Debug mode.
Press Ctrl+N to open a new Mint programming 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 the digital inputs and outputs.
For example, a general purpose
digital input can be configured as an
optional ‘drive enable input’, which
must be active to enable the drive;
see pages 63 and 65 - 68.
If a digital input is to be used as a
home switch input, see Using a digital
input as a home switch input
(optional) on page 63 for important
details.
116 Start-up
Safe Torque Off (STO) acceptance test
Drive commissioning is not complete until the STO function has been tested.
The acceptance test of the safety function must be carried out by an authorized
person with expertise and knowledge of the safety function. The test must be
documented and signed by the authorized person.
See Appendix: Safe Torque Off (STO) on page 169.
Fault tracing 117
10
Fault tracing
What this chapter contains
This section explains common problems and their solutions. The LED indicators are
described in MicroFlex e150 indicators on page 119.
 Problem diagnosis
If you have followed all the instructions in this manual in sequence, you should have
few problems installing the MicroFlex e150. 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.
118 Fault tracing
 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 ABB technical
support by telephone or fax, contact details are provided on the back cover of this
manual.
Please have the following information ready:
•
The serial number of your MicroFlex e150 (if known).
•
Open 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.
•
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.
 Power-cycling the MicroFlex e150
The term ‘power-cycle the MicroFlex e150’ is used in the Troubleshooting sections.
Remove the 24 V supply, wait for the MicroFlex e150 to power down completely (the
Status LED will turn off), then re-apply the 24 V supply.
Fault tracing 119
MicroFlex e150 indicators
 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 EtherCAT Technology Group (ETG)
standard at the time of production.
NET RUN (Green)
Off: INITIALISATION state (or not powered).
Blinking: PRE-OPERATIONAL state.
1 flash: SAFE-OPERATIONAL state.
3 flashes: Device identification. This state can be set from the master to locate the
device.
Continuously illuminated, not flashing: Node in OPERATIONAL state. EtherCAT is
operating normally.
NET ERR (Red)
Off: No errors or not powered.
Blinking: Invalid configuration. The state change requested by the master cannot
be accomplished due to register or object settings or invalid hardware
configuration.
1 flash: Local error. The local node has changed its EtherCAT state.
2 flashes: Process data watchdog time-out or EtherCAT watchdog time out.
Flickering: Booting error.
Continuously illuminated: Application controller failure. A critical communication
or application error has occurred.
LED flash periods
The following diagram shows the definitions of the terms ‘blinking’, ‘flashing’ and
‘flickering’ used in the previous sections, as defined by the EtherCAT Technology
Group.
120 Fault tracing
LED flash timing definitions:
(Not illuminated)
Off
1 flash
1s
1s
2 flashes
1s
Inverted 2 flashes
1s
3 flashes, etc.
1s
Blinking
Flickering
(Continuously illuminated)
On
200 ms
 Drive status display
STO error
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
0.25 s
1s
The drive status display indicates errors and general
MicroFlex e150 status information. When an error occurs, the
drive displays a sequence starting with the symbol E, followed
by the five digit error code. For example, error code 10015 is
displayed:
The decimal point to the right of the number also illuminates to indicate STO errors.
For a complete list of error codes, open Mint WorkBench, press F1, and locate the
Error Handling book. This contains topics listing the drive status display indicators
and basic error codes.
The following information symbols can be displayed:
Symbol
Description
Drive disabled, and one or both STO inputs are not powered. The drive must be
enabled before operation can continue. Both STO inputs must be powered. If an
optional drive enable input has been configured, it must also be powered.
Drive disabled. The drive must be enabled before operation can continue. If an
optional drive enable input has been configured, it must also be powered.
Suspend active. The Mint SUSPEND command has been issued and is active.
Motion will be ramped to zero demand whilst active.
Fault tracing 121
Symbol
Description
Firmware loading (segments are illuminated sequentially). This sequence is
followed by a numerical sequence representing firmware initialization stages.
Hold to Analog (HTA) mode. The axis is in Hold To Analog mode. See the Mint
keyword HTA.
Drive enabled, but idle.
Cam move. A cam profile is in progress. See the Mint keyword CAM.
Dwell. A dwell (wait) ‘move’ is in progress. See the Mint keyword MOVEDWELL.
Flying shear. A flying shear is in progress. See the Mint keyword FLY.
Follow move. The drive is in follow mode. See the Mint keyword FOLLOW.
Homing. The drive is currently homing. See the Mint keyword HOME.
Incremental move. An incremental linear move is in progress. See the Mint
keywords INCA and INCR.
Jog. The drive is jogging. See the Mint keywords JOG, JOGCOMMAND and
related topics.
Offset move. An offset move is in progress. See the Mint keyword OFFSET.
Position move. A linear move is in progress. See the Mint keywords MOVEA and
MOVER.
Torque move. The drive is in torque mode. See the Mint keywords TORQUEREF,
TORQUEREFSOURCE and related commands.
Stop input active. A Mint STOP command has been issued or an optional stop
input is active.
Velocity reference move. The drive is under velocity control. See the Mint
keywords VELREF and related keywords.
Spline. A spline move is in progress. See the Mint keyword SPLINE and related
keyword.
In DS402 mode (under the control of an EtherCAT master), the outer segments will
rotate clockwise or counter-clockwise.
User defined symbols can be displayed using Mint keywords LED and LEDDISPLAY.
122 Fault tracing
 Communication
Drive status display is off:
•
Check that the 24 V DC control circuit supply is correctly connected at X2, and is
switched on.
Drive status display shows ‘r’:
•
The MicroFlex e150 is in firmware recovery mode. This means that it cannot boot
fully, so will allow Mint WorkBench to download firmware from the scan controller
dialog.
Mint WorkBench fails to detect the MicroFlex e150:
•
Ensure that the MicroFlex e150 is powered and the drive status display is
illuminated (page 120).
•
Check that the Ethernet or USB cable is connected between the PC and
MicroFlex e150.
•
For Ethernet connections, check that DIP switch 4 is in the ON position to set
standard Ethernet mode. Power cycle the MicroFlex e150 after changing DIP
switch 4. Check that the cable is connected to port E1 (the port nearest the front
panel).
•
Check that the PC's Ethernet port has been correctly configured for TCP/IP
operation (see Configuring the TCP/IP connection (optional) on page 93).
•
Try an alternative cable or different port on the PC.
•
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 ‘ABB USB Motion Product’ device should be listed in
Windows Device Manager, and 'MicroFlex e150' should be listed in Windows
Devices and Printers (Windows 7).
 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 e150.
Fault tracing 123
Mint WorkBench loses contact with MicroFlex e150 while connected using
USB:
•
Check that the MicroFlex e150 is powered.
•
Check that a ‘ABB USB Motion Product’ device is listed in Windows Device
Manager, and 'MicroFlex e150' is listed in Windows Devices and Printers
(Windows 7). If not, there could be a problem with the PC's USB interface.
 Tuning
Cannot enable the MicroFlex e150 because there is an error 10010:
•
Check the drive enable input, if assigned, is connected and powered correctly.
Cannot enable the MicroFlex e150 because there is an error 10033, 10034
and/or 10035:
•
Check the Safe Torque Off inputs on connector X3 pins 18 & 8 and 19 & 9 are
both connected and powered correctly.
When the MicroFlex e150 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 a lower bandwidth. Click
OK to exit and then start the Autotune Wizard again.
 Ethernet
Cannot connect to the drive over TCP/IP:
•
Check that the PC's Ethernet adapter has been correctly configured, as described
in Configuring the TCP/IP connection (optional) on page 93.
How do I configure my EtherCAT manager to operate with the MicroFlex e150?
•
An EtherCAT ESI file (.xml) that describes the drive to the EtherCAT manager can
be uploaded from the controller using the Mint WorkBench Configuration tool.
124 Fault tracing
I can’t control the MicroFlex e150 from my EtherCAT manager
The drive’s reference source must be set to allow the EtherCAT manager to take
control of the MicroFlex e150. There are several ways to do this:
•
Set the CONTROLREFSOURCESTARTUP parameter to '1' using the Mint
WorkBench Parameter viewer or Command window, and restart the drive. This
will give control to the manager each time the MicroFlex e150 starts.
•
Set the Control Ref. Source to ‘RT Ethernet (CiA402)’ in the Mint WorkBench
Operating Mode Wizard or Commissioning Wizard.
•
Click the Direct button on the Mint WorkBench Motion tool bar, and select ‘RT
Ethernet (DS402)’ in the Axis 0 drop-down.
•
Confirm that the reference source on all controlled nodes has been set to
EtherCAT in the Mint WorkBench Operating Mode Wizard, and that the master
has been configured correctly.
Technical data 125
11
Technical data
What this chapter contains
The chapter contains the technical specifications of the drive, for example, the
ratings, sizes and technical requirements as well as provisions for fulfilling the
requirements for CE and other marks.
126 Technical data
Dimension drawing (all models)
82
(3.23)
79.5
(3.13)
5
(2.5)
(0.2)
6
63.5
(0.24)
11
(0.4)
180
(7.1)
(6.6)
167.7
5.5
Dimensions shown as: mm (inches)
6
(0.24)
Depth:
Weight:
157 mm (6.2 in)
3 A: 1.45 (3.2 lb)
6 A: 1.50 kg (3.3 lb)
9 A: 1.55 kg (3.4 lb)
Technical data 127
Electrical power network specification
A 115 - 230 V AC 3-phase power source (EN 61010 over-voltage category III or less)
is required. An AC power filter is required to comply with the CE directive for which
the MicroFlex e150 was tested (see CE marking on page 150).
Description
Unit
AC input
1Φ
3Φ
115 or 230
115 or 230
Minimum input voltage
105*
105*
Maximum input voltage
250
250
Nominal input voltage
Nominal input current
@ maximum rated output current
Nominal DC-bus voltage
@ 230 V AC input
V AC
A
3A
6A
9A
3A
6A
9A
7.5
15
22
4
8
12
305
321
Frequency
48 to 63 Hz, maximum rate of change 17%/s
Imbalance
Max. ± 3% of nominal
phase to phase input
voltage
Fundamental power factor
0.98 (at nominal load)
Network type
TN (grounded) systems.
Corner grounded TN, and IT (ungrounded)
systems not allowed.
Short-circuit current protection
(UL 508C)
The drive is suitable for use on a circuit
capable of delivering not more than 5000 A
symmetrical amperes (rms) at 230 V
maximum when protected by fuses given in
the fuse table on page 134.
* The MicroFlex e150 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.
128 Technical data
 Effect of AC power supply voltage on DC-bus voltage
DC-bus voltage (V DC)
350
300
Three-phase AC supply
250
Single-phase AC supply
200
150
100
100
125
150
175
200
225
250
AC supply voltage (rms)
 Effect of AC power supply voltage on DC-bus ripple voltage
DC-bus ripple (% of DC-bus voltage)
50
40
30
Single-phase AC supply
20
10
Three-phase AC supply
0
100
125
150
175
200
AC supply voltage (rms)
225
250
Technical data 129
 Effect of output current on DC-bus ripple voltage
DC-bus ripple voltage (Vpk-pk)
60
50
40
Single-phase AC supply
30
20
Three-phase AC supply
10
0
20
30
40
50
60
70
80
90
100
% of drive rated current
110
120
130
140
150
130 Technical data
Temperature derating
The derating characteristics assume the MicroFlex e150 is mounted vertically on
3 mm thick (or less) metal plate. If the MicroFlex e150 is mounted on 10 mm metal
plate, the current characteristics shown below can be increased by up to 7% if there
is no forced air cooling, or 15% if forced air cooling is present. See also Mounting and
cooling on page 29.
 Derating characteristic for 3 A models (E152A03...):
Single-phase AC supply
Rated output current (Arms)
3
1 m/s forced air
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
3
1 m/s forced air
2
Natural cooling
1
0
30
35
40
45
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for models E152A03... is 6 A.
50
55
Technical data 131
 Derating characteristic for 6 A models (E152A06...):
Single-phase AC supply
Rated output current (Arms)
6
1.5 m/s forced air
5
4
1 m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
6
1.5 m/s forced air
5
4
1 m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for models E152A06... is 12 A.
50
55
132 Technical data
 Derating characteristic for 9 A models (E152A09...):
Single-phase AC supply
9
Rated output current (Arms)
8
7
3.5 m/s forced air
6
2.5 m/s forced air
5
1.5 m/s forced air
4
1 m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Three-phase AC supply
Rated output current (Arms)
9
8
3.5 m/s forced air
7
2.5 m/s forced air
6
1.5 m/s forced air
5
4
1 m/s forced air
3
2
Natural cooling
1
0
30
35
40
45
50
55
Ambient temperature (°C)
Notes:
Load power factor = 0.75.
Overload limit for models E152A09... is 18 A.
 Overtemperature trips
The MicroFlex e150 contains internal temperature sensors that will cause it to trip
and disable if the temperature exceeds 80 °C (3 A model), or 75 °C (6 A and 9 A
models). This limit can be read using the TEMPERATURELIMITFATAL keyword - see
the Mint help file for details.
Technical data 133
 Heat dissipation
These figures assume drive efficiency = 95%, power factor = 0.8:
MicroFlex e150
model
Heat dissipation
(W)
3A
50
6A
101
9A
151
134 Technical data
Recommended fuses, circuit breakers and wire sizes
The following table describes the recommended fuses and circuit breakers for AC
power connections, and suitable wires sizes for AC and motor power connections.
Drive
catalog
number
Cont.
output
amps
(RMS)
AC
supply
type
Input fuse
E152A03..
3A
1Ø
Ferraz Shawmut:
6x32 FA series, 10 A
(W084314P)
or
BS88 2.5 URGS 10 A
(N076648J)
3Ø
E152A06..
E152A09..
6A
9A
Circuit
breaker
(C-type)
Minimum
wire gauge
AWG
mm2
10 A
14
2.0
Ferraz Shawmut:
6x32 FA series, 8 A
(V084313P)
or
BS88 2.5 URGS, 7 A
(M076647J)
8A
14
2.0
1Ø
Ferraz Shawmut:
6x32 FA series, 20 A
(A084318P)
or
BS88 2.5 URGS, 20 A
(L097507J)
20 A
14
2.0
3Ø
Ferraz Shawmut:
6x32 FA series, 12.5 A
(X084315P)
or
BS88 2.5 URGS, 12 A
(P076649J)
12.5 A
14
2.0
1Ø
Ferraz Shawmut:
BS88 2.5 URGS, 25 A
(R076651J)
25 A
14
2.5
3Ø
Ferraz Shawmut:
6x32 FA series, 20 A
(A084318P)
or
BS88 2.5 URGS, 20 A
(L097507J)
20 A
14
2.0
Note: All wire sizes are based on 75 °C (167 °F) copper wire. Higher temperature
smaller gauge wire can be used per National Electric Code (NEC) and local codes.
Recommended fuses are based on 25 °C (77 °F) ambient, maximum continuous
Technical data 135
control output current and no harmonic current. Earth/ground wires must be the same
gauge, or larger, than the L1, L2 and L3 wires.
Input power-cycling and inrush
If AC power has been removed from the MicroFlex e150, it should remain
disconnected for the specified period before it is reapplied:
MicroFlex e150
current rating
Minimum power cycle delay period
(seconds)
3A
25
6A
45
9A
65
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 e150.
Discharge period
WARNING! After AC power has been removed from the MicroFlex e150, 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 the table below.
MicroFlex e150
current rating
Time for DC-bus to discharge to 50 V or less
(maximum, seconds)
3A
83
6A
166
9A
248
136 Technical data
Filters
MicroFlex e150
current rating
230 V AC, 1Ø
230 V AC, 3Ø
3A
FI0015A00 + line reactor *
or
FI0029A00 **
FI0018A00 *
6A
FI0015A02 *
or
FI0029A00 **
FI0018A00 *
9A
FI0029A00 **
FI0018A03 *
* See EMC filters starting on page 162 for further details.
** See Foot-mount filter (single phase only) on page 161 for further details.
Maximum earth leakage from the MicroFlex e150 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 EMC filters on page 162).
24 V control circuit supply (X2)
Description
Unit
Nominal input voltage
V DC
3A
6A
24
Minimum input voltage
V DC
20
Maximum input voltage
V DC
30
Maximum ripple
%
±10
Typical input current
(not powering feedback device)
A
0.5 - 0.6
Typical input current
(powering feedback device)
A
0.6 - 0.8
Maximum continuous current
@ 24 V DC
A
1
Power on surge current (typical)
@ 24 V DC, 100 ms
A
4
9A
Technical data 137
Motor output power (X1)
Description
Unit
3A
6A
9A
Nominal phase current
Arms
3
6
9
Peak phase current
for 3 s
Arms
6
12
18
VA
1195
2390
3585
Nominal output
@ 230 V, 3Φ
Output voltage (line-line)
@ V DC-bus = 320 V
Output frequency
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
Vrms
0 - 230
Hz
0 - 2000
kV/µs
2
1.1
1.9
1.8
Nominal switching frequency
kHz
8.0
Minimum motor inductance
mH
1
%
>95
Efficiency
138 Technical data
Brake (X1)
Description
Unit
All models
Nominal switching threshold
V DC
on: 388, off: 376
Nominal power
(10% peak power, r = 57 Ω
kW
0.25
Peak power
(10% peak power, r = 57 Ω
kW
2.7
Maximum brake switching current
Apk
10
Minimum load resistance
Ω
39
Minimum load inductance
µH
100
 Braking capacity
The braking capacity of the MicroFlex e150 can be calculated from the following
formula:
1
E = — × DC bus capacitance ×
2
((Brake switching threshold)
2
–
(¥2 × Supply voltage)
2
)
where the Brake switching threshold is 388 V. This gives the following typical values:
MicroFlex e150
catalog number
DC-bus
capacitance (μF)
Braking capacity (J)
115 V AC supply
230 V AC supply
E152A03...
560
34.7
12.5
E152A06...
1120
69.4
25
E152A09...
1680
104.2
37.6
 Brake resistor selection
The following calculations can be used to estimate the type of brake resistor that will
be required for the application. Some basic information is required to complete the
calculation. Remember to use the worst-case scenario for the application, to ensure
that the braking power is not underestimated. For example, use:
•
The maximum possible motor speed.
•
The maximum inertia.
•
The minimum deceleration time.
•
The minimum cycle time.
Technical data 139
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, Final motor speed:
in radians per second.
V = _____________ rad/s
Multiply RPM by 0.1047 to get radians per
second. This value will be zero if the load is
going to be stopped.
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.
See Duty cycle on page 142.
Cycle time:
e) Total inertia.
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 Autotune tool. If you already know
the motor inertia (from the motor spec.) and the
load inertia (by calculation) insert the total here.
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.
C = _____________ s
J = _____________ kg·m2
140 Technical data
 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:
1 × JîȦ2
E=—
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:
(
) (—12 × J × V )
1 × J × U2 –
E= —
2
1 × J × (U 2
= —
2
–
2
V 2)
= ________________ J (joules)
Calculate E using the values for J, U and V entered in the table on page 139. If E is
less than the drive's braking capacity (see Braking capacity on page 138), a brake
resistor is not required.
If E is greater than the drive's braking capacity, then continue to the next section to
calculate the braking and average power dissipation.
 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
Pr = —
D
= ________________ W (watts)
The resistors shown in the following table can withstand brief overloads, but 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, C, spent braking. The greater the proportion of time spent braking, the greater
the average power dissipation.
D
Pav = Pr × —
C
= ________________ W (watts)
Technical data 141
 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 × Pav
________________ W (watts)
The range of suitable brake resistors is shown in the following table. Choose the
resistor that has a power rating equal to or greater than the value calculated above.
Part
Resistance
Power rating
RGJ139
39 Ω
100 W
RGJ160
60 Ω
100 W
RGJ260
60 Ω
200 W
RGJ360
60 Ω
300 W
Dimensions of brake resistors are shown in Brake resistors on page 165.
* The brake resistors listed in the table above can withstand a brief overload of 10
times the rated power for 5 seconds. Please contact ABB if larger power ratings are
required.
142 Technical data
 Resistor derating
The brake resistors shown in the previous table can achieve their stated power rating
only when mounted on a heat sink. 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
number
Nominal
power rating
(W)
In free air
On heat sink
RGJ139
RGJ160
100
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 heat sink:
200 mm x 200 mm x 3 mm
RGJ260
RGJ360
200
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 heat sink:
400 mm x 400 mm x 3 mm
 Duty cycle
The braking duty cycle is the amount of time taken braking as a proportion of the
overall application cycle time. For example, the following diagram 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
Deceleration 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)
Technical data 143
Input / output
 Analog inputs AIN0, AIN1 (X4)
Description
Unit
Type
Common mode voltage range
All models
Differential
V DC
±10
Common mode rejection
dB
40
Input impedance
kΩ
60
Input ADC resolution
bits
12
(includes sign bit)
Equivalent resolution
mV
±4.9
Sampling interval
µs
1000 (Mint)
250 (Control loop)
Unit
All models
 Analog output AOUT0 (X4)
Description
Type
Output voltage range
Bipolar
V DC
±10
Output current (max)
mA
1
Output DAC resolution
bits
12
(includes sign bit)
Equivalent resolution
mV
±4.9
Update interval
ms
1
 Digital inputs STO1, STO2 (X3)
See Technical data: Digital inputs STO1, STO2 (X3) on page 173.
144 Technical data
 Digital inputs DIN0, DIN3 (X3)
Description
Unit
Type
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
All models
Opto-isolated inputs
V DC
24
12
30
> 12
<2
Input current (maximum, per input)
mA
50
Sampling interval
ms
1
Minimum pulse width
µs
5
 Digital inputs DIN1, DIN2 - high speed (X3)
Description
Unit
Type
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
All models
Opto-isolated inputs
V DC
24
12
30
> 12
<2
Input current (maximum, per input)
mA
20
Sampling interval
ms
1
Minimum pulse width
ns
250
 Digital inputs DIN4 - DIN9 (OPT1, models ...EIOA only)
Description
Unit
Type
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
All models
Opto-isolated inputs
V DC
24
12
30
> 12
<2
Input current (maximum, per input)
mA
50
Sampling interval
ms
1
Minimum pulse width
µs
5
Technical data 145
 Digital outputs DOUT0 (Status), DOUT1, DOUT2 (X3)
Description
Unit
User supply (maximum)
All models
V DC
28
Output current (maximum)
mA
100
Fuse:
Approximate trip current
Reset time
mA
s
200
< 20
Update interval
ms
1
 Digital outputs DOUT3 - DOUT6 (OPT1, models ...EIOA only)
Description
Unit
All models
User supply (maximum)
V DC
28
Output current (maximum)
mA
100
Fuse:
Approximate trip current
Reset time
mA
s
200
< 20
Update interval
ms
1
 Encoder output (OPT1, models ...EEOA only)
Description
Unit
All models
Encoder interface
RS422 A/B Differential, Z index
Output frequency
Matches encoder input (X8)
 Incremental encoder interface (X8)
Description
Unit
Encoder interface
Maximum input frequency
(quadrature)
Hall inputs
Output power supply to encoder
Maximum recommended cable length
All models
RS422 A/B Differential, Z index
MHz
8
RS422 A/B Differential
5 V DC (±7%), 250 mA max.
30.5 (100 ft)
146 Technical data
 SSI encoder interface (X8)
Description
Unit
SSI encoder interface
All models
Differential Data and Clock
Operating mode
(Baldor motors)
Single turn.
Positioning resolution up to 262144
counts/rev (18-bit)
Output power supply to encoder
5 V DC (±7%), 250 mA max.
Maximum recommended cable length
30.5 (100 ft)
 BiSS encoder interface (X8)
Description
Unit
BiSS encoder interface
All models
Differential Data and Clock
Operating mode
(Baldor motors)
Single or multi-turn.
A wide range of devices can be
supported. Contact ABB technical
support before selecting a device.
Output power supply to encoder
5 V DC (±7%), 250 mA max.
Maximum recommended cable length
30.5 (100 ft)
 SinCos / EnDat encoder interface (X8)
Description
Absolute encoder interface
Operating mode
(Baldor motors)
Unit
All models
EnDat / SinCos differential
inputs and data input
Single or multi-turn.
512 or 2048 Sin/Cos cycles per turn,
with absolute positioning resolution
of up to
65536 steps.
(Many other encoder specifications
are supported - contact ABB.)
Output power supply to encoder
Maximum recommended cable length
5 V DC (±7%), 250 mA max.
30.5 (100 ft)
Technical data 147
 Ethernet interface (E1, E2)
Description
Unit
All models
Signal
2 twisted pairs,
magnetically isolated
Protocols
Bit rates
EtherCAT®
& TCP/IP
Mbit/s
100
Unit
All models
Ambient conditions
Description
Operating temperature range
Minimum
Maximum
Derate
V DC
Storage temperature range
Humidity (maximum)
°C
°F
+0
+45
See Temperature
derating on page
130.
+32
+113
See Temperature
derating on page
130.
-40 to +85
-40 to +185
%
93
3A
6A
9A
None
required
1
2.5
Forced air cooling flow
(vertical, from bottom to top)
m/s
Maximum installation altitude
(above m.s.l.)
m
1000
Derate 1.1% / 100 m over 1000 m
ft
3300
Derate 1.1% / 330 ft over 3300 ft
Shock
Vibration
10 G
1 G, 10-150 Hz
148 Technical data
Applicable standards
MicroFlex e150 complies with the following standards.
 Design and test standards
UL508C: Power Conversion Equipment.
UL840: Insulation coordination including clearance and creepage distances for
electrical equipment.
EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Safety
requirements. Electrical, thermal and energy.
EN 60529:1991 + A1:2000 Degrees of protection provided by enclosures.
EN 61800-3:2004 Electromagnetic compatibility. When installed as directed in this
manual, MicroFlex e150 conforms to the category C2 emission limits and the ‘second
environment’ immunity requirements defined by this standard.
See also the CE Declaration of Conformity on page 153.
 Environmental test standards:
EN 60068-1:1994 Environmental testing, general and guidance.
EN 60068-2-1:2007 Environmental testing, Test A. Cold.
EN 60068-2-2:2007 Environmental testing, Test B. Dry heat.
EN 60068-2-6:2008 Environmental testing, Test Fc. Vibration (sinusoidal).
EN 60068-2-27:2009 Environmental testing, Test Ea. Shock.
EN 60068-2-30:2005 Environmental testing, Test Db. Damp heat, cyclic.
EN 60068-2-31:2008 Environmental testing, Test Ec. Rough handling shocks
EN 60068-2-78:2001 Environmental testing, Test Cab. Damp heat, steady state.
 Functional safety standards:
IEC 61508:2010 Functional safety of electrical/electronic/programmable electronic
safety-related systems.
IEC 61800-5-2:2007 Adjustable speed electrical power drive systems: Safety
requirements, Functional.
EN ISO 13849-1:2008 Safety of machinery: Safety-related parts of control systems,
Basic principles.
IEC 62061:2005 Safety of machinery: Functional safety of safety-related electrical,
electronic and programmable electronic control systems
 Marks
See also CE marking on page 150 for general recommendations for CE compliance.
Technical data 149
EtherCAT Conformance Test Certificate
150 Technical data
Degree of protection
MicroFlex e150 complies with EN 60529, IP20 provided connector X1 is shrouded.
For UL purposes the MicroFlex e150 is defined as an open-type, single or three
phase, single axis servo amplifier.
The drive must be installed in a cabinet to fulfil the requirements for shielding from
contact. Access to the cabinet should be restricted to trained maintenance staff.
NOTE: The top surface of cabinets / enclosures which are accessible when the
equipment is energized shall meet at least the requirement of protective type IP3x
with regard to vertical access only.
Materials
Drive enclosure
Side cover: PC+ABS-FR Bayblend FR3010 Black
Front Cover: PC/ABS GN-5001RFH Lupoy Light grey RAL9002
Heat sink: Die cast Aluminium LM6
Package
Cardboard.
Disposal
The drive contains raw materials that should be recycled to preserve
energy and natural resources. The package materials are
environmentally compatible and recyclable. All metal parts can be
recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations.
Most recyclable parts are marked with recycling marks.
The electrolytic DC capacitors and Integrated Power Module are
classified as hazardous waste within the EU and must be removed and
handled according to local regulations.
For further information on environmental aspects and more detailed
recycling instructions, please contact your local ABB distributor.
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the
European, EMC, and machinery directives.
 Compliance with the European EMC Directive
The EMC Directive defines the requirements for immunity and emissions of electrical
equipment used within the European Union. The EMC product standard EN 61800-3
covers requirements stated for drives. See section Compliance with the EN 61800-3
below.
Technical data 151
Compliance with the EN 61800-3
 Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment.
Likewise, the equipment must not disturb or interfere with any other product or
system within its locality.
First environment includes establishments connected to a low-voltage network which
supplies buildings used for domestic purposes.
Second environment includes establishments connected to a network not supplying
domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be
installed and started up only by a professional when used in the first environment.
Note: A professional is a person or organization having necessary skills in installing
and/or starting up power drive systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in
the second environment and not intended for use in the first environment.
 Category C2
The drive complies with the standard with the following provisions:
1. The drive is equipped with a suitable EMC filter; see Filters on page 136.
2. The motor and control cables are selected as specified in this manual.
3. The drive is installed according to the instructions given in this manual.
4. Maximum cable length is 30 meters.
WARNING! The drive can cause radio interference if used in residential or domestic
environment. The user is required to take measures to prevent interference, in
association to the requirements for the CE compliance listed above, if necessary.
 Category C3
The drive complies with the standard with the following provisions:
1. The drive is equipped with a suitable EMC filter; see Filters on page 136.
2. The motor and control cables are selected as specified in this manual.
3. The drive is installed according to the instructions given in this manual.
4. Maximum cable length is 30 meters.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public
network which supplies domestic premises. Radio frequency interference is expected
if the drive is used on such a network.
152 Technical data
Compliance with the European Machinery Directive
This safety related drive complies with the European Union Machinery Directive
requirements for a safety component intended to be integrated into machinery.
Compliance with the machinery directive has been verified according to standards
IEC 61800-5-2:2007, EN ISO 13849-1:2008, IEC 62061:2005, and IEC 61508:2010
parts 1 & 2. The drive has been designed, constructed and equipped in such a way
that when installed as instructed in this manual, all hazards of an electrical nature are,
or can be, prevented. The drive complies with EN 61800-5-1 which specifies safety
requirements in terms of electrical, thermal and energy.
Note: The final assembler of the machinery must take the necessary precautions to
prevent all hazards of an electrical nature when integrating this equipment. General
specifications for design of electrical equipment of machinery is given in EN 60204-1
and EN 60204-11. Specifications for electrical equipment are also given in many
standards for specific categories of machinery.
 Validating the operation of the Safe Torque Off function
See Appendix: Safe Torque Off (STO) on page 169.
Technical data 153
 CE Declaration of Conformity
EC Declaration of Conformity
(In accordance with EN ISO/IEC 17050-1: 2010 and
EC Directives 2004/108/EC & 2006/42/EC)
Manufacturer:
Address:
ABB Ltd
6 Bristol Distribution Park, Hawkley Drive, Bristol, BS32 0BF, U.K.
In accordance with the following Directive(s):
2004/108/EC
2006/42/EC
Electromagnetic Compatibility Directive
Machinery Directive
Hereby declare that the following safety component:
MicroFlex e150 Integrated safe-torque-off drive with type markings:
E152A (followed by additional alpha-numeric digits to signify product variant)
Is in conformity with the applicable requirements of the following documents:
Standard:
EN 61800-3
Title:
Adjustable Speed Electrical Power Drive Systems – Part 3:
EMC Requirements and Specific Test Methods.
EN 61800-5-1
Adjustable Speed Electrical Power Drive Systems – Part 5-1:
Safety requirements - Electrical, thermal and energy.
2007
EN 61800-5-2
Adjustable Speed Electrical Power Drive Systems – Part 5-2:
Safety requirements - Functional.
2007
EN ISO 13849-1 Safety of machinery – Safety-related parts of control systems – Part 1:
General principles for design.
EN 62061
Safety of machinery – Functional safety of safety-related electrical, electronic
and programmable electronic control systems.
Edition/date:
2004
2008
2005
In addition the safety function is certified by EC-type examination:
TÜV NORD Systems GmbH & Co. KG
Branch South
Halderstr. 27
86150 Augsburg, Germany
Notified Body No. 0044
Certification No. SLA-0041/2010
I hereby declare that the equipment named above has been designed to comply with the relevant sections of
the above referenced specifications and is in accordance with the requirements of the Directive(s).
Signed: ………………………………………………… Date: 20th February 2012
Bob Combes
R & D Manager
ABB Ltd, Bristol, U.K
The technical documentation for the product is available from:
ABB Ltd, Bristol, BS32 0BF, U.K
Ref: DE00037-100
154 Technical data
UL marking
The MicroFlex e150 is C-UL US Listed only when used in conjunction with optional
Fan Tray (part FAN001-024, see page 160). The approval is valid with rated voltages.
When used without optional fan tray FAN001-024, the MicroFlex e150 is UL
Recognized.
 UL checklist
•
The drive is to be used in a heated, indoor controlled environment. The drive must
be installed in clean air according to enclosure classification. Cooling air must be
clean, free from corrosive materials and electrically conductive dust. See page
147.
•
The maximum ambient air temperature is 45 °C (113 °F) at rated current. The
current is derated for 45 to 55 °C (113 to 131 °F).
•
The drive is suitable for use in a circuit capable of delivering not more than
5,000 rms symmetrical amperes, 230 V maximum. The ampere rating is based on
tests done according to UL 508C.
•
The cables located within the motor circuit must be rated for at least 75 °C
(167 °F) in UL-compliant installations.
•
Use copper conductors only.
•
The input cable must be protected with fuses. Circuit breakers must not be used
without fuses in the USA. Page 134 lists IEC fuses that are suitable for UL
applications. For suitable circuit breakers, contact your local ABB representative.
•
For installation in the United States, branch circuit protection must be provided in
accordance with the National Electrical Code (NEC) and any applicable local
codes. To fulfill this requirement, use the UL classified fuses.
•
For installation in Canada, branch circuit protection must be provided in
accordance with the Canadian Electrical Code and any applicable provincial
codes. To fulfill this requirement, use the UL classified fuses.
•
The drive provides overload protection in accordance with the National Electrical
Code (NEC).
Technical data 155
Control system
The MicroFlex e150 can use two main control configurations:
•
Servo (Position).
•
Torque Servo (Current).
The configuration is selected using the Mint CONFIG keyword (object 5000h), or by
using the Mint WorkBench System Configuration Wizard. Each configuration
supports different control modes, selected using the Tools, Control Mode menu item
or by using the CONTROLMODE keyword in the Command window (see the Mint help
file). This sets the control mode switch (object 6060h).
 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 on page 156.
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.
6062h
POSDEMAND
+
-
+
60FB
KPROP si1
KINT si2
KINTMODE si8
KINTLIMIT si7
KDERIV si3
Position controller
PID
-
+
KVELFF
60FBh
si5
KVEL
60FBh
si4
6060h
-
POS 6064h
VEL 606Ch
+
+
KVTIME
60F9h si3
Velocity filter
60F9h
KVPROP si1
KVINT si2
KVTRACK si4
Velocity controller
PI + TF
T
6060h
Limiting
Speed
Estimator
Commutation
Measured torque and
magnetizing currents
Electrical angle
Torque
filters
500Ah & 500Bh
TORQUEFILTERTYPE si1
TORQUEFILTERFREQ si2
TORQUEFILTERBAND si3
TORQUEFILTERDEPTH si4
Control mode
switch
P,V
KACCEL
60FBh
si6
+
-
Offset
Comp.
PWM
Position
Feedback
Interface
Raw encoder signals
V
U
Encoder
Current
Sensors
Motor
EFFORT 5033h
CURRENTMEAS Temperature drift
compensation
6078h
Current
Conv.
Current
controllers
PI + TF
60F6h
KIPROP si1
KIINT si2
KITRACK si3
TORQUELIMITPOS 5023h
TORQUELIMITNEG 5022h
CURRENTLIMIT 6073h
Servo configuration control structure, showing DS402 objects
+
5007h
VELERROR
Control mode
switch
P
V
Four-digit numbers indicate DS402 objects.
si indicates the object’s sub index.
60F4h
FOLERROR
606Bh
VELDEMAND
5025h
ACCELDEMAND
6074h
TORQUEDEMAND
156 Technical data
Technical data 157
 Torque servo configuration
The diagram on page 158 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.
6062h
POSDEMAND
+
-
+
60FB
KPROP si1
KINT si2
KINTMODE si8
KINTLIMIT si7
KDERIV si3
Position controller
PID
-
+
POS 6064h
+
T
6060h
KVTIME
60F9h si3
Limiting
Speed
Estimator
Commutation
Measured torque and
magnetizing currents
Electrical angle
Torque
filters
500Ah & 500Bh
TORQUEFILTERTYPE si1
TORQUEFILTERFREQ si2
TORQUEFILTERBAND si3
TORQUEFILTERDEPTH si4
Control mode
switch
P
Velocity filter
+
+
KACCEL
60FBh
si6
+
-
Position
Feedback
Interface
Temperature drift
compensation
Offset
Comp.
PWM
V
U
Encoder
Current
Sensors
Motor
EFFORT 5033h
Raw encoder signals
CURRENTMEAS
6078h
Current
Conv.
Current
controllers
PI + TF
60F6h
KIPROP si1
KIINT si2
KITRACK si3
TORQUELIMITPOS 5023h
TORQUELIMITNEG 5022h
CURRENTLIMIT 6073h
Torque servo configuration control structure, showing DS402 objects
606Ch
VEL
KVELFF
60FBh
si5
KVEL
60FBh
si4
Four-digit numbers indicate DS402 objects.
si indicates the object’s sub index.
60F4h
FOLERROR
606Bh
VELDEMAND
5025h
ACCELDEMAND
6074h
TORQUEDEMAND
158 Technical data
Accessories 159
12
Accessories
What this chapter contains
This section describes accessories and options that you might need to use with your
MicroFlex e150. 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.
160 Accessories
 Fan tray
The fan tray (part FAN001-024) provides sufficient cooling for the 6 A and 9 A
MicroFlex e150. The fan tray might be required for the 3 A model when operating in
high ambient temperatures (see Temperature derating on page 130). The fan tray
requires 23 - 27.5 V DC at 325 mA, which can be sourced from the same filtered
control circuit supply used for the MicroFlex e150. The MicroFlex e150 is UL Listed
(file NMMS.E128059) when used in conjunction with the fan tray, mounted exactly as
shown in the following diagram.
Fan tray
FAN001-024
Fan tray
dimensions
94 (3.7)
84 (3.3)
21.5
(0.85)
142.5 (5.6)
66 (2.6)
Assembled MicroFlex e150 and fan tray
All dimensions shown as mm (inches)
Position of fan tray mounting holes relative to
MicroFlex e150
Bottom of
MicroFlex e150
17.3
(0.68)
Fan tray
16
(0.63)
4.5
(0.18)
It is important that the fan tray is mounted in
close proximity to the MicroFlex e150 as
shown above. Failure to do so will result in
decreased cooling efficiency.
Accessories 161
 Foot-mount filter (single phase only)
The single-phase foot-mount AC power filter (part FI0029A00) provides mounting
holes for the MicroFlex e150 and fan tray. This allows the filter, fan tray and
MicroFlex e150 to use minimal panel mounting space. See pages 162 and 164 for
details of filter FI0029A00.
Foot-mount filter FI0029A00
MicroFlex e150 E152A0...
Fan tray FAN001-024
 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
Output rating
DR-75-24
110-230 V AC
24 V DC
75 W (3.2 A)
DR-120-24
120 W (5 A)
DR-240-24
240 W (10 A)
162 Accessories
 EMC filters
AC filters remove high frequency noise from the AC power supply, protecting the
MicroFlex e150. 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 Filters on page 136.
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)
Filter dimensions, types FI0018A00 and FI0018A03:
B
F
M5
A
D
E
G
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)
Accessories 163
Filter dimensions, types FI0014A00, FI0015A00, FI0015A01, FI0015A02:
L
H
D
E
C
A
G
F
K
J
B
Dimensions: mm (inches)
Dimension
FI0014A00
FI0015A00
FI0015A01
FI0015A02
A
85 (3.35)
113.5 (4.47)
B
54 (2.13)
57.5 (2.26)
C
40 (1.57)
46.6 (1.83)
D
65 (2.56)
94 (3.70)
130.5 (5.14)
E
75 (2.95)
103 (4.06)
143 (5.63)
156 (6.14)
F
27 (1.06)
25 (0.98)
G
12 (0.47)
12.4 (0.49)
H
29.5 (1.16)
32.4 (1.28)
J
5.3 (0.21)
K
6.3 (0.25)
4.4 (0.17)
6 (0.24)
5.3 (0.21)
L
13.5 (0.53)
15.5 (0.61)
164 Accessories
Filter dimensions, type FI0029A00:
B
E
D
F
G
H
C
A
C
A
J
G
K
G
H
K
J
5.5 mm
11 mm
5 mm
10 mm
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)
Accessories 165
 Brake resistors
Depending on the application, MicroFlex e150 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
section Brake (X1) on page 138 for details about choosing the correct resistor.
WARNING! Electrical shock hazard. DC-bus voltages can be present at these
terminals. Use a suitable heat sink (with fan if necessary) to cool the brake
resistor. The brake resistor and heat sink (if present) can reach temperatures in
excess of 80 °C (176 °F).
Brake resistor dimensions:
B
A
C
E
F
G
D
Part
Power
W
Res.
Ω
Dimensions mm (inches)
A
B
C
D
E
F
G
RGJ139
100
39
165
(6.49)
41
(1.61)
22
(0.87)
152
(5.98)
12
(0.47)
10
(0.39)
4.3
(0.17)
RGJ160
100
60
165
(6.49)
41
(1.61)
22
(0.87)
152
(5.98)
12
(0.47)
10
(0.39)
4.3
(0.17)
RGJ260
200
60
165
(6.49)
60
(2.36)
30
(1.18)
146
(5.75)
17
(0.67)
13
(0.51)
5.3
(0.21)
RGJ360
300
60
215
(8.46)
60
(2.36)
30
(1.18)
196
(7.72)
17
(0.67)
13
(0.51)
5.3
(0.21)
166 Accessories
Cables
A wide range of motor and feedback cables are available.
 Motor power cables
For easier installation, it is recommended that a color-coded motor power cable is
used. The part number for a BSM rotary motor power cable is derived as follows:
CBL
025
SP
m
1.5
2.5
3.0
5.0
6.1
7.5
9.1
10
15
15.2
20
22.9
30.5
76
152.5
ft
5*
8.2
10*
16.4
20*
24.6
30*
32.8
49.2
50*
65.6
75*
100*
250*
500*
-12
S
SP
CE style threaded motor
connector (motor end only)
RP
Raw cable
(no connector)
Current
(Amps)
-
Standard
connector
6
12
20
35
50
90
S
Stainless
connector
* North America only
Larger motors requiring 35 A cable or greater normally use terminal box connections, so a motor power connector is
not required. For this reason connectors are not available on 35 A - 90 A cable.
Examples:
A 6.1 m cable, with a CE threaded standard connector, rated for 12 A has part number CBL061SP-12.
A 30.5 m cable, with a CE threaded stainless steel connector, rated for 20 A has part number CBL305SP-20S.
A 50 ft cable, with no connector, rated for 50 A has part number CBL152RP-50.
Accessories 167
 Feedback cables
The part number for a feedback cable is derived as follows:
CBL
m
0.5
1.0
1.5
2.0
5.0
020
ft
1.6
3.3
4.9
6.6
16
SF
SF
RF
-E
1
Servo motor feedback
cable with at least 1
connector
S
E
Incremental
encoder
D
EnDat
SinCos
Raw cable
1
Legacy
controllers
2
Raw cable
(no connector)
Other lengths
available on request
-
S
-
Standard
connector
S
Stainless steel
connector
e100 / e150
BiSS
SSI
Example:
A 2 m encoder feedback cable for a MicroFlex e150 drive, with required connectors at both ends, has part number
CBL020SF-E2.
These feedback cables have the outer shield tied to the connector housing(s). If you
are using an alternative 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). Maximum wire-towire 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).
 Ethernet cables
The cables listed in this table connect MicroFlex e150 to other Ethernet nodes such
as NextMove e100, additional MicroFlex e150s, or other Ethernet compatible
hardware. The cables are standard CAT5e shielded twisted pair (S/UTP) ‘crossover’
Ethernet cables:
Cable description
CAT5e Ethernet cable
Part
CBL002CM-EXS
CBL005CM-EXS
CBL010CM-EXS
CBL020CM-EXS
CBL050CM-EXS
CBL100CM-EXS
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
168 Accessories
Appendix: Safe Torque Off (STO) 169
13
Appendix: Safe Torque Off
(STO)
What this chapter contains
The appendix describes the basics of the Safe torque off function (STO) for the
MicroFlex e150. In addition, application features and technical data for the safety
system calculation are presented.
Basics
The STO function disables the control voltage of the power semiconductors of the
drive output stage, which prevents the inverter generating the voltage required to
rotate the motor (see diagram below). By using this function, short-time operations
(like cleaning) and/or maintenance work on non-electrical parts of the machinery can
be performed without switching off the power supply to the drive.
The drive supports the Safe Torque Off (STO) function according to standards
IEC 61800-5-2, EN 61508:2010, EN ISO 13849-1 and IEC 62061:2005.
See Safety Manual: Safe Torque Off (STO) function for MicroFlex e150 drives
(LT0313...) before using the STO function.
170 Appendix: Safe Torque Off (STO)
MicroFlex e150
PWM control
circuit
Safe Torque Off
connections
Safety circuit
(emergency stop
switch, relay etc.
X3:18
+24 V
X3:8
X3:19
+24 V
X3:9
Common
+0 V
PWM power
circuit
Drivers
High
Integrated
Power
Module
DC+
U+
V+
X1:U
W+
Motor output (U phase shown)
Low
UVW-
DC-
WARNING! The STO function does not disconnect the voltage of the main and
auxiliary circuits from the drive. Therefore maintenance work on electrical parts
of the drive or the motor can only be carried out after isolating the drive system from
the main supply. If the drive was connected to the input power, wait for 5 minutes after
disconnecting the input power.
Appendix: Safe Torque Off (STO) 171
 Operation of the STO function and diagnostics
If both STO inputs are powered, the STO function is in the standby state and the drive
operates normally. If power is removed from one or both of the STO inputs the STO
function is activated, the drive’s motor output power stage is disabled, and the status
output (page 69) becomes inactive. Starting is possible only after both STO inputs
have been powered, and the fault has been cleared.
The SAFETORQUEOFF Mint keyword reports the status of the STO hardware
registers. SAFETORQUEOFF contains an array of values indicating the states of the
STO1 and STO2 inputs, two internal hardware fault circuits, and one internal STO
status output. This array is described in the following table:
Parameter
Meaning
SAFETORQUEOFF(0)
The combined state of the two STO inputs:
STO1 = bit 0, STO2 = bit 1
SAFETORQUEOFF(1)
The state of STO1 input:
0 = not powered, 1 = powered
SAFETORQUEOFF(2)
The state of STO2 input:
0 = not powered, 1 = powered
SAFETORQUEOFF(3)
The combined state of the two hardware fault circuits:
STO1 = bit 0, STO2 = bit 1
SAFETORQUEOFF(4)
The state of the STO1 internal hardware fault circuit:
0 = no fault, 1 = fault
SAFETORQUEOFF(5)
The state of the STO2 internal hardware fault circuit:
0 = no fault, 1 = fault
SAFETORQUEOFF(6)
The state of the internal STO status output:
0 = fault, 1 = no fault
See Safety Manual: Safe Torque Off (STO) function for MicroFlex e150 drives
(LT0313...) for full details.
Status display
When an STO error occurs, the drive displays error code 10033,
10034 or 10035 on its front panel Drive Status display. The right
decimal point is always (and only) illuminated for STO errors.
STO error
172 Appendix: Safe Torque Off (STO)
 Installation
Typical input connections:
MicroFlex e150
Safe
Torque Off
connections
Safety circuit
(emergency stop
switch, relay etc.)
X3:18
X3:9
24 V
External Supply
+24 V
X3:19
X3:9
+0 V
Common
Note: If the contacts of the safety circuit do not open/close within 1 ms of each other,
then a fault in the STO circuit or wiring is assumed and the drive will become
disabled. The maximum allowed cable length between the drive and the activation
switch is 30 m (98 ft).
 Validating the operation of the Safe Torque Off function
IEC 61508 and EN 62061 require that the final assembler of the machinery validates
the operation of the safety function with an acceptance test.
The acceptance test must be performed:
•
at initial start-up of the safety function
•
after any changes related to the safety function (wiring, components, settings,
etc.)
•
after any maintenance work related to the safety function.
If you connect an external Safe Torque Off circuit to the drive, perform the acceptance
test for the Safe Torque Off function as described in Safety Manual: Safe Torque Off
(STO) function for MicroFlex e150 drives (LT0313...).
Appendix: Safe Torque Off (STO) 173
 Technical data: Digital inputs STO1, STO2 (X3)
Description
Unit
All models
Type
Opto-isolated inputs
V DC
Input voltage
Nominal
Minimum
Maximum
Active
Inactive
24
12
30
> 12
<2
Input current (maximum, per input)
mA
50
Sampling interval
ms
1
Minimum pulse width
µs
5
 STO function: data related to safety standards
IEC 61508
EN ISO 13849-1
SIL
PFH
HFT
SFF
PTI
PFD
3
1.12 x 10-10 /h
(0.112 FIT)
1
96.48%
10
years
1.12 x 10-5
PL CCF
e
75
points
MTTFD
DC* Category
20420.9
years
90%
3
* According to the categorization defined in EN ISO 13849-1:2008.
Abbreviation Reference
Description
CCF
EN ISO 13849-1
Common Cause Failure (%)
DC
EN ISO 13849-1
Diagnostic Coverage
FIT
IEC 61508
Failure In Time: 1E-9 hours
HFT
IEC 61508
Hardware Fault Tolerance
MTTFD
EN ISO 13849-1
Mean Time To dangerous Failure: (The total number of life
units) / (the number of dangerous, undetected failures)
during a particular measurement interval under stated
conditions
PFD
IEC 61508
Probability of Failure on Demand
PFH
IEC 61508
Probability of Dangerous Failures per Hour
PL
EN ISO 13849-1
Performance Level: Corresponds SIL, Levels a-e
PTI
Proof Test Interval
SFF
IEC 61508
Safe Failure Fraction (%)
SIL
IEC 61508
Safety Integrity Level
STO
IEC 61800-5-2
Safe Torque Off
174 Appendix: Safe Torque Off (STO)
 STO function: TüV certificate
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type designation and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Sales, Support and Service network.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.
Providing feedback on ABB Drives manuals
Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library – Manuals feedback form (LV AC drives).
Document library on the Internet
You can find manuals and other product documents in PDF format on the Internet.
Go to www.abb.com/drives and select Document Library. You can browse the library
or enter selection criteria, for example a document code, in the search field.
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 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
Baldor Electric Company
(A member of the ABB group)
5711 R.S Boreham, Jr. St.
P.O. Box 2400
Fort Smith, AR 72901
USA
Telephone +1 479 646 4711
Fax
+1 479 648 5792
www.baldor.com
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 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
LT0291A01 (EN) EFFECTIVE: 2012-06-28
Contact us
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